Crown Boiler CHC68-96 manual

P/N: MO-426 (Printed Instruction Manual) Note: This page is not to be included as part of printed hard copy. Overall Specifications: Material: white plain paper Printed text: black Binder: staple upper left corner Individual page specifications: Cover page: printed single-side up The balance of instruction manual pages to be printed utilizing both [...]

OIL-FIRED CENTRAL FURNACE Installation, Operation, And Service Manual With Users Information Section Models: CHB68-112 CHC68-96 CLBF68-112 C L B R 6 8 - 1 1 2 c WARNING : • Do NOT store or use gasoline or othe r flammable vapors and liquids in the vicinity of this or any other appliance. • Improper installation, adjustment, alte ration, service[...]

2 Contents SECTION PAGE Notice to the Installer .................................................................................................. 4 INSTALLATION GU IDELINES ...................................................................................... 5 Codes .................................................................................[...]

3 APPENDIX A: SOURCES FOR REFE RENCED STANDA RDS ................................... 40 APPENDIX B: ELECTRICAL DIAGRAMS ..................................................................... 41 APPENDIX C: SPECIFICAT ION SHEETS .................................................................... 43 APPENDIX D: REPLACEMENT PARTS .....................[...]

4 Notice to the Installer Installation of this oil-fired furnace must be performed by a qualified installer in accordance with all local codes and authorities having jurisdic tion. In the absence of local governing codes, installation shall conform to these instructions and to the regulations of the National Fire Protection Association’s Standard[...]

5 INSTALLATION GUIDELINES Codes All local codes and regulations take precedence over the instructions in this manual and shall be followed accordingly. In the absence of local codes, this installation must conform to these instructions and to the r egulations of the National Fire Protection Association (NFPA) publications, the Standard for the Inst[...]

Figure 1: Recommended Support Frame for Horizontal / Counterflow Furnaces 6 Closet and Alcove Installation All furnace models may be installed in a clos et or alcove on combustible flooring with specified (standard) clearances to combustible construction. The horizontal / counterflow furnace model requires an optional combustible surface-mounting b[...]

7 Accessibility clearances, which are typica lly greater, may exceed fire protection clearances. Therefore, consider providing at least 24 inches of clearance from the front (and the rear, for lowboy furnaces) of the furnace to obstructions and surfaces for adequate service and maintenance access. The minimum clearances from furnace casing surfaces[...]

8 Often, household chemicals contain chlo ride-bearing compounds. There are many compounds representative of this classifica tion of chemicals. A few common examples are listed below. • Cleaning solvents • Varnish and paint removers • Bleaches • Fabric softeners • Water softener salt • Tile adhesives Avoid storing or using these chemica[...]

9 Provide two (2) permanent openings, one (1) located within 12 inches of the floor and one (1) within 12 inches of the ceiling, or roof, of the room. These openings shall allow for direct exchange of air between the room and outdoors. If required, ducting between the room and the outdoors shall be provided. • For horizontally -oriented ducts, ea[...]

10 Chimney Inspection The chimney, vent, or any passageway for the stack gases to flow to the outdoor atmosphere is a very important part of the heating system. No furnace, regardless of the efficiency of the design, can perform satisfac torily when the chimney to which it is connected is inadequate or in poor conditi on. Any of the following sympt[...]

11 If desired, with the furnace flue elbow turned to the right, the standard furnace top front panel (p/n 52-17346-1) may be replaced with t he top front panel from the rear flue lowboy model (p/n 52-17383-1). Refer to Appendix D: Replacement Parts for sketches of these parts. Contact your Crown distributor to purchase this part. All horizontal sec[...]

12 Duct Work and Air Conditioning Design and installation of the duct system should follow the current guidelines of the Air Conditioning Contractors of America (ACCA) or the American So ciety of Heating, Refrigeration and Air Conditioning Engineer s, Inc. (ASHRAE). Refer to the Residential Duct Systems, Manual D , from the ACCA, and the ASHRAE Han[...]

On the highboy furnace, it is necessary to cu t the return air opening in the lower side, or rear, of the casing depending upon t he needs of the specific installation, refer to Figure 3. Figure 3: Cutaway view of fan section of a typical highboy furnace. The side casings have each been pre-punched with four (4), square, knockout openings for use i[...]

14 Electrical Connections NOTICE: All field wiring must conform to local, state, and national installation codes. A disconnecting switch equipped with overcurrent pr otection rated at 15 A. (e.g. a time delay-type fuse or inverse time, circuit break er) should be installed in the service line for shutting down and protecting the furnace and electri[...]

15 The room thermostat should be located on an inte rior wall in the natural circulating path of the room air. The thermostat should not be installed in a location where it is directly exposed to, • cold air infiltration, i.e. drafts from outside openings such as windows and doors, • air currents produced by supply air registers, and • heat f[...]

16 Nozzle selection (i.e. heating capacity of the fu rnace) shall be based on a rate of heat loss (heating load) calculation for the buildi ng. These calculations should be made according to the manuals provided by the Air Conditioning Contractors of America (ACCA) or the American Society of Heat ing, Refrigeration and Air Conditioning Engineers, I[...]

Figure 4: Side view of correct burner insertion into combustion chamber 4) Push the burner flange gasket (incl uded with the burner) on to the burner mounting plate threaded studs. Seat t he gasket against the mounting plate. 5) Using fasteners supplied in the parts bag with each furnace, three (3) 5/16 in. brass hex nuts and three (3) steel flat w[...]

18 the gap between the outer surface of the air tube and t he inner wall surface of the combustion chamber opening to provi de a seal, keeping hot combustion gases within the chamber. 6) Insert and secure the cable or conduit from the wiring harness in the burner junction box. Snap together the two (2) ma ting, multipin quick connections, on the wi[...]

Horizontal / Counterflow Furnace Setup The horizontal / counterflow furnace is shi pped from the factory up right for vertical installation (counterflow configuration). If the furnace is to be installed lying down on the right-hand or left-hand side (horizont al configuration), the posit ions of the oil burner and the fan and limit control thermost[...]

4) When the furnace is installed in the horizontal configuration, the high limit and fan control must also be located in the upper position on the casing when the furnace is placed in the final installed pos ition, refer to Figure 7. If the control must be relocated, remove the cover of the control to gain access to the mounting screws. Remove the [...]

21 INITIAL OPERATION OF THE FURNACE Initial Burner Operation c WARNING: To avoid possible explosion, DO NOT attempt to light the burner if: • Oil has accumulated in the base of the combustion chamber. • The furnace is full of fuel vapors. • The combustion chamber is very hot. c CAUTION: The oil burner must be installed and adjusted using rece[...]

22 7) Measure the oil pump pressure. If r equired, adjust it to deliver the appropriate pressure for the burner. T he oil pump should be set to produce, • 130 PSIG, for the R.W. Beckett model AF burner, • 150 PSIG, for the R.W. Beckett model NX burner, • 140 PSIG, for the Carlin Combustion model EZ-1HP, and • 150 PSIG, for the Riello model [...]

10) Flue Gas Temperature – The flue gas temperature will vary depending on heat input rate, air temperature ri se across the heat exchanger, and air flowrate through the furnace. To prev ent excessive water vapor condensation from the flue gases, the gross flue gas temperature should not fall below 330ºF. In addition, if the gross flue gas tempe[...]

One way to measure the temperature rise ac ross the furnace is to insert temperature measuring devices (e.g. thermometers) into the return air duct and into the supply air duct about 12 inches from the furnace. Afte r the furnace has been firing continually for over 20 minutes, read the temperature difference between the two (2) thermometers. The t[...]

25 Furnace Limit and Blower Controls All furnaces are equipped with a combined t hermostatic high temperature limit and blower (fan) control. The high temperature limit is set such that it does not permit a supply (discharge) air temperature above 200ºF. The thermostatic fan control should be set so the greatest fuel utilization efficiency of the [...]

26 Room Thermostat Most room thermostats are equipped with user adjustable, or selectable, levels of heat anticipation. This feature helps to reduce t he amount of room air temperature overshoot that occurs after a heating cycle. To adjust the heat anticipator, measure the electrical current output of the oil burner primary safety control to the ro[...]

27 SERVICE Troubleshooting c WARNING: When testing electrical e quipment, always follow standard electrical safety procedures. Before beginning these troubleshooting procedures, always review these basic points. 1) Check for 120 VAC power to the fur nace. If there is no voltage, check the disconnecting switch for circuit breaker trip or blown fuses[...]

28 3) Confirm the room thermostat is wired correctly, set on the “HEAT” mode, and “calling for heat”. 4) For all primary controls, lock out can be confirmed by measuring voltage from the oil primary safety c ontrol to the burner motor. If none, depress the oil primary reset butt on. [On the Honeywell oil primary control, lockout has occurre[...]

29 C. Symptom: Burner short cycles on high limit thermostat, but does not “lock out” on oil primary safety control. Items to check: 1) Open dampers or registers in t he air distribution system. Clear any duct system restrictions. 2) Inspect and clean all air filter s in the air distribution system. 3) Inspect blower for interference wit h rotat[...]

30 6) Measure the draft at the point wher e the vent connector attaches to the heat exchanger flue pipe. With the burner operating, the stack draft should not exceed 0.05 in. W.G. If the stack draft has been adjusted above this value to give the proper overfire draft, the heat exchanger will require cleaning. If there is little or no stack draft, t[...]

31 Flame Sensor (“Cad Cell”) Checkout Procedure On the Honeywell oil primary control, to che ck the electrical resistance of the flame sensor (referred to as a cadmium sulfide photocell, or “cad cell”), depress the reset button on the oil primary safety control while the burner is firing. The oil primary control will report the measured res[...]

32 On the Riello 40-F3 burner only, the cad cell is an integral part of the oil primary control. If replacement of t he cad cell is required, the entire primary control must be replaced. Replacement Parts Appendix D of this manual contains a list of replacement parts available for these furnaces.[...]

33 MAINTENANCE Air Filter(s) c CAUTION: To avoid injury from moving parts, hot surfaces, or electrical shock, shut off the power to the furnace and allow the furnace to cool BEFORE removing any furnace access doors to service air filters. Highboy and lowboy furnace models are fact ory-supplied with a permanent-type, air filter. At least twice a yea[...]

NOTICE: A qualified heating contractor MU ST inspect the heat exchanger in this furnace at least once a year. If heavy deposits are found, immediate cleaning is required. All heat exchanger surfaces should be as cl ean as possible for the most efficient operation of the furnace. The heat exc hanger may require cleaning after every heating season, a[...]

35 The heat exchanger may also be cleaned through the flue pipe connection. With the furnace turned off and at room temperature, carefully remove the vent connector and the heat exchanger flue pipe, if equipped, to inspect and clean the heat exchanger. The inner radiator of the heat exchanger may be cleaned from the inside of the combustion chamber[...]

36 USERS INFORMATION c WARNING: • The area around the furnace should be kept free and clear of flammable vapors, liquids, and material, especially papers and rags. • NEVER burn garbage or refuse in the furnace. NEVER try to ignite oil by tossing burning papers or other material into the furnace. • This oil furnace is designed to burn No. 2 di[...]

37 4) This furnace is equipped with an electr onic ignition system that automatically lights the burner. DO NOT try to light the burner by hand. 5) Turn on the electric power to t he furnace at the disconnecting switch. 6) Adjust the room thermostat to the des ired setpoint and set the operating mode, if equipped, to “HEAT”. 7) If the furnace w[...]

38 • Annually, have a bottom sample from the fuel oil tank taken for analysis. If present in excessive quantities, sludge and water s hould be removed. Fuel oil additives may be of benefit in helping to resolve some probl ems that are indicated by the analysis. In severe cases, tank cleaning may be requi red. Consult your fuel oil supplier for re[...]

39 Venting System: The furnace flue pipe, vent c onnector, barometric damper, and chimney should be inspected for: • Signs of excessive rust, corrosion pitting, and holes. • Signs of condensation or moisture leak age (sometimes indicated by soot or condensate streaks). • Evidence of structural damage, and l oose or disconnected piping joints.[...]

40 APPENDIX A: SOURCES FOR REFERENCED STANDARDS 1. Air Conditioning Contractors of America 1712 New Hampshire Avenue, N.W. Washington, D.C. 20009 http://www.acca.org/ 2. American Society of Heating, Refri geration, and Air-Conditioning Engineers, Inc. 1791 Tullie Circle N.E. Atlanta, Georgia 30329 http://www.ashrae.org/ 3. National Fire Protection [...]

APPENDIX B: ELECTRICAL DIAGRAMS For your safety, read this i nformation before operating this furnace. WARNI NG: Fail ure to fo l low thes e instruc tions may result in a fire or exp losion causin g prope rty damage, personal inj ury, or loss of life. WHAT TO DO IN THE EVENT OF AN O IL LEA K: • DO NOT try to operate this or any other nearby appli[...]

For your safety, read this information before o perating this furnace. WARNING: Failure to f ollow these inst ructions may result in a fire or explosion causing property damage , personal injury, or loss of life. WHAT TO DO IN THE EVENT OF AN OI L LEAK : • DO NOT try to operate thi s or any other nearb y appliance . • If present, close the manu[...]

APPENDIX C: SPECIFICATION SHEETS Mod el Heat I n put Ra te ( BTUH): 140000 * 119,000 105,000 84,000 N o mi n al Th e r mal E ff i c i e n c y (% ): Heat ing Cap aci ty (BTUH): 115000 * 98,0 00 87,00 0 70,00 0 N o mi n al T e mp . R i s e (d e g . F . ) : Mi n i mum A FU E R at i n g ( %) : Gros s H e at Excha nge A rea (sq. ft.): Cas ing Height (in[...]

Model H e a t In pu t R a te (B T U H ): 140000 * 119,000 105,000 84,0 00 Nom inal Therm al Effi ciency (%): Mini m um H eati ng Capacit y (BTUH ): 114000 * 98,000 87,000 70,000 Nom inal Tem p. Rise ( deg. F.): Mi n i mu m A FU E R a t i n g ( %) : G ross Heat Exchange Area ( sq. ft . ) ** : Casing Hei ght ( in .): Casing W i dth (i n): Casing Dept[...]

Model Heat Input Rate (BTUH ): 119,000 105,000 84,000 Nom inal Therm al Effici ency (%): Minimum Heati ng Capa city (BT UH ): 98,000 86,000 69,000 Nom inal Tem p. Rise (deg. F.): Minimu m Efficiency Rati ng (AFU E): Gros s H eat Exchange Area (sq. ft. ): Casi ng Dept h ( i n. ): Nom inal Fl ue Ou tl et Dia. (i n.): Supply Air Outlet Siz e (i n. x i[...]

APPENDIX D: REPLACEMENT PARTS Highboy Model 46[...]

Lowboy Front Flue Model 47[...]

Lowboy Rear Flue Model 48[...]

Horizontal/Counterflow Model 49[...]