Reznor OH User manual
Form I-OH, PN 120390 R4, Page 1
�
Form I-OH (Version C)
Obsoletes Form I-OH (Version B)
Installation/Operation/Maintenance
Applies to: Model OH
Installations in the
United States
Installations in Canada
FOR YOUR SAFETY
The use and storage of gasoline or other ammable vapors and liquids in open
containers in the vicinity of this appliance is hazardous.
WARNING
Improper installation, adjustment, alteration, service, or maintenance can cause
property damage, injury or death. Read the installation, operation, and maintenance
instructions thoroughly before installing or servicing this equipment.
Model OH,
Oil-Fired Unit Heater
Form I-OH, PN 120390 R4, Page 2
WARNING: This appliance is not designed for use in hazard-
ous atmospheres containing ammable vapors or combus-
tible dust, or atmospheres containing chlorinated or haloge-
nated hydrocarbons.
1. General Installation should be done by a qualied agency in accordance with the instructions
in this manual and in compliance with all codes and requirements of authorities hav-
ing jurisdiction. The instructions in this manual apply to Reznor Model OH, Oil-Fired
Unit Heater. Model OH has a propeller fan for air delivery and requires a vent with a
barometric draft regulator.
1.1 Hazard Labels
and Notices
There are warning labels on the unit and throughout this manual. For your safety, read
the denitions below and comply with all boxes labeled CAUTION, WARNING, and
DANGER during installation, operation, maintenance, and service of this heater.
Denitions of Hazard Intensity Levels in this Manual
HAZARD INTENSITY LEVELS
1. DANGER: Failure to comply will result in severe personal injury or death
and/or property damage.
2. WARNING: Failure to comply could result in severe personal injury or
death and/or property damage.
3. CAUTION: Failure to comply could result in minor personal injury and/or
property damage.
1. General .......................................................... 2
1.1 Hazard Labels and Notices ............................ 2
1.2 General Information ........................................ 3
1.3 Warranty .......................................................... 3
1.4 Installation Codes ........................................... 3
2. Location ........................................................ 3
2.1 Arrangement .................................................... 3
2.2 Throw ............................................................... 4
3. Receiving, Uncrating, and Moving .............. 4
4. Clearances and Dimensions ........................ 4
4.1 Clearances ....................................................... 4
4.2 Dimensions ..................................................... 5
5. Suspension or Mounting .............................. 5
5.1 Weight .............................................................. 5
5.2 Hanging the Heater ......................................... 5
5.3 Mounting the Heater ....................................... 6
6. Mechanical .................................................... 6
6.1 Fuel Tank and Supply Lines........................... 6
6.2 Venting and Combustion Air .........................11
7. Electrical Supply and Connections ........... 13
7.1 General .......................................................... 13
7.2 Supply and Line Wiring ................................ 13
7.3 Wiring Diagrams ........................................... 14
7.4 Major Components ....................................... 15
7.5 Control Wiring ............................................... 17
8. Commissioning and Startup ..................... 17
8.1 Checklist Prior to Startup ............................ 17
8.2 Check-Test-Start (Operating Procedure) .... 18
9. Maintenance and Service ........................... 20
9.1 Maintenance Requirements ......................... 20
9.2 Maintenance Procedures ............................. 20
9.3 Troubleshooting ............................................ 24
INDEX ............................................................... 27
Table of Contents
Form I-OH, PN 120390 R4, Page 3
1.4 Installation
Codes
1.3 Warranty Refer to the limited warranty information in the "Literature Bag"
WARRANTY: Warranty is void if......
a. Wiring is not in accordance with diagram furnished with the heater.
b. Heater is operated in presence of chlorinated vapors.
c. Ducts are attached to fan models.
This heater is for commercial or industrial use only. In the United States, the installation
must be in accordance with the Standard for the Installation of Oil Burning Equipment
NFPA 31, the National Electrical Code NFPA 70, and the requirements of the inspec-
tion authorities having jurisdiction. Model OH units for installation in the United States
have a UL logo on the rating plate.
In Canada, the installation must be in accordance with CSA Standard B139, Installa-
tion Code for Oil Burning Equipment; CSA Standard C22.1, Canadian Electric Code,
Part 1; and with requirements of local regulatory authorities. Model OH units for instal-
lation in Canada have a CSA logo on the rating plate.
This heater should be installed by a trained installer who is thoroughly familiar with the
installation of oil-red appliances.
Prior to beginning installation, become familiar with the heater and its particular instal-
lation requirements.
1.2 General
Information
Fuel Specications
The burner in this oil-red heater is designed and oriced for use with #2 fuel oil (140,000
BTU/gallon) at 100 psig. However, the following substitute fuels may be used:
#1 fuel oil - 132,000 BTU/gallon
Kerosene (domestic only; do not use foreign) - 132,000 BTU/gallon
#1 diesel fuel - 132,000 BTU/gallon (see NOTE)
#2 diesel fuel - 140,000 BTU/gallon (see NOTE)
NOTE: Diesel fuel is not approved for use in Canada.
WARNING: Do not use gasoline, crankcase oil, or any oil
containing gasoline. Do not use aviation fuel.
Due to higher viscosity, some #1 oils's BTU/gallon capacity may be 128,000 to 130,000
BTU/gallon. Check BTU content of substitute fuel to determine burner input.
• Size 95 burns an average of .85 gallons per hour.
• Size 140 burns an average of 1.25 gallons per hour.
• Size 190 burns an average of 1.65 gallons per hour.
CAUTION: Do not attempt to burn paper or garbage in this
heater.
2. Location 2.1 Arrangement
These oil-red unit heaters should be installed in such a manner as to derive maximum
efciency and a minimum of heat loss to the outside environment. As a rule, single
heaters should be suspended over an area of low heat loss with output air directed
toward the area of the greatest heat loss. Where two or more heaters are used in a
common installation, heaters should be arranged around the outside walls and blow-
ing parallel to them. Heaters may be arranged in a supporting consecutive air pattern
so that the output of one blows beneath the air-intake side of another. In installations
where there are concentrated heat loss areas, a combination of single and multiple
arrangements is desirable. See illustrations in FIGURE 1.
Form I-OH, PN 120390 R4, Page 4
4. Clearances and
Dimensions
3. Receiving,
Uncrating, and
Moving
TABLE 1 lists air throw of a Model OH heater installed at 9-foot (2.7M) mounting
height.
OH Size 95 140 190
Throw 50 ft 65 ft 65 ft
15.2M 19.8M 19.8M
2.2 Throw
Immediately upon uncrating the unit, check for any damage that may have been incurred
in shipment. If any damage is found, immediately document the damage with the trans-
porting agency and contact an authorized Reznor Distributor. If you are an authorized
Distributor, follow the FOB freight policy procedures as published by Thomas & Betts
for Reznor products. The unit was inspected and tested at the factory prior to crating
and was in operating condition at that time.
To prevent damage to the painted cabinet, it is recommended that the crate bottom be
left in place until after the unit has been suspended.
A cleaning rake base is included with all units. If the heater is being installed in Canada,
an Option DB1 barometric draft regulator is required. The option kit is shipped sepa-
rately. The installation could also include a variety of other shipped-separate options.
Be sure that all optional components to be used in the installation are at the job site.
4.1 Clearances
Clearance to combustibles is dened as the minimum distance from the heater to a
surface or object that is necessary to ensure that a surface temperature of 90°F above
the surrounding ambient temperature is not exceeded.
The heater should be suspended at a height so that the heat exchanger cannot be
touched. For additional information on installation clearances, refer to CAN/CSA-B139,
"Installation Code for Oil Burning Equipment", Paragraph 8 -- Installation Clearances.
TABLE 2 - Clearances (inches/mm)
Top 2" 51mm
Front 48" 1219mm
Sides (allow for Service Access) 18" 457mm
Rear 24" 610mm
Bottom 6" 152mm
Flue Pipe 18" 457mm
WARNING:
Clearances
apply to ALL
combustibles.
DO NOT leave
paper, rags, or any
combustible
near the heater.
Narrow Building - Single units arranged to compensate for heat loss from four exposed outside walls.
Wider Building - Single units
arranged to compensate for heat
loss from four exposed outside
walls.
FIGURE 1 -
Recommended
Arrangements
TABLE 1 - Throw of a
heater installed at 9-ft
(2.7M)
2. Location
(cont'd)
2.1 Arrangement (cont'd)
Form I-OH, PN 120390 R4, Page 5
4.2 Dimensions
FIGURE 2 - Model OH Dimensions
TABLE 3 - Dimensions (inches/mm)
Size A B C D
95 inches 8 17-3/8 33 7
mm 203 441 838 178
140 and
190
inches 9-1/2 37-3/8 43 8
mm 241 949 1092 203
5. Suspension or
Mounting
5.1 Weight
Before suspending the heater, check the supporting structure to ensure that it has suf-
cient load-carrying capacity to support the weight of the heater. For clearances and
dimensions, refer to Paragraph 4.
Model OH Net Weights - lbs (kg)
Size 95 140 190
lbs 290 345 345
kg 132 156 156
TABLE 4 - Unit Weight
FIGURE 3A - Suspension with 1/2" threaded rod
1/2” Threaded Rod
(See NOTE)
Flat Washer
Hex Nut
Lock Nut
NOTE: Units manufactured prior to 10/94 are
suspended with 3/8" rods and hardware.
5.2 Hanging the
Heater
Use four 1/2" diameter threaded rods. Lock threaded rod using a washer and nut as
shown in FIGURE 3A. Or, use optional swivel connectors (Option CK10) and eld-pro-
vided 1" threaded pipe. Lock swivel connections as shown in FIGURE 3B.
Lock Nut
1” Standard Pipe
Swivel Assembly
Flat Washer
FIGURE 3B - Suspension with
optional swivels (Option CK10) and
1" threaded pipe
Form I-OH, PN 120390 R4, Page 6
Remove the shipping crate bottom from the heater. Remove the angle clips that attached
the shipping crate to the heater. Re-insert the screws into the heater cabinet.
WARNING: Units must be supported level for proper operation.
Do not place or add additional weight to the suspended
heater.
5.3 Mounting the
Heater
6. Mechanical 6.1 Fuel Tank and Supply Lines
Four methods of piping fuel to an oil-red heater are illustrated in this Paragraph.
Piping system selection depends on the application but certain systems are recom-
mended for specic installation conditions.
The one-pipe arrangement (Paragraph 6.1.1) is used with the standard 1-stage
burner pump.
The two-pipe (Paragraph 6.1.2) arrangement can be used with either the standard
1-stage burner pump or an optional 2-stage burner pump.
The loop and pressurized systems (Paragraphs 6.1.3 and 6.1.4) may be used
when installing more than one heater and require an additional booster pump for
oil delivery.
Fuel Tank
Oil tanks must be installed in accordance with all local regulations and the National
Board of Fire Underwriters or CSA Standard.
All oil tanks must include a vent pipe to the outdoors. The lower end of the vent pipe
should not extend more than one inch below the upper most point of the tank. The vent
pipe terminal should be weatherproof and clogproof.
Installation of the fuel tank and piping is the responsibility of the installing contractor.
Pipe Tubing
All piping shall be standard full weight black iron pipe with standard ttings or approved
brass or copper tubing, with UL listed ttings. At least 1/2" iron pipe or 3/8" O.D. cop-
per tubing (1/2" O.D. copper tubing is preferred) having a wall thickness not less than
0.049" shall be used to connect the burner to the tank.
All piping shall be protected from possible injury and shall be rigidly fastened. Where
practical, it should be buried underground or in a concrete oor or placed in a metal-
covered pipe trench. If installed above ground, the pipe must be insulated to avoid
freezing. Do not cover the piping until the burner has been installed and operated so
that any leaks may be detected and corrected. Pipe joints and connections shall be
made tight and only unions and tube ttings of an approved type shall be used. Use
only pipe thread compound resistant to oil. Do not use TEFLON® tape or TEFLON®-
based pipe dope. (TEFLON® is a registered trademark of E. I. DuPont de Nemours and
Company).
Oil Filter
Install a UL-listed (U.S.A.) or CSA/USC (Canada) oil lter of generous capacity between
the tank shutoff valve and the burner. For ease of servicing, locate the lter and shutoff
valve close to the oil burner.
Shutoff Valve
Install a readily accessible manual shutoff valve at each point to properly control the
ow of fuel in normal operation and where required to avoid oil spillage during servic-
ing. The valve should close against the supply. If the heater will not be operating for an
extended period of time, close the shutoff valve.
Where a shutoff is installed in the discharge line of an oil pump that is not an integral
•
•
•
5. Suspension
or Mounting
(cont'd)
5.2 Hanging the Heater (cont'd)
If ordered with an optional workbench fuel tank (Option OT) and heater stand (Option
HS), follow the recommendations with the tank and in Paragraph 6.1 for positioning the
tank. Follow the instructions shipped with the stand to assemble the parts.
Set the Model OH heater on the stand to create a unied structure. Follow the stand
instructions to secure the unit.
Form I-OH, PN 120390 R4, Page 7
part of a burner, connect a pressure relief valve into the discharge line between the
pump and the shutoff valve and arrange to return surplus oil to the supply tank or to
bypass it around the pump, unless the pump includes an internal bypass.
Any fuel oil line incorporating a heater shall be provided with a relief valve arranged
to discharge to the return line when any valve, pump, or other device may prevent the
release of excessive pressure because of the expansion of the oil when heated.
Where oil is supplied to a burner requiring uniform ow by gravity feed and a constant
level valve is not incorporated in the burner assembly or the oil is not supplied by an
automatic pump, install a constant level valve in the supply line at the gravity tank or as
close as practical, to ensure uniform delivery of oil to the burner. The vent opening of
the constant level valve should be connected by piping or tubing to the outside of the
building, unless the constant level valve is provided with an anti-ooding device. Do
not connect the vent piping or tubing of constant level valves to tanks or tank vents.
Prior to entering enclosures, such as vaults or pits, where pumps and accessories are
installed, provide for adequate ventilation.
6.1.1 Standard Single Stage Burner Pump with Single Supply Pipe
The standard burner is equipped with a single-stage, 3450 RPM pump with the lift
capacity shown in FIGURE 4. Maximum lift is 8 ft (2.4M). Fittings, valves and lters
will reduce total line length allowed. Check component manufacturer's information for
equivalent length reduction required to compensate for pressure loss. A one-pipe sup-
ply system must be absolutely airtight, or leaks and/or loss of prime may result. Follow
instructions in Paragraph 8.2, Check-Test-Start (Operating Procedure) to bleed the
line. Bleed for 15 seconds after last air is seen from easy ow bleed valve to be certain
lines are air free.
FIGURE 4 - Single Pipe Supply System (single-stage burner pump)
Maximum Horizontal Line Length (ft) by
Heater Size and Size of Tubing
Maximum Horizontal Line Length (M) by
Heater Size and Size of Tubing
Lift 95 140 190 Lift 95 140 190
(ft) 3/8" 1/2" 3/8" 1/2" 3/8" 1/2" (M) 3/8" 1/2" 3/8" 1/2" 3/8" 1/2"
0 822 3158 556 2222 423 1667 0.0 251 963 169 677 129 508
1 719 2763 486 1944 370 1458 0.3 219 842 148 593 113 444
2 616 2368 417 1667 317 1250 0.6 188 722 127 508 97 381
3 514 1974 347 1389 264 1042 0.9 157 902 106 423 80 318
4 411 1579 278 1111 211 833 1.2 125 481 85 339 64 254
5 308 1184 208 833 158 625 1.5 94 361 63 254 48 191
6 205 789 139 556 106 417 1.8 62 240 42 169 32 127
7 103 395 69 278 53 208 2.1 31 120 21 85 16 63
8 0 0 0 0 0 0 2.4 0 0 0 0 0 0
Length =
6 ft - (.75 X Lift)
(.0086 for 3/8" tubing or
.00218 for 1/2" tubing) X(Firing Rate in GPH - OH95, .085;
OH140, 1.25; OH190, 1.35)
Formula for determining gures (ft) in TABLE 5 above.
TABLE 5 - Maximum Horizontal Line Length
(ft/M) with a Single Pipe Supply System
6.1.2 Two-Pipe Supply System with Standard Single-Stage Pump
or Optional Two-Stage Pump
A two-pipe supply system may be used with the standard burner pump or with a two-
stage pump if Option BZ1 was ordered. The two-stage pump provides dual pumping
gears. To install the two-pipe supply system, remove the 1/4" plug from the return line
port and insert the 1/16" bypass plug (Shipped with the burner pump; see FIGURE
17, page 17.). Attach the inlet and return lines. Always terminate the return line 3 to 4
inches (76 to 102mm) above the supply line inlet. See FIGURE 5.
Form I-OH, PN 120390 R4, Page 8
6. Mechanical
(cont'd)
6.1 Fuel Tank and Supply Lines (cont'd)
FIGURE 5 - Two-Pipe Supply
System (standard 1-stage or
optional 2-stage burner pump)
Maximum Horizontal Supply Line Length for
Two-Line System (Supply and Return)
Lift Std 1-stg pump Opt 2-stg pump
ft (M) 3/8" OD 1/2" OD 3/8" OD 1/2" OD
0 (0) 84 (25.6) 100 (30.5) 93 (28.3) 100 (30.5)
1 (.3) 77 (23.5) 99 (30.1) 88 (26.8) 99 (30.1)
2 (.6) 71 (21.6) 98 (29.8) 83 (25.3) 98 (29.8)
3 (.9) 65 (19.8) 97 (29.5) 78 (23.8) 97 (29.5)
4 (1.2) 59 (18) 96 (29.3) 73 (22.2) 96 (29.3)
5 (1.5) 52 (15.8) 95 (29) 68 (20.7) 95 (29)
6 (1.8) 46 (14) 94 (28.6) 63 (19.2) 94 (28.6)
7 (2.1) 40 (12.2) 93 (28.3) 58 (17.7) 93 (28.3)
8 (2.4) 34 (10.3) 92 (28) 52 (16) 92 (28)
9 (2.7) 27 (8.2) 91 (27.7) 47 (14.3) 91 (27.7)
10 (3) 21 (6) 90 (27.4) 42 (12.8) 90 (27.4)
11 (3.3) 15 (4.5) 89 (27.1) 37 (11.3) 89 (27.1)
12 (3.6) 9 (2.7) 71 (21.6) 32 (9.8) 88 (26.8)
13 (3.9) 49 (14.9) 27 (8.2) 87 (26.5)
14 (4.2) 27 (8.2) 22 (6.7) 86 (26.2)
16 (4.8) 11 (3.4) 84 (25.6)
18 (5.4) 58 (17.7)
6.1.3 Loop System
The loop piping system uses the standard single-stage burner pump and an optional
boost pump (Option DA1 or DA2; see Paragraph 6.1.5.). A loop system is one in which
a boost pump supplies fuel oil from the supply tank to individual heaters in excess of
burner requirements. The fuel oil is returned to the supply tank. This system should
not be operated at line pressures greater than 3 psi at the rst burner supplied. Boost
pump operates full time during the heating season.
NOTE: If a two-foot rise cannot be maintained, use Pressurized System, Paragraph
6.1.4.
FIGURE 6 - Loop
Supply System
for Multiple Unit
Installation
Boost pump must
run continuously.
See Paragraph 6.1.5.
TABLE 6 - Maximum Horizontal
Supply Line Length with Two-Pipe
Supply System (ft/M) - All OH Sizes
6.1.2 Two-Pipe Supply System with Standard Single-Stage Pump
or Optional Two-Stage Pump (cont'd)
Form I-OH, PN 120390 R4, Page 9
All manifold and feeder lines must run in a horizontal plane at an elevation above the
fuel intakes of the units. Extend feeder lines downward to fuel burner intakes.
6.1.4 Pressurized System
A pressurized system is one in which a boost pump is used to supply fuel oil to a
manifold for which branch lines supply each heater. The end of the manifold is capped,
and the system is operated at a pressure not exceeding 3 psi at the rst burner sup-
plied. BTU output in this type of system is determined by boost pump capacity and
the subsequent number of burners that can be supplied adequately by fuel oil. For
example, a 30 GPH booster pump will sustain eighteen 1.65 GPH burners. An optional
solenoid valve is recommended to protect burner pump seal against excessive pres-
sure. Optional pressure switch monitors nozzle pressure and will start booster pump
on pressure fall.
Boost pump operation in a pressurized system may be continuous or may be intermit-
tent when optional pressure switches are used.
6.1.5 Boost Pump Assembly (Option DA1 or DA2)
The boost pump is equipped with a motor and is supplied with a two-stage fuel unit
incorporating a regulator valve and strainer. The valve acts as a check to prevent loss
of oil supply between the boost pump and the burner, thus assuring instantaneous
starts following shutdown periods. Regulator valve also prevents excessive pressures.
Complete assembly with motor is approximately 15" (381mm) long, 7-1/2" (191mm)
high and 6-3/4" (171mm) wide overall.
FIGURE 7 -
Pressurized Supply
System (multiple
units)
Boost Pump will run
intermittently. See
Paragraph 6.1.5.
FIGURE 8 - Boost
Pump and Mounting
Bracket
Boost Pump
Bracket
Mounting
Dimensions
(Bottom View)
Boost Pump
30GPH/70GPH
TABLE 7A - Maximum Horizontal Length from Boost Pump to Burner(s)
Boost Pump GPH 1/2" OD Tubing 1/2" Pipe 3/4" Pipe
ft M ft M ft M
Option DA1 30 175 53.3 300 91.4 1800 548.6
Option DA2 70 50 15.2 100 30.5 600 182.9
Boost Pump Capacities
Maximum Height from Boost Pump to Burner -- 35 feet (10.7M).
Form I-OH, PN 120390 R4, Page 10
FIGURE 9 - Boost
Pump Wiring for
Constant Operation
(Loop System,
Paragraph 6.1.3)
FIGURE 10 - Boost
Pump Wiring for
Intermittent Operation
(Pressurized System,
Paragraph 6.1.4)
TABLE 7B - Maximum Horizontal Length from Oil Supply to Boost Pump by Line Size
Line Size 1/2" OD Tubing 5/8" OD Tubing 1/2" Pipe
Maximum Horizontal Length from Oil Supply to Boost Pump (ft)
Lift 0-7 ft 10 ft 15 ft 0-7 ft 10 ft 15 ft 0-7 ft 10 ft 15 ft
Opt DA1, GPH30 64' 49' 24' 100' 100' 65' 100' 100' 100'
Opt DA2, GPH70 44' 34' 17' 100' 95' 48' 100' 90' 65'
Maximum Horizontal Length from Oil Supply to Boost Pump (meters)
Lift 0-2.1 M 3 M 4.6 M 0-2.1 M 3 M 4.6 M 0-2.1 M 3 M 4.6 M
Opt DA1, GPH30 19.5M 14.9M 7.3M 30.4M 30.4M 19.8M 30.4M 30.4M 30.4M
Opt DA2, GPH70 13.4M 10.4M 5.2M 30.4M 29M 14.6M 30.4M 27.4M 19.8M
6. Mechanical
(cont'd)
6.1 Fuel Tank and
Supply Lines
(cont'd)
Boost Pump Pressure Switch (Option DF1, shipped separately)
Application - Intermittent boost pump operation in a pressurized system (Para-
graph 6.1.4).
This low voltage, normally open type switch closes at approximately 50 psi. Maximum
allowable pressure is 150 psi. One is required for each burner. The switch is speci-
cally designed for fuel oil and includes a 1/8" male pipe thread connector and screw
terminals.
A manual switch, for initial starting (or continuous operation) is recommended for instal-
lation in the low voltage circuit.
Pressurized piping systems must not exceed 3 psi. An oil solenoid valve (Option DD1)
is recommended at each unit to prevent seal damage should the pressure for any rea-
son exceed the maximum of 3 psi.
6.1.5 Boost Pump Assembly (Option DA1 or DA2) (cont'd)
Form I-OH, PN 120390 R4, Page 11
WARNING: Failure to provide proper venting could result in
death, serious injury, and/or property damage. Unit must be
connected to ue having sufcient draft to ensure safe and
proper operation. Unit must be properly vented to the outside
of the building. Safe operation of any gravity-vented heating
equipment requires a properly operating vent system, correct
provision for combustion air, and regular maintenance and
inspection. See Hazard Levels, page 2.
6.2 Venting and
Combustion Air
6.1.6 Optional Solenoid Valve (Option DD1, shipped separately)
Use of the optional solenoid valve is recommended with the pressurized oil delivery
system (Paragraph 6.1.4). It is designed to operate simultaneously with the burner
motor.
6.1.7 Optional Oil Safety Valve (OSV) (Option DC1, shipped
separately)
The oil safety valve is opened by the slight vacuum created by the burner pump and
closes when the vacuum condition subsides. This prevents siphoning of the supply
line and eliminates spill, if any leaks develop downstream from the OSV. Use of the
optional oil safety valve is highly recommended.
6.1.8 Check Valve
The check valve prevents reverse ow of oil maintaining static head pressure between
the check valve and the automatic valve on the burner, thus preventing siphoning.
Check valves are eld provided and are not needed when an oil safety valve (Option
DC1) is used.
6.2.1 Venting Masonry chimneys and metal chimneys must be built in accordance with accepted
building code practice. A Class A chimney or equivalent is required for this heater.
Standards for chimneys can be found in NFPA Standard No. 211, published in National
Fire Codes, Volume 4; the National Building Code of the American Insurance Associa-
tion, New York, NY; ULC Standards for chimneys; or the National Building Code of
Canada published by the National Research Council, Ottawa.
If an existing masonry or metal chimney is being used, prior to installing the heater,
clean and inspect the chimney. Make any necessary repairs and be sure that the chim-
ney meets all requirements.
If an approved factory-built chimney is being installed, be sure that it meets all require-
ments and install it according to the manufacturer's instructions. If a eld-constructed
metal chimney is being installed, follow all of the requirements listed below.
• Use at least 8" (203mm) diameter vent pipe for Sizes 140/190 and at least 7"
(178mm) diameter for Size 95.
• Use either 24-gauge or heavier, galvanized steel or triple-wall stainless steel vent
pipe. (Triple-wall stainless steel vent pipe is recommended.)
• If the venting arrangement includes passing through a ceiling, triple-wall stainless
vent pipe is required above the ceiling. The point of passage through a ceiling
must be guarded by a metal ventilated thimble not less than 12" (305mm) larger in
diameter than the pipe.
• Install a tee with a cleanout cap at the bottom of the vertical rise.
The smallest dimension of the chimney must be at least 8" in diameter for Size 140
and 190 heaters and at least 7" in diameter for a Size 95 model. The chimney must
be at least three feet (.9M) above the highest point of exit where it passes through the
roof, and at least two feet (.6M) higher than any portion of a building within ten feet
(3M) of the chimney. Total chimney height must be a minimum of eight feet (2.4M). The
chimney must be capable of maintaining a steady draft of .04" w.c. If draft is below the
minimum required, a draft inducer must be installed.
For the vent connection from the ue outlet of the heater to the chimney, use vent pipe
of either 24-gauge or heavier galvanized steel or triple-wall stainless steel. For Sizes
Form I-OH, PN 120390 R4, Page 12
140 and 190 use 8" diameter pipe; for Size 95, use 7" diameter pipe. Keep the length of
the vent pipe connection as short and direct as possible. As it leaves the heater, slope
the horizontal run upward at least one inch for each three feet of pipe. The horizontal
run should not be longer than one-half of the vertical or chimney height and never over
ten feet (3M) unless a draft inducer is being installed.
If the vent pipe connector passes through a combustible wall, it must be guarded at
the point of passage by either a metal ventilated thimble not less than 12" (305mm)
larger in diameter than the pipe, or a metal or burned reclay thimble built in brickwork
or other approved reproong material extending not less than 8" (203mm) beyond all
sides of the thimble. If a thimble is not installed, all combustible material in the wall or
partition must be cut away 9" (229mm) from the pipe. If any material is used to close
this opening, it must be non-combustible.
Fasten all vent piping with sheetmetal screws and support horizontal vent pipe from
above with noncombustible straps. Avoid sharp turns in the vent pipe or other construc-
tion features that would create resistance to the ow of the ue gases. Do not use a
manually operated damper or any other device that will obstruct the free ow of the
ue gases.
The end of the vent pipe connection must not extend past the inside wall of the chim-
ney. A thimble may be used in the chimney connection to facilitate removal for cleaning.
The thimble should be permanently cemented in place with high-temperature cement.
Draft Regulator
Requirements
6. Mechanical
(cont'd)
6.2 Venting and
Combustion Air
(cont'd)
Option DB1,
Barometric
Draft
Regulator
FIGURE 11 - Draft
Regulator, Option
DB1 (Required in
Canada. Option
DB1 or equivalent
is required in U.S.)
6.2.1 Venting (cont'd)
Canadian Installation - Option DB1 certied barometric draft regulator is required and
must be installed near the heater ue outlet. The preferred mounting location for the
draft regulator is in the vertical ue pipe (See FIGURE 11). Depending on the venting
arrangement, the alternate location for installing the draft regulator is in the horizontal
run. Follow the manufacturer's instructions included with the draft regulator.
U.S.A. Installation - A UL listed type barometric draft regulator such as Option DB1,
must be installed (See Installation Note below for exception) in the ue near the heater
ue outlet. The preferred mounting location for the draft regulator is in the vertical ue
pipe (See FIGURE 5). Depending on the venting arrangement, the alternate location
for installing the draft regulator is in the horizontal run. Install the draft regulator accord-
ing to the manufacturer's instructions.
(INSTALLATION NOTE: Do not install a barometric draft regulator if the installation
includes an optional outside combustion air inlet, Option DE1.)
Optional Draft Inducer Relay (Option DH1)
A eld-supplied U.L. (U.S.A.) or CSA/ULC (Canada) listed draft inducer is required
when the draft in the ue measures less than .04" w.c. on a draft gauge. Instructions
for measuring draft are included in Paragraph 8.2. A relay (Option DH1) is available for
connecting the draft inducer.
When a draft inducer is installed, a safety provision must be made to shut off the fuel
supply to the burner in the event of the failure of the draft inducer. See optional exhaust
ow safety switch on the wiring diagram.
Form I-OH, PN 120390 R4, Page 13
6.2.2 Combustion Air WARNING: Exercise care to ensure that an adequate supply of
combustion air is available and free to enter the air openings
on all units.
Openings equal to one inch square per each 1,000 BTUH
should be used to allow combustion air to enter the room
where the heater is installed.
FIGURE 12 - Optional
Outside Combustion
Air Intake Adapter,
Option DE1
Optional Outside Combustion Air Intake Adapter Kit, UL Listed,
Option DE1 (shipped separately) (Not available for Canadian
installation.)
The combustion air adapter will provide outside air for combustion. Follow the manu-
facturer's instructions furnished with the kit.
7. Electrical
Supply and
Connections
7.1 General
All wiring must be done in accordance with the National Electric Code or CSA Standard
C22.1, Canadian Electrical Code, Part 1, and local ordinances. In many localities, No.
14 wire run in rigid conduit must be used, but where permissible, two and three wire BX
is recommended, particularly for connections to the controls and burner motor. A cutoff
switch for the main 115 volt line to the burner should be mounted on a reproof wall in
an accessible place close to the burner.
The heater is equipped with low voltage controls (24V) for thermostat control. See
separate instructions for any optional equipment provided.
7.2 Supply and Line
Wiring
TABLE 8 - Electrical
Ratings, 115V, 60 Hz
Check the rating plate on the heater for supply voltage and current requirements. A
separate line voltage supply with fused disconnect switch should be run directly from
the main panel to the heater, making connection to leads in the junction box. All exter-
nal wiring must be within approved conduit. See wiring diagram in the heater junction
box. Conduit from the disconnect switch must be run so as to not interfere with heater
service access.
All replacement wiring must be type SF, SEWF, TW, TEW or equivalent. Use 18 gauge
wire for control circuits; 14 gauge or larger, depending on current requirements, for line
connections.
OH
Size
Total Current
Amperes
Minimum Circuit
Ampacity
Minimum
Fuse Size
95 6 8 15
140 7 9 15
190 7 9 15
Form I-OH, PN 120390 R4, Page 14
115/1/60
7.3 Wiring Diagrams
FIGURE 13 - Typical
Wiring Diagram for
Model OH with a UL
Logo, W.D. 119645
FIGURE 14 - Typical
Wiring Diagram for a
Model OH with a CSA
Logo, W.D. 228148
7. Electrical
Supply and
Connections
(cont'd)
Form I-OH, PN 120390 R4, Page 15
7.4 Major Components
Motors - See electrical characteristics in TABLE 9. The fan motor is totally enclosed
and is equipped with internal overload protection.
Motor Size HP Volts Amps RPM
Fan
95 1/8 115 2.7 1050
140, 190 1/4 115 3.7 850
140, 190 3/4 115 11 1725
Std 1-Stage Burner Pump 95, 140,
190
1/7 115 2 3450
Opt 2-Stage Burner Pump 1/7 115 2 3450
Optional Boost Pump 1/8 115 5.8 1725
Electrodes and Nozzle Location
IMPORTANT: Check the electrode adjustment prior to ring
the unit. Electrodes are adjusted at the time of manufacture.
However, they should be checked at time of installation to be
sure that they are still set as illustrated in FIGURES 15 and
16.
CAUTION: Turn off main electric supply switch before
attempting to check or adjust electrodes.
FIGURE 16 - Nozzle Position in Relation to
Burner Head
FIGURE 15 - Electrode Gap for Beckett
Burner (Front View and Side View)
Burner Pump
This oil-red heater has either a standard single-stage, 3450 RPM pump or an
optional two-stage, 3450 pump (Option BZ1). Review the burner pump illustra-
tion, FIGURE 17, for port, bleed, inlet, regulator, and bypass plug locations.
NOTE: Bypass plug must be inserted when return connection is made by two-
pipe supply system.
Pump Pressure Check (See Paragraph 8.1) - If a pressure check is made, use either
the gauge port or nozzle port. Do not use easy ow bleed valve port. The easy ow
bleed valve port contains pressure higher than operating pressure. Setting pump
pressure with gauge in the easy ow bleed valve port results in WRONG operat-
ing pressure.
TABLE 9 - Electrical
Characteristics of
Motors
Form I-OH, PN 120390 R4, Page 16
FIGURE 17 -
Burner Pump
Vacuum Check - A vacuum gauge may be installed on either side of the 1/4"
inlet ports or in the 1/8" return port (on single pipe installation), whichever is
most convenient. With a standard 1-stage pump, vacuum should not exceed
6" hg on single-pipe system or 12" hg on two-pipe system. With an optional 2-
stage pump, vacuum should not exceed 17" hg.
IMPORTANT: Long or oversized inlet lines may require the pump to operate during
initial bleeding period. In such cases, the priming may be assisted by injecting fuel oil
into the pump gearset. Under lift conditions, oil lines and ttings must be airtight. To
assure this, oil resistant pipe dope should be applied to both the used and unused inlet
and both return ttings.
Fan and Limit Controls
This heater is equipped with a fan and limit control assembly consisting of a specially
designed control mounting bracket with a fan control, a circulating air high limit control,
and a super high limit control attached. To access the fan and limit control assembly,
remove the plate illustrated in FIGURE 18. For service information, see Troubleshoot-
ing Guide, High Limit Cycles, Paragraph 9.3.
The main functions of the fan/blower control are to provide (1) delay of fan or blower
operation, preventing circulation of cold air at startup, and (2) continued fan or blower
operation as long as the unit temperature is above the minimum setting (120°F). The
fan/blower control also provides additional safety control by keeping the fan or blower
in operation in the event that a malfunction would cause the oil burner to continue to
re when the thermostat is satised.
Remove plate to access fan
and limit control assembly.
Circulating Air
High Limit
Fan
Control
FIGURE 18 - Access
and Identication of
the Fan and Limit
Controls
Fan and Limit
Control Assembly
Super
Limit
7. Electrical
Supply and
Connections
(cont'd)
7.4 Major
Components
(cont'd)
CAUTION: Pres-
surized or gravity
feed installations
must not exceed 3
PSI on inlet line or
return line at the
pump. A pressure
greater than 3 PSI
may cause damage
to the shaft seal.
Form I-OH, PN 120390 R4, Page 17
Primary Control System
The primary control, mounted on a 4x4 outlet box on the burner is responsible for start-
ing the burner, supervising a safety operating cycle, shutting the burner off at the end
of the call for heat, and locking out "on safety" if there is a ame failure beyond the
safety timing.
The primary control system has a cadmium sulde cell that responds to light intensity
to sense the presence or absence of ame. The ignition system is comprised of an
ignition transformer and two electrodes that deliver a concentrated spark across a xed
gap to ignite the oil droplets in the nozzle spray. If the spark is inadequate, the cad-
mium sulde cell will not sense the presence of ame and the primary control system
will lock out.
Blocked Vent Switch (CSA only)
The blocked vent switch is mounted on a bracket on the control side of the heater. It is
a manually reset, temperature sensitive switch designed to shut down the burner when
there is a positive pressure in the combustion chamber.
Before attempting to restart a heater that has been shut down by the blocked vent
switch, nd and remove the blockage causing the positive pressure. After correcting
the problem, reset the switch.
7.5 Control Wiring Thermostat
Use either an optional thermostat supplied with the heater or a eld-supplied thermo-
stat. A 24-volt thermostat is required to actuate the low voltage controls on this heater.
A line voltage thermostat can be used when wired for low voltage use. Do not attempt
to wire relays or other accessories to the thermostat connections as these are
not load terminals.
The thermostat should be located ve feet above the oor on an inside wall, not in the
path of warm or cold air currents, nor in corners where air may be pocketed. DO NOT
install on or directly suspend from the heater. DO NOT install the thermostat on a cold,
outside wall. For specic connection details and instructions on setting the heat antici-
pator, refer to manufacturer's instructions provided with the thermostat.
8. Commissioning
and Startup
8.1 Checklist Prior to Startup
Check clearances. Be certain that the clearances listed in Paragraph 4.1 have
been observed.
Check hangers. Be certain that all hangers are adequately anchored and that all
unions or threaded ttings are snug and do not rotate under conditions of vibration.
Heater must be level.
Check electrical supply. Be sure that wire gauges are as recommended and
that the voltage is as stated on the furnace. A service disconnect switch should be
used. Also determine that fusing or circuit breakers are adequate for the load use.
Check oil supply.
Check piping. After installation and before being covered, piping should be tested
for leaks. Before testing, disconnect supply piping at the burner and cap. Test pip-
ing hydrostatically, or with equivalent air pressure, not less than 1-1/2 times the
maximum working pressure but not less than 5 pounds per square inch at the
highest point of the system. The test shall be made so as not to impose a pressure
□
□
□
□
□
The circulating air high limit switch has a nonadjustable setting of 145°F for a Size 95
heater and 160°F for Sizes 140 and 190. The limit control automatically cycles when
the internal temperature exceeds those setpoints. For the heater to operate properly
and safely, the cause for the temperature exceeding the high limit setpoint must be
determined and corrected.
The super high limit switch provides redundant safety control and is calibrated to open
at a much higher temperature (350°F) than the standard automatic reset limit switch.
An interruption of the circuit by the super high limit switch indicates a major failure
caused by a malfunction of the primary safety controls or mis-wiring. Before attempt-
ing to re-start the heater, the cause must be corrected and the fan and limit assembly
replaced.
CAUTION: Make
sure the thermostat
has an adequate
VA rating for the
total requirements.
Form I-OH, PN 120390 R4, Page 18
of more than ten pounds per square inch on the tank. This test shall be maintained
for at least 30 minutes or for sufcient time to complete a visual inspection of all
joints and connections. Instead of a pressure test to check piping, suction lines
may be used under a vacuum of not less than 20 inches of mercury maintained for
at least 30 minutes.
Check vents. Be sure that vent pipe and chimney meet requirements shown
in Paragraph 6.2. An approved draft regulator is required. In order to measure
the draft in the stack after ring, drill a 5/16" hole in the ue pipe halfway
between the heater and the draft regulator for insertion of the draft gauge.
Check electrode adjustment. See instructions in Paragraph 9.2.3. Turn off the
electric power before making check.
Check oil delivery. For an accurate check on the oil delivery, remove the burner
assembly and connect it outside the rebox. Disconnect high tension lead. Start
the burner, collect the oil ow for one minute and measure it in a container marked
in cubic centimeters. (Some safety controls may trip when operated for one min-
ute. If this occurs, collect the ow from the nozzle for 30 seconds, measure the
cubic centimeters, multiply by two and check with the chart.) Listed in the table is
the required ow in cubic centimeters (cc) per minute to obtain the output in gal-
lons per hour.
□
□
□
8.2 Check-Test-
Start (Operating
Procedure)
Priming the heater -- single pipe system. The oil supply line to the heater must
be full of oil and free of air for proper heater operation. Follow the steps below to
ll the oil line. Note: Priming the oil line could take up to 30 minutes depending on
the size of heater and the length of the supply line.
Be sure that the oil tank is lled to a level at least 6" (152mm) above the foot valve.
Set the thermostat to its lowest setting.
Connect a piece of rubber tubing to the air bleed valve on the burner pump (See FIG-
URE 19) and place the other end into an open container (no smaller than a pint).
Turn off the electrical power at the switch on the heater electrical box. See FIGURE
20.
Using a 3/8" wrench, loosen the air bleed valve two or three turns.
Set the thermostat above room temperature.
Turn the electric power on. Burner pump will operate.
Oil will run into the container when the air has been bled from the line. (While operat-
ing under these conditions, the heater will not light because the pressure valve in the
pump will not open.) If the primary control activates to shut down the pump before the
line is bled, push the reset button. See FIGURE 20. It may be necessary to push the
reset button several times while bleeding off air. Wait three to four minutes between
pushes of the reset button to allow the internal bimetal strip to cool down. The pump
will run for 45 seconds each time.
After all of the air is bled from the line, close the bleeder valve. Turn the main power
off.
Priming the Unit - two-pipe supply system. Install a pressure gauge and turn
the burner on. The system will vent itself through the return line. Flame will appear
as soon as the air has been eliminated.
Check and adjust nozzle pressure.
1) Install a pressure gauge (125 psig minimum) into the pressure gauge port on the
burner pump. (See FIGURE 19.)
2) The air shutter was preset at the factory. Verify the air shutter setting on the burner
with the chart in FIGURE 21. All other controls should be in normal position.
3) Turn off the electrical power.
4) Set the thermostat to above room temperature.
□
1.
2.
3.
4.
5.
6.
7.
8.
9.
□
□
8. Commissioning
and Startup
(cont'd)
8.1 Checklist Prior
to Startup
(cont'd)
Size GPH CC per Minute
95 0.85 54.0
140 1.25 78.5
190 1.35 85.0
TABLE 10 -
Check Oil
Flow Rate
Form I-OH, PN 120390 R4, Page 19
5) The pump will start and the burner ignite. With the burner ignited, check the oil
pressure and adjust, if necessary, to a pressure of 100 pounds for Sizes 95 and
140 or 150 pounds for Size 190.
Burner
Electrical
Switch
FIGURE 19 - Burner Pump
Check draft. Prior to continued operation, check to be sure that there is sufcient
draft for proper combustion. A draft of negative .01" w.c. is required over the re.
When ring, the draft measurement in the stack should be a negative .03-.04" w.c.
Instructions for measuring draft:
1) To measure draft over the re, remove the metal plug in the observation door
(See FIGURE 21, page 20.).
2) Insert air pressure gauge (such as Dwyer pressure gauge). Draft measurement
gauge must read a negative .01".
3) If measurement is not correct, adjust draft regulator until measurement is correct.
4) Replace plug.
5) To measure ue draft, insert air pressure gauge in the 5/16" hole that was drilled
in the ue pipe halfway between the furnace and the draft regulator. Flue draft
measurement must be a negative .03-.04" w.c.
If there is insufcient draft, it will create a back pressure resulting in oil fumes
in the building and/or pulsating when the burner starts and stops. It may cause
excess deposits of soot. To correct this problem, the height of the chimney may
need to be increased and/or a UL listed draft inducer may need to be installed. If
a draft inducer is used, provision must be made to shut off the fuel supply to the
burner in the event of the failure of the draft inducer.
If there is too much draft, it could cause ignition problems, erratic burner, and
loss of thermal efciency. To correct this problem, adjust the barometric damper
regulator to reduce the draft.
CAUTION: If there is a backdraft or downdraft, do not continue
operation of the heater until the situation is corrected. Equipment
and/or property damage could result. Back pressure (backdraft
or downdraft) may be caused by the chimney being lower than
surrounding objects, such as buildings, hills, trees, rooftops, etc.
It may be caused by an exhaust fan in the building. The air intake
in the room where the heater is installed must be sufcient size
so that there is no change in the draft reading in the ue with the
exhaust fan running.
Check combustion air shutter and air band settings. The heater is shipped
from the factory with the settings shown in the table in FIGURE 21. Ordinarily,
□
Location of Primary
Ignition Control
(NOTE: Unit illustration
shows older model controller.)
FIGURE 20 - Heater Controls
Primary Ignition
Control with
Reset Button
Form I-OH, PN 120390 R4, Page 20
9. Maintenance
and Service
The service and troubleshooting information in this section is designed to assist a
qualied service person.
9.1 Maintenance Requirements
Like all quality equipment, this oil-red unit heater will operate with a minimum of main-
tenance. However, to ensure long life and satisfactory performance, the following ser-
vice regimen is recommended.
Heaters should be inspected once every four months where the equipment is operating
under normal conditions. If the heater is located in an area where an unusual amount
of dust or soot or other impurities are contained in the air, more frequent inspection
is recommended. Check the motor for cleanliness. Remove dirt and grease from the
outside of the motor, and especially around the shaft. Keep air openings free of grease
and dirt. The heat exchanger should be checked at least once a year and more often
in areas where the air is heavily dust laden.
9.2 Maintenance
Procedures
9.2.1 Cleaning Combustion Chamber, Heat Exchanger, and Flue
Pipe
WARNING: Turn off electric power before inspecting or
cleaning this heater.
Instructions for removing soot from the combustion chamber/heat
exchanger
On the burner end of the heater, locate the small exhaust door panel underneath
the burner tray. See FIGURE 22. On Canadian Models, there is a screw (not shown
1.
8.2 Check-Test-
Start (Operating
Procedure
cont'd)
8. Commissioning
and Startup
(cont'd)
Air Band
Observation Door
Air Shutter
FIGURE 21 - Combustion Air Band and Air Shutter Settings
Size Air
Shutter
Air
Band
CO2
Range
95 #6 #0 9-11%
140 #6 #0 10-12%
190* #7-1/2 #0 11-13%
*Size 190 manufactured before 6/96 had
same settings as Size 140.
TABLE 11 - Settings
these settings will result in a CO2 level shown in the tabled ranges. However, cer-
tain eld conditions may require a change. In order to determine if the air setting
needs to be adjusted, a smoke tester and CO2 analyzer are required.
Air Adjustment Procedure:
1) Service and clean the burner, combustion chamber, and heat exchanger if
necessary.
2) Operate the unit for at least 10 minutes.
3) Adjust the overre draft to read between -0.01" to -0.02" w.c. Draft readings in the
breaching will be higher depending on the ue passages of the heater. The more
restrictive and lengthy the ue, the higher the draft necessary to obtain accepted
overre conditions.
4) Follow the instructions of the manufacturer of the smoke tester and take a smoke
reading. Adjust the combustion air to obtain a preliminary reading of about a No. 3
smoke spot. Then readjust the air until a reading between No. 0 and No. 1 (trace
smoke) is achieved. Do not open the air adjustment more than absolutely neces-
sary to obtain a trace or No. 0 smoke spot.
5) Follow the instructions of the manufacturer of the CO2 gas analyzer and take a
CO2 sample. Open the air shutter until the CO2 level lowers by 1%. The CO2 read-
ing should fall within the range specied in the table shown in FIGURE 21. Your
burner is now set for optimum but stable efciency.
WARNING: Turn
off electric power
before inspecting
or cleaning this
heater.
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