Royal Appliance Air Furnace manual

29733 R2 06/01/2003 Installation, Operation and Maintenance Manual Oil Fired Warm Air Furnace HO-B Series Up-flow or Horizontal Model THE INST ALLAT ION OF THIS FURNACE SHAL L BE IN ACCORDANCE W ITH THE REGULAT ION OF AUTHORITIES HAVING JURISD ICTION AND NFPA STANDARD 31 (U .S.A.) OR CSA STANDAR D B139 (CAN .). FOR YOUR SAFET Y Do not store or use [...]

29733 R2 06/01/2003 2 How to read an Oneida Royal Model Number: HO – B – 120 F B A 4 In the above exam ple, the fur nace is an Oneida Royal Highboy with the 2 nd generation heat exchanger, s tandard size, front br eeched, belt drive, Beck ett Oil Bur ner, 4 tons of cooling. Highboy 2 n d Generation Heat Exchanger Nominal O utput (BTUH) 80 – C[...]

29733 R2 06/01/2003 3 Table of Contents 1. Intr oducti on .......................................................................................................................................................... 4 2. Heat Loss .................................................................................................................. .......[...]

29733 R2 06/01/2003 4 1. INTRODUCTION Please read these ins truc tions com pletely and carefully before ins talling and operating the fur nace. The f urnace m us t be installed and set up by a qualified contractor MO DEL 80F Model 80F is an oil-f ired upf low forced air furnace, with an output capacity range of 58,100 BTU/Hr. to 78,900 BTU/Hr. T he[...]

29733 R2 06/01/2003 5 NOTE : The r ecom m ended installation clearanc es do not take into c onsideration the clear ances neces sary to replace the air f ilter or per form other r outine maintenanc e. UP-FLOW INSTA LLA TION Both furnac es m odels have been as sem bled for installation in the up-f low position. Maintain all clearances to com bus tibl[...]

29733 R2 06/01/2003 6 NON-SUSPENDED INSTALLA TION Maintain clearanc es to com bus tibles as outlined in T able 1. Installation on a c om bustible floor requires a c learance of 1 inch. T his c an be done by using a noncombus tible m aterial s uch as one-inch thic k c hannel iron or s im ilar mater ial. T he f urnace m ust be s upported in suc h a w[...]

29733 R2 06/01/2003 7 Figure 2: Common Chimney Problems 6. CHIMNEY VENTING The chim ney mus t be sized correc tly and be in good repair. If the chim ney is oversized, there is a high ris k of the flue gases condensing res ulting in dam age to the chim ney and other venting par ts. T his problem m ay be correc ted by the use of an appropriately size[...]

29733 R2 06/01/2003 8 Table 2: Com m on Chim ney Problems - conti nued Key Tr ouble Diagnostic Remedy K Smoke pipe extends into chimney. Measurement of pipe from within or observation of pipe by means of a lowered light. Length of pipe must be reduced to allow end of pipe to be flush with inside of tile. L Failure to extend the length of flue parti[...]

29733 R2 06/01/2003 9 installed in ac cordanc e to the instruc tions supplied with the regulator. 8. FURNA CE CONTROLS The f urnace is controlled by either of two systems, depending on the oil pr im ary control and electronic f an timer co mbination. System 1, used with Beck ett burners, includes the blower m ounted Honeyw ell ST9103 E LECTRONIC F [...]

29733 R2 06/01/2003 10 The power requir ements for the HO-B Series m odels are: 120 VAC, 1 Æ , 60 Hz., 12A. 5-ton models: 120 VAC, 1 Æ , 60 Hz., 16A. Access ories requiring 120 VAC power sourc es suc h as electronic air cleaner s and hum idifier transf orm ers m ay be powered from the ST 9103 EFT . Do not use the direct drive m otor connec tions [...]

29733 R2 06/01/2003 11 The furnac es m ay be installed with a one-pipe s y stem with gravity feed or lif t. T he m axim um allowable lift on a single line system is 8 f eet. Lift should be m eas ured f rom the bottom ( outlet) of the tank , to the inlet of the burner. Sizing a single line sy stem is c omp lex becaus e of the diff iculty estimating [...]

29733 R2 06/01/2003 12 CHECK THE ALIGNMENT OF T HE COM BUSTION CHA MBER AND OIL BURNER BEFORE FIRING. IT IS POSSIBL E FOR T HE COM BUSTION CHAMBER TO SHIFT IF SUBJECTED T O ROUGH HA NDLING DURING TRANSIT . The c erafelt c om bustion cham ber is quite soft initially . After firing, it bec om es very brittle. Be sure to do all alignment and pos ition[...]

29733 R2 06/01/2003 13 Figure 6: T est po rt location for smoke test vertical. PROCEDURE: Start the burner and allow it to run at least ten m inutes. Set the air s hutter to give a good flam e visually. On Beck ett burners, the c om bustion air s upply to the burner is c ontrolled by manipulating the air shutter on the lef t side of the burner , an[...]

29733 R2 06/01/2003 14 IF THE FURNACE FA ILS TO IGNITE, CHECK THE OIL T A NK FUEL GAUGE. IF THE FUEL GAUGE SHOWS T HAT OIL IS PRESENT , PRESS THE RESET BUT T ON ONCE ONLY . IF T HE BURNER FA ILS TO IGNIT E, CONTACT YOUR SERVICE CONTRACTOR. A LL FURNA CE CONT ROLS ARE SENSITIVE A ND SHOULD NOT BE SUBJECT ED TO T AMPERING. IF PROBLEM S PERSIST, CALL [...]

29733 R2 06/01/2003 15 THE BEL T DRIVE CO MPO NENTS O PERA TE AT HIGH SPEEDS AND CA N EA SILY SNAG LOOSE CLOTHING, CAUSING SERIOUS PERSONA L INJURY. TH IS PROCEDURE SHOULD BE LEFT T O TRAINED SERVICE PERSONNEL. If the blower RPM operates above 1000 RPM, it is advisable to replace the s intered bronze blower bearings with roller Bearings. The c ircu[...]

29733 R2 06/01/2003 16 B: A nnual Service By Contractor THE COM BUST ION CHA MBER (FIREPOT ) IS FRA GILE. USE CARE WHEN INSPECTING A ND CLEA NING THIS AREA . The heat ex changer should be ins pected periodic ally and cleaned if nec essar y . if cleaning is necessar y , SHUT OFF POWER TO T HE FURNA CE and r em ove the burner. Using a s tiff brush wi[...]

29733 R2 06/01/2003 17 motor wiring, or replace the fan belt. Finally , restore power to the furnace. E) Oper ate the furnac e through a m inim um of three full heating cycles. During this tim e, check f or f uel oil leaks, gross air leakage f rom the supply air ductwork, unusual noises originating anywhere within the heating sy s tem which may cau[...]

29733 R2 06/01/2003 18 TA BLE A -1 BECKETT A FG OIL BURNER SET-UP BECKETT AFG SERIES OIL BURNERS FURNACE MODEL OUTPUT BTU/Hr BURNER MODEL NOZZLE PUMP PRESSURE FLOW RATE HEAD STATIC PLATE 80F (060) 58,100 1, 2 AF76BO 0.50 / 70° W 100 PSIG 0.50 GPH F0 3-3/8 in. 80F (070) 68,000 2 AF76BN 0.65 / 70° W 100 PSIG 0.65 GPH F3 3-3/8 in. 80F (080) 78,900 2[...]

29733 R2 06/01/2003 19 TA BLE A -3 DIRECT DRIVE BLOWER SE T-UP BLOWER SET-UP COOLING CAPA CITY 0.20 in. w.c. 0.50 in w.c. FURNACE MODEL BLOWER MOTOR HP Speed Speed Htg. CFM Range 1 Tons 2 MOTOR HP Clg. CFM Range 80F (060) Low M ed - Low 629 - 972 80F (070) Med - Low Med - High 792 - 1223 80F (080) G10 DD ½ Med - H igh High 857 - 1324 3 ½ 900 - 11[...]

29733 R2 06/01/2003 20 TA BLE A -5 BELT DRIVE B LOWER SET-UP Blower Set-Up Model HO-B 0.20 in. w.c. 0.50 in. w.c. Cooling Capacity Pulley Pulley Bonnet Output (BTUH) Blower Motor hp Fan Belt Blower Motor Turns Out Blower Motor Turns Out Tons CFM Range 80 (60,000) 3 2 80 (70,000) 2 1 80 (80,000) G10 ½ 4L360 5 x ¾ 3¼ x ½ 2 5 x ¾ 3¼ x ½ 1 3 100[...]

29733 R2 06/01/2003 21 GENERA L DIMENSIONS Table A -6: General Dimensions (inches) Plenum O penings Cabinet Supply Air Return Air Flue W idth A Depth B Height C D x E Side F x G Bot tom Dia. Height H Filter (Perm.) Ship W eight (lb) 80F 22 31 49-½ 20½ x 20 14 x 22 14 x 22 5 42 16 x 25 x 1 190 120F 22 31 58- ⅛ 20½ x 20 14 x 22 14 x 22 6 46-½ 1[...]

29733 R2 06/01/2003 22 WIRING DIA GRA M: OIL FURNA CE WITH ST9103 EFT & R7184 CONTROL A ppendix B WIRING[...]

29733 R2 06/01/2003 23 WIRING DIA GRA M: OIL FURNA CE WITH ST9103 EFT & RIELLO OIL BURNER A ppendix B WIRING[...]

29733 R2 06/01/2003 24 WIRING NOTES: HO-B SERIES OIL FURNACE CONTINUOUS FAN OPERA TION : The ST9103 EFT has provis ions to run the blower m otor continuously on a speed lower than the cooling or heating speeds. On a call for cooling, the fan m otor will switch to cooling speed, and on a c all for heating, the fan will switch to heating speed, each [...]

29733 R2 06/01/2003 25 R7184 DETA ILED SEQUENCE OF OPERA TION Power is applied to unit. The R7184 c om pletes a self -diagnostic procedur e. If no light or f lam e is present, and unit passes its self -diagnostic procedure, the c ontrol enters into the idle m ode. Thermostat c alls for heat : A. Saf ety check is m ade for f lam e (4 sec ond delay )[...]

29733 R2 06/01/2003 26 IDLE STATE THERM OSTAT CALLS FOR HEAT SAFETY CHECK FOR FLAM E (5 SEC.) BURNER MOT OR & IGNITOR START SOLENOID VALVE OPENS TRIAL FOR IGNIT ION 15 SEC. BURNER FLAME M ONITORED CARRYOVER STAT E · Provides continuous spark · LED diagnostic light ON · Start Carr y over Time r CARRYOVER TIM ER EXPIRES RUN STATE · I g nitor [...]

29733 R2 06/01/2003 27 RIELLO 40F3 TROUBLESHOOTING CH A RT Thermostat is calling for heat, burner is not running. Reset control box. Burner Starts Burner Does Not Start Test for 120 Vac Supply at sub-base betw een L and N or terminals #3 and #5. 120 Vac No Voltage · Check system fuse, ensure serv ice switch is O N. · Verify that all control limit[...]

29733 R2 06/01/2003 28 Burner Locks Out A fter Trial For Ignition · Low resistance or no contact on starting circuit of coil, terminals #2 and #8. (1.3 ohm ± %). · No oil supply – tank empty, valve closed, dirty filter, damaged supply lines. · Defective or dirty oil v alve stem, nozz le, or pump strainer. · Broken pump drive key, defectiv e [...]

29733 R2 06/01/2003 29 TABLE C-1: ST9103 DET AILED SEQUENCE OF OPERATION Mode Ac tion Sys tem Response HEAT Therm os tat calls f or heat. ("W " terminal is energized). a. ST9103 c loses oil prim ar y control T - T connec tions). b. Ignition system and R7184 oil prim ar y control st art the fur nace. Oil flows as long as the oil prim ary c[...]

29733 R2 06/01/2003 30 Continued from las t page Mode Ac tion Sys tem Response Limit s witch string opens. ( continued ) d. Circulating f an runs as long as lim it string s tay s open. If there is a call for cooling or f an, the circ ulating fan switches fr om heating to cooling speed. LIMIT Limit s witch string clos es (with existing c all for hea[...]

29733 R2 06/01/2003 31 R7184 LED DIA GNOSTIC LIGHT The LED diagnostic light has several f unctions. It indicates the s tate or m ode in which the oil burner is operating. It will also indica te f ault conditions, and help determ ine cad cell resis tance while the burner is operating. N ORMAL C ONDITIONS : The LED diagnos tic light will turn on when[...]

29733 R2 06/01/2003 32 C HECK O IL P RIMARY C ONTROL A ND I GNITOR If the trouble does not appear to be in the burner or ignition hardware, check the oil prim ar y control and the ignitor by using the following equipment: à screwdriver . à voltmeter (0 - 150 VAC ) à insulated jum per wires with both ends str ipped. Electrical Shock Haz ard . Tro[...]

29733 R2 06/01/2003 33 · Table C-3: R7184 T roubleshooting continued from previous page Procedure Stat us Corrective A ction Burner star ts. Trouble is in therm ostat c ircuit. Check therm os tat wiring connections. If connec tions are clean and tight, c heck therm ostat wires f or continuity. · Disconnect line voltage power and open line swi tch[...]

29733 R2 06/01/2003 34 Table C-3: R7184 T roubleshooting continued from previous page Procedure Stat us Corrective A ction Burner star ts. Trouble in ther m ostat or lim it c ircuit. Check therm ostat or lim it wiring connec tions. 5. Jum per therm ostat ( T -T ) term inals on R7184 IM PORTANT First rem ove one ther mos tat lead wire. Burner does n[...]

29733 R2 06/01/2003 35 Table C-3: R7184 T roubleshooting continued from previous page Procedure Stat us Correctiv e A ction Burner lock s out. G o to step 10. 9. Check cad cell s ighting for view of f lam e. · Disconnect line voltage power and open line switch. · Unplug cad cell and clean cad ce ll face with soft cloth. Check sighting for clear v[...]

29733 R2 06/01/2003 36 Table C-3: A Troubleshooting continued from previous page . Procedure Stat us Corrective A ction Indicator light is on. Replace cad cell brac ket as sem bly. 11. Check c ad cell brack et assembly . · Disconnec t line voltage power and open line swi tch. · Remove ca d cell wi res from quick c onnect connectors on the and lea[...]

29733 R2 06/01/2003 37 T AB L E C-4: S YS TEM & G ENERA L T ROUBLES HOOTING , continued from previous page Problem Possible Cause Remedy No fuel oil. Check fuel oil supply. Check that all hand operated fuel oil valves are in the open position. F ill oil storage tank if necessar y . Clogged nozz le. Replac e nozz le with high quality replac em e[...]

29733 R2 06/01/2003 38 T AB L E C-4: S YS TEM & G ENERA L T ROUBLES HOOTING , continued from previous page Problem Possible Cause Remedy Electrodes out of adjustm ent or def ective. Check electrode settings . check electr odes f or dirt build- up or crac ks in porcelain. Poor transf orm er high voltage connections or defective tr ansfor m er. C[...]

29733 R2 06/01/2003 39 T AB L E C-4: S YS TEM & G ENERA L T ROUBLES HOOTING , continued from previous page Problem Possible Cause Remedy Airflow block ed or dir ty air filter. Clean or replace air filter. Therm os tat adjustm ents or location. Check therm ostat heat anticipator setting against meas ured am perage draw. Incr ease heat anticipato[...]

29733 R2 06/01/2003 40 HOME OWNER’S RE FERENCE T ABLE : Installation Contractor : Model No. Serial No. Date Installed Contractor Contact Address Postal Code Telephone No. After Hours No. Service Contra ctor if different fr om Installation Contractor : Servi ce Tech. Telephone No. After Hours No. Fuel Supplier: Oil Supp lier Contact Telephone No. [...]