INSTALLATION INSTRUCTIONS - Alpine Home Air … Lennox International Company 421 Monroe Street II Bellevue, OH 44811 A CAUTION The installation of the furnace, wiring, warm air ducts,

INSTALLATION INSTRUCTIONSModels: R/LUF, R/LHF, R/LBF, R/LBR, & R/LHR

Oil-Fired Furnaces

A WARNINGImproper installation, adjustment, alteration, service, or maintenance can cause injuryor property damage. Refer to this manual. For assistance or additional information,consult a qualified installer or service agency.

AWARNINGDo not store combustible materials, includinggasoline and other flammable vapors andliquids, near the furnace, vent pipe, or warm airducts. The homeowner should be cautionedthat the furnace area must not be used as abroom closet or for any other storage purposes.Such uses may result in actions that couldcause property damage, personal injury, ordeath.

A CAUTIONNever burn garbage or paper in the heatingsystem and never leave rags, paper, or anyflammable items around the unit.

TABLE OF CONTENTS

START-UP CHECKLIST 2

INSTALLATION 3Location 3Clearances 3Venting 6Filters 10

START-UP 10

SEQUENCE OF OPERATION 12

MAINTENANCE AND SERVICE 12

WIRING DIAGRAMS... 13

AWARNINGThis furnace is not approved for installation ina mobile home. Do not install this furnace in amobile home. Installation in a mobile homecould result in actions that could cause prop-erty damage, personal injury, or death.

Manufactured ByA.A.C.

A Lennox International Company421 Monroe StreetBellevue, OH 44811

IIA CAUTION

The installation of the furnace, wiring, warm air ducts, venting, etc. must conform to the requirements of theNational Fire Protection Association Standard for the Installation of Oil Burning Equipment, NFPA No. 31; theNational Electrical Code, ANSI/NFPA No. 70 (in the USA); the Installation Code for Oil Burning Equipment,CSA Standard CAN/CSA B139 (in Canada); the Canadian Electrical Code Part 1, CSA 22.1; the Recom-mendations of the National Environmental Systems Contractors Association; and any state or provincial lawsor local ordinances. Local authorities having jurisdiction should be consulted before installation is made. Suchapplicable regulations or requirements take precedence over the general instructions in this manual.

#41996B002 Save these instructions for future reference Pagei

Provided courtesy of www.alpinehomeair.com

OIL FURNACE START-UP CHECKLIST(Complete this page and keep for future reference)

Customer Name

Address

City

Furnace Model #

Input Rate

State Zip Code

Serial #

New Construction

Date of Installation

Nozzle Used.

Replacement

Installation DataFurnace Location:A. Basement-Open_B. Utility room-OpenC. Closet-OpenD. Crawl space-Open

Enclosed*Enclosed*Enclosed*Enclosed*

Provisions must be made for adequate air for combus-tion. See Combustion and Ventilation Airon page 6.

Chimney Data:A. InsideB. Brick or Masonry.C. Lined

Outside

Size:D. Type: Class A all-purposeE. Condition

TypeL

Flue Pipe:A. Distance to chimneyB. Diameter

Pitch

C. Barometric damper installedD. Drill 5/16" hole in flue pipe 12" upstream of barometric

damper _______E. Obtain drafting reading; adjust barometric

OilTankData:A. Installed in basementB. Outside _C. Buried/Depth: _D. Size: _____E. Age:F. Date of last cleaning:

gallons

Oil Lines:A. Size: 3/8" .B. Single pipeC. Distance from tankD. Filter type

1/2" OtherTwo pipe

_ LiftInspect Change

E. Pressure testF. Recheck all fittings for tightness.

ThermostatA. Type: HeatingB. Anticipator set.C. Wires: New

Cooling

Old

Air FilterA. Type: PermanentB. InstalledC. Size:

Disposable

A.B.C.

D.E.

F.

G

Start-Up ProcedureClose disconnect switch _______Set thermostat to call for heatBleed air from lines and pump; run for 20 secondsafter bubble disappearsInstall vacuum gauge; check pump vacuumInstall pressure gauge; adjust pressure to 140 psig(except on 57 models - adjust to 100 psig) _______Always verify proper pump pressure to correspondingtables with instructions supplied with unit.After 10 minutes of operation, obtain flue temperaturereading: 1s t 2nd 3rd

Obtain smoke reading:•jst 2 n d

H. MeasureCO-1 s t

J .K.

L.

M.

Check draft overfireAir shutter setting

Breech _Locked

Measure static pressure in duct systemStatic pressure on supply sideStatic pressure on return side ,Static pressure drop

Temperature rise after steady state conditions havebeen achieved: Supply side Return sideBlock off return air (limit control checkout); burnershould shut down in 2 or 3 minutes

Owner RecordInstalled By:

Dealer

Address

Telephone #

License #

Manufactured ByA.A.C.

A Lennox international Company421 Monroe StreetBellevue, OH 44811

Page 2 These checks or tests are required for all oil units. #41996B00Provided courtesy of www.alpinehomeair.com

INSTALLATION

Read all instructions before starting work so installationwill conform to Underwriters' Laboratories or CanadianStandards Association requirements.The furnace must belevel when placed on its foundation (upflow, counterflow,and basement models) or in its suspended position(horizontal models). Using a carpenter's level, check thefurnace in at least two directions. The weight must bedistributed evenly before the duct work is attached.

These instructions must be placed on or near thefurnace in a conspicuous place.

Inspection of Shipment

This furnace is shipped in one package, completelyassembled and wired. The thermostat is shipped in aseparate carton when ordered.

Upon receipt of equipment, carefully inspect it for possibleshipping damage. If damage is found, it should be noted onthe carrier's freight bill. Damage claims should be filed withthe carrier immediately. Claims of shortages should befiled with the seller within 5 days.

Location

Locate the furnace as centrally as possible so that allwarm pipes to the various rooms are nearly the samelength. This allows each room to receive an equal andproper amount of heat. This may vary with each particularinstallation. Position the furnace so the pipe connection tothe chimney will be of minimum distance and have aminimum of fittings.

In utility rooms or similar installations, the door or accessopening should be large enough to permit replacement ofthe furnace, or another appliance such as a water heater,without disturbing any other equipment.

The R/LHR 196 rear flue models are approved forhorizontal applications only.

A WARNINGIn any installation where damage from oi! mayoccur, a drain pan must be installed. The drainpan must be large enough size to completelyprevent any potential oil damage. The drainpan piping must be sized to drain the oil pumpcapacity and the piping must be routed todrain the oil back to the oil tank.

For attic installations, a booster oil pump may be requiredto supply oil to the oil burner. Check state and local codesfor specific requirements.

Clearances

A minimum of 24" is recommended in front of the furnacefor servicing the burner on all modeis.

See Table 1 for a complete listing of the minimum clear-ances required for basement type and upflow installations.See Figure 2 on page 4 for the minimum clearancesrequired for horizontal installations and Figure 3 on page 5for the minimum clearances required for counterflowinstallations. When accessibility clearances are greater

Minimum Clearances to Combustibles - Upflow Installations

Top of Plenum andDuct Work

Plenum Sides

Furnace Sides

Furnace Rear

From Front Door

Flue Pipe Clearanceto Combustibles**

Type of Floor

Combustion AirOpenings (2 req'd)

Basement Type Units

R/LBF& R/LBR

57/72 - 84/95

2"

3"

6"*

24"

4"

9"

Comb.

10"x20"

112/125

2"

3"

6"*

24"

4"

9"

Comb.

11"x22"

140/168- 168/196

2"

3"

6"*

24"

4"

9"

Comb.

11"x22"

Hi-Boy {Upflow)

R/LUF

57/72 - 84/95

2"

3"

0"

0"

4"

6"

Comb.

10"x20"

112/125

2"

3"

0"

0"

4"

6"

Comb.

11"x22"

A passage, suitable for alarge person, shall beprovided between thefurnace and chimney forinspection or replacementof the flue connector whennecessary. A clearance of24" shall be allowed at therear and on one side of thefurnace for service andcleaning of the blower.

The minimum clearanceshown to the flue pipe maybe reduced by usingspecial protection permit-ted by local building codesand National Fire Protec-tion Association Standardsand CSA 139.

#41996B002 Table 1Page 3


than fire protection clearances, the accessibilityclearances take precedence.

Non-Suspended Horizontal Installation

To support the furnace from below, set the furnace on non-combustible material suitable to support the weight of theunit. Using a carpenter's level, check the furnace in atleast two directions. To make adjustments, use shims ofnon-combustib!e material. Seven inches minimum clear-ance between the bottom of the flue pipe and combustiblematerial is required. Installation on a combustible floorrequires a 1" clearance from the floor.

Suspended Horizontal Installation

Before suspending the furnace, remove the knockouts inthe top of the pane! at the warm air discharge and at theblower panel. Use 3/8" threaded rods cut to the desiredlength. Use one flat washer and two nuts on each rod.Place one nut and one flat washer on the inside of the unitand one nut on the outside. The outside nut serves as thelocking nut. Leve! the unit using the inside nuts. SeeFigure "I.

Hanger Rod Installation

«.__Rod

,Nut Top of*• . x Furnace

WasherNut

Figure 1

Horizontal Installation Reversing the Air Flow

This furnace is assembled to discharge warm air out theleft side (when viewed facing the burner side of thefurnace). If installation requires that the flow be reversed,follow these steps:

1. Rotate the furnace 180° so that the warm air is dis-charged out the right side.

2. Remove the oil burner and the screws securing theburner mounting plate. Rotate the burner mountingplate 180° and reattach with screws. Remount theburner in the upright position.

3. Remove the screws holding the limit control in place.Relocate the limit control to the top side of the frontpanel using the knockout hole provided.

Horizontal Installation

Top View

Supply Return

Return

Front View

A

B

C

D

E

F

G

Minimum Clearances - HorizontalInstallations

Top

Duct

Sides

Bottom

Rear

Front

Flue

84-Front

1

1

1

1

1

24

7

125Flue

"

57-196Rear Flue

4"

6"

6"

4"

24"

24"

9"

Figure 2

Counterflow Installation

This furnace is assembled to discharge warm air out theleft side (when viewed facing the burner side of thefurnace).To convert to counterflow:

1. Rotate the furnace so the return is on top and thesupply is on bottom.

2. Remove the oil burner and the screws securing theburner mounting plate. Rotate the burner mountingplate 90° clockwise and reattach the screws into theheat exchanger. Remount the burner.

3. Refer to Figure 3 for minimum clearances required.

Page 4 #41996B002Provided courtesy of www.alpinehomeair.com

Counterflow (Closet Installation)

Minimum ClearancesCounterflow Installations

A

B

C

D

LJJ

F

G

H

J

Sides

Return Plenum Top

Supply Plenum Side

Return Plenum Side

Supply Plenum Bottom

Front

Rear

Flue

Top

1"

0

1"

0

1"

16"

1"

1"*

0

The minimum clearance shown to the flue pipemay be reduced by using special protectionpermitted by local building codes and National FireProtection Association Standards and CSA 139.

A minimum of 24" must be provided in the front ofthe furnace for servicing the burner and filter. Apassage suitable for a large person shall be providedbetween the furnace and chimney for inspection orreplacement of the flue connector when necessary.

Figure 3

When installing a counterflow unit on combustibleflooring, a combustible floor base must be used. SeeFigure 4 for more information on using a combustible floorbase kit.

Combustible Floor Installation -Counterflow Units

Blower,Comparment

Sub-baseInsulation'

O oo

•JJLULLLII m I TTHV ; ; ' ' / / . - / • ' ' - / / ' / , • / . •

Cold AirDuct

Burner

CombustibleFloor Base

Warm Air Plenum

Slab Flooring j(12" minimum)

ITl I I I I I ; I I I/ / / / / • • ' / , • / • ' . -

Joist

ModelSize

(Down flow)

57/7284/95

112/125

Cold AirDuctSize

18-1/4" x18-1/4"

21-1/4"X21-1/4"

Warm AirPlenum

Size

18-1/4" x18-1/4"

21-1/4" X21-1/4"

FloorHole Size

(Wood)

19" x 19"

22"x22"

FloorHole Size

(Slab)

18-1/2" x18-1/2'

21-1/2" x21-1/2"

CombustibleFloor BaseKit Number

ABASE 537-1

ABASE 538-1

Figure 4

Kits are also available for counterflow applications where avestibule cover is needed for safety reasons.

Vestibule cover kits:

Kit for 57/72 & 84/95 counterflow models - AVEST547-1Kit for 112/125 counterflow models - AVEST548-1

It is very important that the furnace be exactly levelsince a levei unit is necessary for proper fitting ofparts. Using a carpenter's level, check the furnace in atleast two directions. If the furnace is not level, placefireproof wedges or shims between the low side ofthe furnace and the floor and check again with the

#41996B002 Page 5Provided courtesy of www.alpinehomeair.com

level. The weight of the unit must be distributedevenly on all four corners.

Air Conditioning

A WARNINGWhen an air conditioning unit is used in con-junction with the furnace, the evaporator coilmust be installed in the discharge (supply) air.Do not install an evaporator coil in the returnair; excessive condensation will occur withinthe furnace. < <; $

Venting

AWARNINGCombustion air openings in the front of thefurnace must be kept free of obstructions. Anyobstruction will cause improper burner opera-tion and may result in a fire hazard or injury.

The barometric control shall be in the sameatmospheric pressure zone as the combustionair inlet to the furnace. Deviation from thispractice will cause improper burner operationand may result in a fire hazard or injury.

Combustion and Ventilation Air

Adequate provisions for combustion air, ventilation offurnace, and dilution of the gases must be made. When afurnace is installed in an unconfined space in a building, itcan be assumed that infiltration will be sufficient to supplythe required air.

If the furnace is installed in a confined space and combus-tion air is taken from the heated space, the supply air andventilating air must be through two permanent openings ofequal area. A confined space is "a space whose volume ismore than 50 cubic feet per 1000 BTU per hour of thecombined input rating of all appliances installed in thatspace." One opening must be within 12" of the ceiiing andthe other within 12" of the floor. Each opening must have aminimum free area of at least 1 square inch per 1000 BTUper hour of total input rating of all appliances within thespace but not less than 100 square inches.

If the furnace is installed in a space within a building oftight construction, air must be supplied from outdoors. Inthis case, one opening shall be within 12" of the ceiling

and the other within 12" of the floor. If vertical combustionducts are run, each opening must have a free area of atleast 1 square inch per 4000 BTU per hour. If horizontalcombustion ducts are run, 1 square inch per 2000 BTU perhour of the total input of all appliances is required.

A return air duct system is recommended. Where there isno complete return air duct system, a return connectionshould be run full size to a location outside the confinedspace and completely sealed so that no air from theconfined space can be circulated through the heating ductsystem.

Outdoor Make Up Air

A minimum mixed return air temperature of 60 - 65°F mustbe maintained for outdoor make up air to prevent conden-sation and corrosion.

Chimney

Before installing the furnace, a thorough inspection of thechimney should be made to determine whether repairs arenecessary and that the chimney is of the proper size andconstructed in accordance with the requirements of theNational Board of Fire Underwriters or Canadian StandardsAssociation. The smallest dimension of the chimneyshould be at least equal to the diameter of the flue pipe ofthe furnace. Be sure the chimney will produce a steadydraft sufficient to remove all the products of combustionfrom the furnace. A fabricated vent system the same sizeas the flue outlet of the furnace may also be used. If amanufactured vent is used, it must be listed for use withoil-fired equipment.

Vertical Venting

A WARNING

This furnace is certified for use with Type "LTvent, Type "A," and "factory-built" chimneys. "B"vent must not be used with oil furnaces.

1. Local building codes may have more stringent installa-tion requirements and should be consulted beforeinstallation of the unit.

2. The flue pipe should be as short as possible to do thejob.

3. The flue pipe should not be smaller than the outletdiameter of the flue outlet of the furnace.

4. Single wall flue pipe should not run outside or throughany unconditioned space.

5. The chimney should terminate 2' above the highestpeak of a peaked roof, and 3' higher than a flat roof.

Page 6 #41996B002


6. The flue pipe must not pass through a floor or ceiling.Clearances to single wall flue pipe should be no lessthan specified in the Clearances section beginning onpage 3.

7. The flue pipe may pass through a wall where provi-sions have been made for a thimble as specified in theStandards of the National Board of Fire Underwriters(see Figure 5).

WallThimble

Combustible Wall-

Thimble1

Rue Pipe

Figure 5

8. The flue pipe should slope upward toward thechimney on a horizontal run of at least 1/4" perfoot and should be supported by something other thanthe furnace (see Figure 6 on this page and Figure 7 onpage 8).

9. Extend the flue pipe into the chimney so that it isflush with the inside of the flue liner. Seal the jointbetween the pipe and the liner.

10. The furnace shall be connected to a factory-builtchimney or vent complying with a recognized stan-dard, or a masonry or concrete chimney lined with alining material acceptable to the authority havingjurisdiction.

11. When two or more appliances vent into a commonflue, the area of the common flue should not be lessthan the area of the largest flue or vent connectionplus 50% of the areas of the additional vents or flueconnections. The chimney must be able to sufficientlyvent all appliances operating at the same time.

12. The flue pipe shall not be connected to a chimneyflue serving a solid fuel appliance or any mechani-cal draft system.

13. All unused chimney openings should be closed.

14. All vent pipe run through unconditioned areas oroutside shall be constructed of factory-built chimneysections (see Figure 6).

Factory-Built Chimney

Barometric Control(in either location)*

DDD

TTTTT

.Factory-BuiltChimney

Front Flue


Factory-BuiltChimney

I I I IDrain forCondensate

Rear Flue

Barometric control may be installed in either thevertical or horizontal section of the flue pipe within18" of the flue outlet of the furnace.

Figure 6

15. Where condensation of flue gases is apparent, thevent shall be constructed to prevent the condensationfrom entering the flue transition box opening. Provi-sions shall be made to drain off the condensate (seeFigure 6).

16. Vent connectors serving this appliance shall not beconnected into any portion of a mechanical draftsystem operating under positive pressure.

17. Keep the area around the vent terminal free of snow,ice, and debris.

#41996B002 Page 7


Masonry Chimney


\ -JUT

DDD

Cleanout

Liner

•Cleanout

MasonryChimney

Front Flue

Barometric Control(in either location)

Cleanout

Liner

Cleanout

MasonryChimney

Rear Flue

* Barometric control may be installed in either thevertical or horizontal section of the flue pipe within18" of the flue outlet of the furnace.

Figure 7

Horizontal Venting

The design of this furnace has been approved for horizon-tal venting with the following mechanical vent systems:

Manufacturer

Tjernlund(sideshot)

Field Control

Model

SS1,SSC,SS2*

SWGII-5-SSwith CK61 Control Kit

Refer to the manufacturer's installation instructions forproper installation procedures and service parts informa-tion.

Vent systems are available through the local distributor.

* SS2 vent system is not approved for 196 oil furnaces

Page 8

•Barometric draft control must be used in the horizontalventing (sidewall) system. It must be located within 18" ofthe furnace flue outlet (see Figure 8).

Do not common vent with any other appliance when usingthe sidewall system.

Horizontal Venting

BarometricControl*

\

DDD

Control forHorizontalVenting

Front Flue

BarometricControl*

\Control forHorizontalVenting

Rear Flue

Barometric control must be installed in the horizon-tal venting system and located within 18" of the fiueoutlet of the furnace.

Figure 8

Maximum permissible vent length is 100 equivalent feet,and minimum permissible length is 15 equivalent feet.Calculate the equivalent vent pipe footage from the furnaceto the mechanical vent system by adding the straight ventpipe length and equivalent elbow lengths together. Each90° elbow is equivalent to 10' of straight pipe; each 45°elbow is equal to 5" of straight pipe.

Removal of Unit from Common Venting System

When an existing furnace is removed from a commonventing system serving other appliances, the venting

#41996B002


system is likely to be too large to properly vent theremaining attached appliances.The following test shouldbe conducted with each appliance while the other appli-ances connected to the common venting system are not inoperation.

1. Seal any unused openings in the common ventingsystem.

2. Visually inspect the venting system for proper sizeand horizontal pitch and determine there is no block-age or restriction, leakage, corrosion, or other deficien-cies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors andwindows between the space in which the appliancesremaining connected to the common venting systemare located and other spaces in the building.Turn onclothes dryers and any appliance not connected to thecommon venting system.Turn on exhaust fans, suchas range hoods and bathroom exhausts, so they willoperate at maximum speed. Do not operate a summerexhaust fan. Close fireplace dampers.

4. Following the lighting instructions, place the unit beinginspected in operation. Adjust the thermostat so theappliance will operate continuously.

5. Test for spillage at the draft control relief opening after5 minutes of main burner operation. Use the flame of amatch or candle.

6. After it has been determined that each applianceremaining connected to the common venting systemproperly vents when tested as outlined above, returndoors, windows, exhaust fans, fireplace dampers, andany other fuel burning appliance to their previouscondition of use.

7. If improper venting is observed during any of theabove tests, the common venting system must becorrected. See National Fuel Gas Code, ANSI Z223.1(latest edition) or CAN/CGA B149.1 & .2 InstallationCodes to correct improper operation of commonventing system.

Smoke Pipe and Draft Control

Connect the furnace vent to the chimney with galvanizedsmoke pipe and fittings, maintaining full diameter offurnace vent throughout. No reduction in diameter of pipe isallowed. It is best to have smoke pipe as short and directas possible. The smoke pipe shall maintain a rise of atleast 1/4" per foot. Install draft control at least 12" beyondthe furnace. If there is no space to install the draft controlin the smoke pipe, it may be installed in the chimneyabove the smoke pipe (see Figure 9).

Draft Control Installation

Flue Pipe Draft Control

12" Minimum - 18' Maximum

Figure 9

Supply and Return Air Plenum

Secure return air plenum to unit using sheet metal screws.

Follow these procedures when installing the supply airplenum:

1. Use sealing strips of fiberglass.

2. Attach the plenum to the furnace or evaporator cabinetwith sheet metal screws.

3. Both supply and return air plenums shall be squareand at least 18" long.They should be the samedimension as the furnace opening.

4. Install supply and return air ducts as desired.

Oil Supply and Oil Filter Connection

Continuous lengths of heavy wall copper tubing or steelpipe are recommended and should be installed under thefloor or near walls to protect from damage. Do not run lineson floor joists or other reverberating surfaces. Always useflare fittings located in accessible places.

Install a generous capacity oil filter inside the buildingbetween the fuel shut-off valve and the burner. Locate filterand valve close to the burner for easy servicing. A10-micron filter is recommended.

An oil filter is required for all models.

#41996B002 Page 9


Combustion Chamber

The combustion chamber is installed in the furnace at thefactory. Read the instruction plate on the front of the unitconcerning proper care of the chamber.

This combustion chamber is made of preformed ceramicfiber material. Use extreme care when installing the oilburner so that the chamber is not damaged around theburner tube.

Fan & Limit Control

The fan & limit control is installed and wired at the'factory.Replacement of the fan & limit control must be made with anidentical control as originally supplied on the equipment fromthe factory including "fan" and "limit" stops. The use of anyother controls will void the warranty of the furnace. Operationof this furnace with greater than 130°F"Fan On" air tempera-ture will also void the warranty of the furnace.

Electrical Wiring

All wiring must conform to the National Electrical Code, theCanadian Electrical Code, and any local codes. Connectthe 115-volt, single phase service to the unit at thejunction box. Use a separate fused branch electrical circuitcontaining a properly sized fuse or circuit breaker. Run thiscircuit directly from the main switch box to an electricaldisconnect that is readily accessible and located near thefurnace. Follow carefully the wiring diagram adhered to theinside of the blower compartment door.

The electrical supply to the mechanical vent system mustbe supplied from the appliance. All wiring must be appropri-ate Class I wiring. Wiring must be installed in rigid metalconduit, intermediate metal, or be otherwise suitably pro-tected from physical damage. Refer to the wiring diagramssupplied with the venter kit for proper electrical connections.

Thermostat

Locate the thermostat on an inside wall in a room usuallyoccupied during the day, such as a living room or diningroom, at a height of 4-1/2' from the floor. Avoid directsunlight or supply air from a register. Make sure thelocation is not adjacent to appliances such as ovens orlights. Wire the thermostat with minimum of #18 AWGthermostat wire.

Humidifier

A humidifier can be installed with this furnace. Refer to thehumidifier manufacturer's instructions for specific connec-tion information (see also Figure 14 on page 16).

Electronic Air Cleaner

An electronic air cleaner can be installed with this furnace.Refer to the electronic air cleaner manufacturer's instruc-

tions for specific connection informatibn (see also Figure15 on page 16).

Filters

Horizontal/Countertlow

Neither the horizontal nor the counterflow units containfilters. Filters must be installed in the return duct system.Optional filter kits are available. Contact the supplier toobtain the correct filter kit.

Optional filter kits:

Kit for 57/72 & 84/95 units - #AFILT535-1Kit for 112/125 units - #AFILT536-1Kit for 196 units - #AFILT561 -1

Upflow/Basement

Permanent filters are supplied with these units.The largeupflow unit comes with two filters. Use both filters whenmore than 1600CFM is needed.To clean the filters, shaketo remove any excess dirt and/or use a vacuum cleaner.Wash with soapy detergent water and dry. Metal permanentfilters need to be oiled after washing to increase theireffectiveness. The filters should be cleaned at least once amonth, or more frequently in unusually dusty environ-ments.

Never leave the access panels to the blower compart-ment off or partially open.

START-UP

Oil Burner

It is recommended that the nozzle and oil filter be checkedbefore each heating season. Also recheck the conditionsshown on the OIL FURNACE START-UP CHECKLISTfound on page 2. Always keep the valve shut off if theburner is shut down for an extended period of time.

A CAUTIONDo not start burner unless blower access dooris secured in place.

Burner Specification: Factory Settings

1. Burner type: AFG (57 -196)

2. Air tube combination:AF50YB (57/72 - 84/95 -112/125)AF55YB (140/168)AF56WF (196)

3. AFG Static Plate 2-3/4"

Page 10 #41996B002Provided courtesy of www.alpinehomeair.com

FurnaceModel

57*

IT

84*

95*

112

125

140

168

196

BurnerHead

F0

FO

F6

F6

F6

F6

F6

F6

F16

Nozzle/Angle

.50 GPH/800

.65 GPH/800

.65 GPH/800

.75 GPH/800

.85 GPH/800

1.00GPH/800

1.10GPH/800

1.25GPH/800

1.50GPhl/80D

SprayPattern

Del-o-flo A

Delavan B

Delavan B

Delavan B

Delavan B

Delavan B

Delavan B

Delavan B

Delavan B

PumpPressure

100 PSI

100 PSl

140 PSI

140 PSI

140 PSI

140 PSI

140 PSI

140 PSI

140 PSI

Denotes low fire baffle instalied. See oil burner specifi-cations included with instructions.

Table 2

Burner A djustment

All adjustment to this furnace and its componentsmust be done by a qualified service technician.

Refer to Table 2 for nozzle and pump pressure information.The proper way to adjust an oil burner is with a CO2

analyzer and a smoke gun. A properly adjusted burner willresult in a quiet, clean fire which will prevent sooting andfrequent cleaning. To establish tolerance or a "window ofoperation" into the unit, do not exceed #1 smoke. This willgive the burner more flexibility when there are changes inthe surrounding environment.To adjust the burner:

1. Operate burner continuously for 5 - 1 0 minutes.Thiswill purge the fuel lines and level out combustion.

2. Make sure all inspection openings are closed tightlyand all fitting joints between the furnace and the pointwhere CO2 and smoke readings are taken are tightlysealed or taped. An air leak at the inspection openingsor fittings wiil cause false COE readings.

3. Punch a 5/16" diameter service hole in the flue outletbetween the furnace and the draft control.Take draftreadings, CO2 readings, and the smoke test from thispoint.

4. Adjust barometric draft control in the stack to achievean overfire draft of .00" to -.02".

5. Loosen the air control adjustment screw on the bulk airband and rotate the band until the flame appears clean.Retighten the air control adjustment screw.

6. Take a CO2 reading at the service opening in the stackusing a C02 analyzer.

Beckett Oil Burner Nozzle Adjustment

Burner must be removed fromfurnace for this procedure.

Gauge

To adjust nozzle:

1. Loosen screw.2. Slide entire nozzle/electrode assembly back and

forth until nozzle just touches gauge.

Figure 10

7. Take a smoke reading using the same service hole.Use a standard smoke tester. If smoke is evident, itcould be caused by a poor nozzle or combustionsetting. In some cases, it may be caused by a differ-ence in oil or an unusual condition of installation.

Nozzle and Electrode Alignment

Proper nozzle and electrode depth and alignment areessential for proper burner operation. Figure 10 shows theproper adjustment procedure using the Beckett T" gauge.To check and adjust the nozzle depth:

1. Insert the small end of the "T" gauge into the end ofthe cone and measure from the flat of the end cone tothe tip of the nozzle.The proper measurement shouldbe 1.13". When the depth is correct, the tip of thenozzle should just touch the base of the "T" gauge.

2. Nozzle adjustments are made by sliding the entirenozzle assembly forward or backward within the blasttube (see Figure 10).

To check nozzle alignment:

1. Insert the small end of the T gauge into the end ofthe cone and measure the nozzle and electrodealignment against the center lines marked on thegauge.

2. If the nozzle is not centered, but found to be too farleft or right, a new nozzle will need to be ordered. Donot attempt to adjust by bending the 90° elbow inthe oil line.

#41996B002 Page 11


SEQUENCE OF O P E H A I I U K

The thermostat calls tor heat, activating the venter motor.

After a 15-second pre-purge period, power is sent tothe burner and ignition is established.

After the thermostat is satisfied, the thermostat circuitwill open.

. Power to the burner is interrupted, thus shutting downthe burner.

If you are using the optional pre- and post-purge kit,upon the thermostat circuit opening, the post:purgetiming on the vent system and burner will initiate andthe oil valve will close.

Note: Post-purge timings are adjustable to suitindividual requirements. A 3- to 5-minute post-purge time is recommended, but may vary perapplication.

5. When post-purge time has expired, the venter motorand/or (if the pre- and post-purge kit is used) theburner motor will stop operation.

MAINTENANCE AND SERVICE

Flue Pipe

Have the flue pipe inspected annually by a qualifiedservice technician. If any soot or ash has formed insidethe flue pipe, remove and clean. If the flue pipe has anyholes or is rusted out, replace with a new flue pipe of thesame size. Inspect the flue draft control device andreplace if defective.

Blower

Blower motor is pre-lubricated and sealed for extendedoperation. No further lubrication is required.

The blower assembly may be removed from the cabinet forcleaning and servicing of the blower. Disconnect power tothe unit before servicing.

Heat Exchanger

To clean the heat exchanger:

1. Remove the vent pipe from the furnace.

2. Remove the locking screws and the caps from the twocleanout tubes; remove the flue access elbow.

3. Using a long spiral wire brush, sweep down the outerdrum of the heat exchanger. Using a shop vacuumhose attachment, vacuum out all loose debris.

tube and with the spiral wn c u,toward the rear of the heat exchanger to clean out thecrossover tube; replace the locking screw and cap onthe inspection tube.

5. Do not attempt to clean the combustion chamber, as ican be easily damaged.

6. Replace the three previously removed cleanout capsand flue access elbow, making sure to reinstall thelocking screws.

7. Brush out and vacuum the vent outlet area of theouter drum and reattach the vent pipe.

8. Clean up around the burner, blower deck, and vestibiarea.

Heat exchanger cleanout kit #ABRSH380-3 is availablefrom the manufacturer.

Emergency Fuel Pump Replacement

If replacement of the A2EA6520 fuel pump becomesnecessary, replace it with another Beckett CleanCut futpump. In an emergency situation where the correct re-placement parts are not available, an A2VA7116 fuel pcould be used.This option can produce a smoky start-and shutdown that could result in fouling of a heat ex-changer. This is only a short-term option and shoulused only until the correct parts can be obtainedinstalled.

Complete National Fuel Gas Codes are available f

1. American Gas Association1515 Wilson BoulevardArlington, VA 22209

2. National Fire Protection Association, Inc.I Battery March ParkQuincy, MA 02269

3. American National Standards Institute, Inc.Publications Sales DepartmentI1 West 42nd StreetNew York, NY 10036

Page 12


cc

CO

03

o

BLUE

c3

CQCD

(DO

CDI

o

11S3

i§.N03

5"(0

22.D)p*

5"3

NOTE: IF ANY OFTHEORIGINALWIRE IS REPLACED,THE SAME TYPE AND SIZE WIRE MUST BE USED.

ELECTRODESPRINGS

120 VAC60HZ-1PH

FUSED MANUALDISCONNECT

CAPACITOR{IF USED)

SEE NOZZLE SIZE GPH ON RATING PLATE

GPH

.50

.65

.75

.851.001.101.251,50

LOWEST PERMISSIBLE HEATING SPEED

UP FLOW

LOWLOWMEDMEDMED

COUNTER FLOW/HORIZONTALLOWLOWMEDMEDMEDMEDMEDHIGH

BASEMENT

LOWLOWMEDMCDMEDMEDMEDHIGH

7184PRIMARY

CONTROL

BURNERJUNCTION

BOX

IGNITIONTRANSFORMER

LINE VOLTAGE-FACTORYLINE VOLTAGE-INSTALLERLOW VOLTAGE-FACTORYLOW VOLTAGE-INSTALLER

PART NO. 46563-001


BLUE

(DO

CD

539

3 13

o"

NOTE: IF ANY OF THE ORIGINAL WIRE IS REPLACED,THE SAMETYPE AND SIZE WIRE MUST BE USED.

ELECTRODESPRINGS

120 VAC60HZ-1PH


CAPACITOR(IF USED)

SEE NOZZLE SIZE GPH ON RATING PLATE

GPH

.50

.65

.75

.851.001.101.251.50

LOWEST PERMISSIBLE HEATING SPEED

UP FLOWLOWLOWMEDMEDMED

COUNTERFLOW/HOR1ZONTALLOWLOWMEDMEDMEDMEDMEDHIGH

BASEMENTLOWLOWMEDMEDMEDMEDMEDHIGH

7184PRIMARY

CONTROL

BURNERJUNCTION

BOX

IGNITIONTRANSFORMER

LINE VOLTAGE-FACTORYLINE VOLTAGE-INSTALLERLOW VOLTAGE-FACTORYLOW VOLTAGE-INSTALLER

PART NO. 46666-001


BLUE

WNOTE: FOR FIELD CONNECTION

USE COPPER CONDUCTORS ONLYRATED MINIMUM 105° C.

03(D

(Oc

CO

<D (D

00)E*3

(D

o

gCDCD

3

RH W Y G RC

OIL BURNERIGNITIONTRANSFORMER

120 VAC60HZ-1PH


OIL BURNERJUNCTION BOX

NOTE: IF ANY OF THE ORIGINALWIRE IS REPLACED, THESAME TYPE AND SIZEWIRE MUST BE USED.

"003

(QCD

LINE VOLTAGE-FACTORYLINE VOLTAGE-INSTALLERLOW VOLTAG E-FACTORYLOW VOLTAGE-INSTALLER


Humidifier Wiring

N

I— W2 4 V -

Humidmeror

HumidifierTransformer

Some humidifier manufacturers may require24V contact supply power instead of 120V.

This diagram is intended as a general guide only. See the humidifiermanufacturer's installation instructions for detailed connection information.

Figure 14

Electronic Air CieanerWiring

L, N

Sail Switch(locate in circulating

air supply)

This diagram is intended as a general guide only. See the electronic air cleanermanufacturer's installation instructions for detailed connection information.

Figure 15

Page 16 #41996B002


Documents

INSTALLATION INSTRUCTIONS - Alpine Home Air … Lennox International Company 421 Monroe Street II Bellevue, OH 44811 A CAUTION The installation of the furnace, wiring, warm air ducts,