THV1M087A936, 948, 9V3, 9V5SA - HighboyTLF1M087A936, 948, 9V3, 9V5SA- Lowboy Front FlueTLR1M087A936, 948, 9V3, 9V5SA - Lowboy Rear FlueTDF1M087A936, 948, 9V3, 9V5SA - Downflow/ Horizontal

OIL FIRED CENTRAL FURNACE

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

IMPORTANT — This Document is customer property and is to remain with this unit.Please return to service information pack upon completion of work.

Installer’s Guide

18-DE01D1-8

THV1Highboy Vertical

Flue

TLF1Lowboy Front Flue

TLR1Lowboy

Rear Flue

TDF1Downflow/HorizontalFront Flue

AVAILABLE IN FRENCH CANADIAN (FC)

© 2009 Trane All Rights Reserved 18-DE01D1-8

Installer’s Guide

▲ WARNING!EXPLOSION HAZARDDo NOT store or use gasoline or other flammable va-pors and liquids in the vicinity of this or any other ap-pliance.Improper installation, adjustment, alteration, service, ormaintenance can cause a fire or explosion resulting inproperty damage, personal injury, or loss of life.For assistance or additional information consult aqualified installer or service agency.

Safety signal words are used to designate a degree orlevel of seriousness associated with a particular hazard.The signal words for safety markings are WARNING,and CAUTION.

a. WARNING indicates a potentially hazardous situa-tion which, if not avoided, could result in death orserious injury.

b. CAUTION indicates a potentially hazardous situationwhich, if not avoided, may result in minor or mod-erate injury. It is also used to alert against unsafepractices and hazards involving only property damage.

SHIPPING DAMAGEMaterial in this shipment has been inspected atthe factory and released to the transportationagency without known damage. Inspect exteriorof carton for evidence of rough handling in ship-ment. Unpack carefully after moving equipmentto approximate location. If damage to contents isfound, report the damage immediately to the de-livering agency.If this furnace was damaged during transit, please im-mediately request the transportation company inspectthe furnace and issue a concealed damage report.The party receiving the furnace should file the claim forshipping damage. Report any shipping damage im-mediately.It is absolutely essential that a damage report be ob-tained. If a concealed damage report is not obtained, wecannot provide assistance in recovering your claimagainst the transportation company.

SAFETY CONSIDERATIONSThe following safety practices and precautions must befollowed during the installation, servicing, and opera-tion of this furnace.

1. Use only with the type of fuel oil approved for thisfurnace. Refer to the furnace rating plate.

2. Install this furnace only in a location and position asspecified in these instructions.

3. Provide adequate combustion and ventilation air tothe furnace space as specified in “Air for Combus-tion and Ventilation” (page 9), of these instructions.

4. Combustion products must be discharged outdoors.Connect this furnace to an approved vent systemonly, as specified in Standard for the Installation ofOil-Burning Equipment, NFPA 31-2001.

5. Always install the furnace to operate within thefurnace’s intended temperature-rise range with aduct system which has an external static pressurewithin the allowable range, as specified on the unitrating plate. Airflow with temperature rise for cfmversus static is shown in the Service Facts accom-panying this furnace.

6. When a furnace is installed so that supply ductscarry air circulated by the furnace to areas outsidethe space containing the furnace, the return airshall also be handled by a duct(s) sealed to the fur-nace casing and terminating outside the space con-taining the furnace.

7. An oil-fired furnace for installation in a residentialgarage must be installed as specified in “InstallationLocation” section (page 3), of these instructions.

Notice to the Installer:Installation of this oil-fired furnace must be performedby a qualified installer in accordance with all local codesand authorities having jurisdiction. In the absence of lo-cal governing codes, installation shall conform to theseinstructions and to the regulations of the National FireProtection Association’s Standard for the Installation ofOil-Burning Equipment, NFPA 31-2001, and the Na-tional Electrical Code, ANSI/NFPA 70-2002, or the lat-est editions thereof.A qualified installer, also referred to in this instruc-tion manual as a “qualified heating contractor”, is anindividual, or agency, properly licensed and expe-rienced to install and service oil-burning equip-ment in accordance with all local codes and ordi-nances.

MATERIAL AND WORKMANSHIPThis furnace was built with the highest quality materi-als and attention to workmanship. However, omissionsand defects occasionally occur. Before installing the fur-nace, inspect the furnace thoroughly. If missing parts,defective material, or poor workmanship are evident,report the model and serial numbers imprinted onthe furnace rating label to the seller for adjustment.

PACKAGINGA complete furnace is contained within a single pack-age. The factory completed all feasible assembly. How-ever certain components including draft regulator and,if supplied, door handle, air filter(s), and air filterrack(s), must be assembled to the furnace, or the vent-ing system, in the field.

18-DE01D1-8 3

Installer’s GuideContentsCONTENTS

INSTALLATION GUIDELINES 2Location 2Clearances 4Downflow/ Horizontal Furnace Setup 4Air for Combustion and Ventilation 5Chimney Inspection 13Chimney Sizing 13Chimney Height 13Flue/ Chimney/ Vent Connector 14Draft Regulator 16Power (Side-Wall) Venting 16Duct Work and Air Conditioning 17Air Filter Mounting 17Oil Burner and Oil Nozzle Installation 18Fuel System Installation 19Electrical Connections 20

8. The furnace may be used for temporary heating ofbuildings or structures under construction onlywhen the following conditions have been met:a. The furnace venting system must be complete

and installed per manufacturers instructions.b. The furnace is controlled only by a room thermo-

stat (no field jumpers).c. The furnace return air duct must be complete

and sealed to the furnace and clean air filtersare in place.

d. The furnace input rate and temperature risemust be verified to be within nameplate mark-ing.

e. 100% of the furnace combustion air requirementmust come from outside the structure.

f. The furnace return air temperature range is be-tween 70 and 100 degrees Fahrenheit.

g. Clean the furnace, duct work, and componentsupon substantial completion of the constructionprocess, and verify furnace operating conditionsincluding ignition, input rate, temperature riseand venting, according to the manufacturer's in-structions.

▲ WARNING!The manufacturer of this equipment assumes no liabil-ity for any damages resulting from unauthorized modi-fications made to the furnace, or any componentsthereof, or improper installation of the furnace in thefield. Furthermore, any such field modifications VOIDTHE WARRANTY and place responsibility for safe andreliable operation of the furnace on those who per-formed the modification(s).

INSTALLATION GUIDELINES CODESAll local codes and regulations take precedence over theinstructions in this manual and shall be followed accord-ingly. In the absence of local codes, this installationmust conform to these instructions and to the regula-tions of the National Fire Protection Association(NFPA) publications, the Standard for the Installation ofOil-Burning Equipment, NFPA 31-2001, and the Na-tional Electrical Code, ANSI/NFPA 70-2002, or the lat-est editions thereof.

INSTALLATION LOCATION

▲ CAUTION!To prevent shortening its service life, the furnaceshould not be used as a “Construction Heater” duringthe finishing phases of construction until the require-ments listed in item 8, a-g of the safety section of thispublication have been met. Condensate in the pres-ence of chlorides and fluorides from paint, varnish,stains, adhesives, cleaning compounds, and cementcreate a corrosive condition which may cause rapiddeterioration of the heat exchanger.

▲ WARNING!SUPPORT FURNACE PROPERLYDO NOT hang the downflow/ horizontal furnace froma structure, or surface, by any integral part or fas-tener of the furnace. The furnace was not designed tosupport itself in this manner.

In as much as practical, the furnace should be posi-tioned near a chimney or vent and should be centralizedwith respect to the air distribution system.For a utility room installation, the entrance door mustbe wide enough to permit the largest part of the furnaceto pass through the doorway or allow sufficient clear-ance to permit the replacement of another appliance,e.g. a water heater, in the room.If the furnace is installed in a residential garage, itmust be installed so the burner is located higher than18 inches above the floor. Also, the furnace must be lo-cated or protected to avoid physical damage from im-pacts by vehicles.Highboy and lowboy furnace models must rest onsturdy, stable, and level surfaces.The downflow/ horizontal model may be mounted on alevel surface, as described above, or it may be sus-pended from an overhead structure or surface. If thismodel is suspended from hanger rods, support thefurnace from the bottom casing surface at three(3) places, across both ends of the casing and acrossthe casing, near the middle of the furnace.Generally, a simple support frame for the furnace canbe fabricated from structural steel angle, threaded steelrod, and fastener hardware, refer to Figure 1. Adjustthe height of the support angles to level the unit in posi-tion.

4 18-DE01D1-8

Installer’s Guide

STANDARD CLEARANCESStandard clearances are mandatory minimum clear-ances from heated surfaces of the furnace to combus-tible materials to assure protection from fire hazardduring furnace operation. (Refer to the Standard for theInstallation of Oil-Burning Equipment, NFPA 31-2001,for definitions of combustible and non-combustible ma-terials.)Accessibility clearances, which are typically greater,may exceed fire protection clearances. Therefore, con-sider providing at least 24 inches of clearance from thefront (and the rear, for lowboy furnaces) of the furnaceto obstructions and surfaces for adequate service andmaintenance access.

CLOSET AND ALCOVE INSTALLATIONAll furnace models may be installed in a closet or alcoveon combustible flooring with specified (standard) clear-ances to combustible construction.The horizontal/ downflow furnace model requiresan optional combustible surface-mounting base(model # BAYSUB10ABASEAA) for vertical instal-lation (i.e., downflow configuration) directly oncombustible materials, refer to Figure 2.

1

Recommended Support Frame for Downflow/Horizontal Furnaces

2

Downflow Furnace CombustibleSurface-Mounting Base

The minimum clearances from furnace casingsurfaces to combustible materials are:- 3 inches from casing sides and rear- 8 inches from front casing of furnace to the closet

door, with exception of:* The lowboy rear flue model only requires 3 inches

from front casing of the furnace to the closet door.* The downflow/ horizontal furnace requires 22

inches from front casing of the furnace to the closetdoor.

- 9 inches from flue pipe/ vent connector.- 3 inches from casing top.- 3 inches from any side of supply air plenum.- 3 inches above supply air ducts, within 6 feet of fur-

nace.- For the downflow/ horizontal furnace only, when

the optional combustible surface-mounting base isused with the furnace in the downflow configuration,adequate clearances from the supply end surface ofthe furnace casing to combustible surfaces are pro-vided by the design of the mounting base.

Though these are approved clearances for these fur-naces, space must be provided at the front (18 inchesminimum, 24 inches recommended) and at the rear ofthe furnace for access, service, and replacement of theoil burner, air filter(s), circulating air blower, and fanmotor.

DOWNFLOW/ HORIZONTAL FURNACESETUPThe downflow/ horizontal furnace is shipped from thefactory upright for vertical installation (downflow con-figuration). If the furnace is to be installed lying downon the right-hand or left-hand side (horizontal configu-ration), the positions of the oil burner and the fan andlimit control thermostat may have to be changed. SeeFigure 3.The horizontal furnace may be turned end for end, orrotated, making the top into the bottom, as shown inFigure 3. Refer to the following instructions for install-ing the oil burner and thermostat.

Note: See Illustration on page 24 for thedimensions of the mounting base.

18-DE01D1-8 5

Installer’s GuideAIR FOR COMBUSTION AND VENTILATION

▲ CAUTION!VENTILATION REQUIRED!Relief openings in the front or top of the furnace cas-ing should not be obstructed or blocked. These open-ings supply combustion and ventilation air to the fur-nace.

Chloride, fluoride, iodide, and bromide bearing com-pounds when present, even in low concentrations, in airsupplied for combustion to the furnace, can result in ac-celerated and severe corrosion of the heat exchangerand/or the venting system. This condition can occurwith less efficient furnaces, but is more likely to happenon furnaces with efficiencies of 80% or greater.

1) When the furnace is installed in the horizon-tal configuration, the oil burner must bemounted in an upright position. It will be necessaryto remove the burner then cutoff one (1) of thethreaded burner-mounting studs before attemptingto reposition the burner in the upright position. SeeFigure 3. Trial fit the burner to the burner mount-ing plate to determine which stud to remove. (A ro-tary tool with a cutting (abrasive) disk or a hacksawshould work well to remove the stud.)A machine bolt (furnished with the parts package)will substitute for the removed stud and provide athird point to secure the burner flange to theburner mounting plate. Thread the bolt through theburner-mounting flange and into the open holewithin the burner mounting plate. See Figure 3.

2) Install the flange gasket and the burner on themounting plate threaded studs. Using fastenerssupplied in the parts bag with each furnace [use two(2) or three (3) 5/16 in. brass hex nuts and flat wash-ers, as required], secure the burner to the mount-ing studs on the burner mounting plate.

3) Secure the electrical conduit of the wiring harnessto the oil burner junction box with the hardwareprovided.

▲ WARNING!POSSIBLE OVERHEATING!When converting to horizontal, the high limit and fancontrol may have to be moved.Failure to do so may result in an overheating conditionleading to property damage, or loss of life.

4) When the furnace is installed in the horizon-tal configuration, the high limit and fan controlmust also be located in the upper position on thecasing when the furnace is placed in the final in-stalled position, refer to Figure 4.If the control must be relocated, remove the coverof the control to gain access to the mountingscrews. Remove the mounting screws and the con-trol. Insert the control into the alternate mountinghole in the casing and mark the screw locations.Drill pilot holes for the new screws. Install the con-trol in the new mounting location and secure itwith the mounting screws. Replace the cover of thecontrol. A metal, snap-in cap is furnished with thefurnace to close the unused hole, for the control, inthe cabinet.

6 18-DE01D1-8

Installer’s Guide

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18-DE01D1-8 7

Installer’s Guide

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8 18-DE01D1-8

Installer’s Guide

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18-DE01D1-8 9

Installer’s Guide

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10 18-DE01D1-8

Installer’s Guide

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18-DE01D1-8 11

Installer’s Guide

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12 18-DE01D1-8

Installer’s GuideOften, household chemicals contain chloride-bearingcompounds. There are many compounds representativeof this classification of chemicals. A few common ex-amples are listed below.- Cleaning solvents- Varnish and paint removers- Bleaches- Fabric softeners- Water softener salt- Tile adhesivesAvoid storing or using these chemicals within closeproximity to the furnace. In addition, avoid storing orusing any chemicals, of an unknown and possibly flam-mable nature, in close proximity to the furnace. If it isnecessary to store or use chemicals in the same spaceas the furnace, the area should be well-ventilated andall containers should be sealed when not in use. If pos-sible, keep chemicals in a separate, well ventilated,room closed off from the furnace with a door.The furnace shall be installed in a location within thebuilding that permits a satisfactory supply of air forcombustion, ventilation, and proper operation of theventing system. While all forms of building constructioncannot be covered in detail in this installer's guide, thisrequirement may usually be met by application of oneof the following methods in ordinary building construc-tion. However, applicable local installation codes al-ways take precedence and shall be followed.The content of certain pertinent passages of NFPA 31-2001 on methods to obtain and ensure adequate airflowto the furnace has been excerpted and, in some cases,paraphrased below for reference purposes. Consult theStandard for the Installation of Oil-Burning Equipment,NFPA 31-2001, for special cases and further details.

1. Utility Room (example of a confined space)a. In buildings of conventional construction with

normal air infiltration, two (2) permanent open-ings connecting to a well-ventilated crawl space,attic, or another large, well-ventilated internalarea shall be provided. Each opening shall have aminimum free area of one (1) square inch per1000 BTUH of total input rate (sum of the indi-vidual appliance input rates) of all appliances tobe installed in the utility room. One openingshould be located near, or in, the ceiling of theroom and the other should be located near, or in,the floor.

b. In buildings of unusually tight construction (e.g.those having continuous water vapor barriers;tightly-fitting, or weather-stripped, doors andwindows; and gasketed, caulked, or sealed outerwall joints and penetrations), wherein infiltrationand air exchange with the outdoors is very lim-ited (0.35 air changes per hour, or less), provisionmust be made to provide sufficient air for com-bustion. The following method will usually be ad-equate to ensure sufficient airflow into the space.

Provide two (2) permanent openings, one (1) locatedwithin 12 inches of the floor and one (1) within 12inches of the ceiling, or roof, of the room. These open-ings shall allow for direct exchange of air between theroom and outdoors. If required, ducting between theroom and the outdoors shall be provided.- For horizontally -oriented ducts, each opening shall

have a minimum free area of one (1) square inch per2000 BTUH of the total input rate (sum of the indi-vidual appliance input rates) of all appliances to be in-stalled in the room.

- For vertically -oriented ducts, the minimum free areamay be reduced to one (1) square inch per 4000BTUH of the total input rate (sum of the individualappliance input rates) of all appliances to be installedin the room.

- The minimum dimension of any air opening shall notbe less than 3-inches.

- When an opening in the outside wall must be pro-vided, it should be furnished with properly screenedmetal sleeves.

2. Full Basement (example of an unconfined space)a. Where a furnace is installed in a full basement,

in a building of conventional construction withnormal air infiltration, infiltration is normally ad-equate to provide air for combustion and ventila-tion.

b. In buildings of unusually tight construction (suchas those where weather stripping and storm sashwindows are used, and where basement windowsare also weather-stripped), one (1) permanentopening connecting to a well-ventilated attic, orwith the outdoors shall be provided, using a duct,if necessary. This opening shall have a minimumfree area of one (1) square inch per 5000 BTUHof total input rate (sum of the individual appli-ance input rates) of all appliances to be installedin the basement.

When an opening in the outside wall must be pro-vided, it should be furnished with properly screenedmetal sleeves.

18-DE01D1-8 13

Installer’s GuideIf an exhaust fan, additional air consuming machines(e.g. an air compressor), or a return air grill is presentin the furnace room, there should be increased concernabout providing adequate airflow to the furnace. Addi-tional efforts may be required to assure an adequatesupply of combustion and ventilation air is available tothe furnace under all conditions.CHIMNEY INSPECTIONThe chimney, vent, or any passageway for the stackgases to flow to the outdoor atmosphere is a very im-portant part of the heating system. No furnace, regard-less of the efficiency of the design, can perform satisfac-torily when the chimney to which it is connected is in-adequate or in poor condition.Any of the following symptoms may indicate a chimneyhas severe structural damage and is unsuitable for use:- Chimney appears to be leaning to the side.- Chimney appears to have structural damage, i.e.

loose or missing blocks or bricks, or excessive deterio-ration at mortar joints.

- Tile liner damaged or missing.- Flue gas leakage along the length of the chimney be-

tween the chimney connector and discharge termina-tion.

- Excessive corrosion at the cleanout port or at thechimney connector entrance into the chimney.

- Structural debris, i.e. mortar or tile liner flakes, inbase of the flue way.

A qualified person shall inspect the chimney to confirmit is correctly sized for the application, properly con-structed, and in sound condition. Refer to the Standardfor the Installation of Oil-Burning Equipment, NFPA 31-2001, for details on proper chimney sizing and construc-tion. If needed, the chimney should be cleaned beforeinstalling the furnace. Any accumulation of dirt or de-bris at the bottom of the flue should be removed.CHIMNEY SIZING:The furnace must be connected to an adequate chimneyor an approved vent in accordance with these instruc-tions. An adequate chimney is one that is sealed andlined with the capability of producing a (-).04" WC fluedraft and having the capacity to handle the amount ofstack gases that are introduced into it. A chimney withan internal construction of corrosion resistant tile,stainless steel, or some other material that will with-stand flue gas temperatures up to 900°F is required.The following are common chimney requirements nec-essary for the furnace to operate correctly:A masonry chimney serving an oil fired furnace mustcomply with local codes and NFPA Standard for Chim-neys, Fireplaces, Vents, and Solid Fuel Burning Appli-ances (NFPA211-1996 or latest edition).All installations and services must beperformed by qualified service personnel.

Proper chimney termination height for pitched roofs

The inside area of the chimney liner shouldequal, at minimum, the area of the vent pipe exitingthe furnace-EXAMPLE: π x r2 = Area of Pipe (sq. in.)

r = radius of pipeπ = 3.1417Flue Pipe Diameter = 6" [Radius of pipe = ½diameter of pipe = ½ ( (6 in.) = 3in.]π x 32 = 28 sq. in.

NOTE: This formula calculates the minimum insidearea of the chimney. If more than one appliance ventconnector pipe is connected to the chimney, the mini-mum inside area of the chimney should be equal to thearea of the largest vent pipe plus one half the area ofany additional vent pipes. If the chimney is too large orcondensation has been a problem in the past refer tothe NFPA Standard for the Installation of Oil BurningEquipment (NFPA31-1997 or latest edition) Appendix Efor proper liner sizing.

CHIMNEY HEIGHT:The chimney shall terminate at least 3 feet above thehighest point where it passes through the roof of abuilding and at least 2 feet higher than any portion ofa building within a horizontal distance of 10 feet. (SeeFig. 5a).If the chimney penetrates a roof more than 10 feetfrom a ridge, wall or parapet, a minimum of 3 feetabove roof or exit point must be maintained. SeeFigure 5b.

5

14 18-DE01D1-8

Installer’s Guide

venting system must be supported at least every five (5)feet with metal straps to prevent sagging of the ventpiping.Secure all joints in the vent connector with sheet metalscrews or equivalent fasteners.The vent connector pipe should extend only to (andnot beyond) the inside wall of the chimney (See Fig.8).A thimble should be used to connect the ventconnector pipe to the chimney so that the ventconnector pipe may be readily removed in case ofinspection or replacement.

If the roof is flat rather than the normal residentialPitched roof, refer to Figure 6 for proper clearances.

FLUE/ CHIMNEY/ VENT CONNECTOR▲ CAUTION!

PROPER VENTING REQUIRED!DO NOT install a manual damper in the chimney orvent connector.Thermally-activated type vent dampers are NOT AL-LOWED for use on these furnaces.

It is desirable to install the shortest vent connector(also referred to as a flue or chimney connector) pos-sible with the fewest number of fittings, i.e. transitionsand elbows.

In cases where the chimney extends to the basementfloor, the draft can usually be improved by filling thebase of the chimney with sand to within 12 inches ofthe vent connector pipe after relocating the clean-outdoor. (See Fig. 9).

Generally, 6-inch diameter, 24 Ga. or heavier, singlewall, lock seam-type, galvanized steel vent pipe and fit-tings are satisfactory materials for the fabrication of avent connector.However, always consult local codes and authorities forspecific minimum requirements.For some installations, it may be prudent to turn thefurnace flue elbow 90 degrees clockwise, with respect tothe front of the furnace, such that the elbow is open tothe right-hand side of the unit, rather than upward.Turning the flue elbow may better facilitate connectionof the vent connector piping to the flue elbow on thehighboy. See Figure 7. Due to the presence of the fanand limit control and the wiring harness, the elbowmay not be rotated 90 degrees counterclockwise.The installer must remove the upper right hand knock-out to allow the vent connector to pass through thecabinet.If desired, with the furnace flue elbow turned to theright, the standard furnace top front panel may bereplaced with a BAYTRM10AVENTAA. It includes topfront panel and a vent trim ring. Contact yourdistributor to purchase this part.All horizontal sections of the vent connector must slopeupward not less than ¼ inch per foot from the furnace tothe vent termination. Long horizontal sections of the

All joints of the chimney must be tightly sealed. Theinside of the chimney should be free of anyobstructions, such as loose brick, broken pieces oftile, or corroded metal.

Proper chimney termination height for flat roofs.

6

7

Proper insertion of the vent connector in chimney.

8

Suggested method to improve chimney draft.

9

18-DE01D1-8 15

Installer’s Guide

Reduction of Clearances with Specified Forms of Protection

Type of Protection Allowable Clearance withSpecified Protection (in.)

Applied to and covering allsurfaces of combustible materialwithin the distance specified asthe required clearance with noprotection. See Figure 11.

Where the required clearancewith no protection from theappliance or chimneyconnector is: 9 inches

Above Sides & Rear

a. 3 -1/2" thick masonry wallwithout ventilation air space.....

--- 6

b. 1/2" insulation board over 1"glass fiber or mineral woolbatts.....

6 5

c. 0.024 (24 gauge) sheet metalover 1" glass fiber or mineral woolbatts reinforced with wire on rearface with ventilated air space.....

5 3

d. 3 - 1/2" thick masonry wall withventilation air space.....

--- 6

e. 0.024 (24 gauge) sheet metalwith ventilated air space.....

5 3

f. /2" insulation board withventilated air space....

5 3

g. 0.024 (24 gauge) sheet metalwith ventilated air space over0.024 (24 gauge) sheet metal withventilated air space.....

5 3

h. 1" glass fiber or mineral woolbatts sandwiched between twosheets 0.024 (24 gauge) sheetmetal with ventilated air space

5 3

A. Equal the required clearance with no protection.B. Equals the reduced clearance permitted in accordance with thepreceeding clearance chart.C. The protection applied to the construction that covers thecombustible material should extend far enough in each directionto make C equal to A.

The vent connector pipe between the furnace andchimney shall be of equal diameter as the flue outletof the furnace.The vent connector pipe must be made of 24gauge (or thicker) corrosion-resistant steel.The vent connector pipe should be as short aspossible and installed so that it has a continuous risefrom the furnace to the chimney. The horizontallength of a connector to a natural draft chimney orvent serving a single appliance shall not be morethan 75 percent of the height of the vertical portionof the chimney or vent above the connector. Elbowsshould be minimized and the pipe should be joinedwith metal screws and supported by straps. Allhorizontal runs of vent connector pipe should bepitched upward a minimum of 1/4 inch per foot ofrun.A thimble should be used to connect the ventconnector pipe to the chimney so the pipe may bereadily removed in case of inspection or replacement.See Fig. 10.

All chimney clean-out doors and flue connectionsmust fit tightly so they will seal to avoid air leaks.If chimney flues are divided or there are multipleflues within one chimney, make sure there are noopenings in the partition separating the divided orindividual flues.The vent connector pipe must not pass through acombustible wall or partition unless adequateprotection is provided at the passageway. Anacceptable passageway could be either an approved,ventilated metal thimble which is at least 12 incheslarger in diameter than the vent connector pipe, orbrick work which is at least 8 inches thickconstructed into the wall and surrounding the ventconnector pipe. (See Fig. 10).

Suggested method to acommodate vent connector passage through a wall composed of combustible material.

0 Alternate construction that allows reducedclearances to combustible materials.

q

16 18-DE01D1-8

Installer’s GuideTo prevent condensation, it is necessary that theinternal chimney wall temperature always be keptabove the dew point. If the chimney is a masonrytype, it may have to be fitted with a flue liner, whenthe temperature loss is too great for the furnace. Ifthe chimney is a metal type, then an “all fuel”chimney must be used, such as a Class “A” triple wallor insulated metal chimney. A liner will act as aninsulator and reduce the stack gas temperature loss.Insulation may be added around the liner for furthertemperature stability. If the chimney is on thehome’s exterior or passes through a sizable,unheated area of the building, such as a porch, highceiling attic, etc., and condensing occurs, thechimney must be insulated around its exterior tohelp the flue hold its temperature. Also, check to seeif the chimney is too large for the furnace and otherappliances connected to it. If so, reduce to proper size(see Appendix E of NFPA31) by lining. Be sure to usestainless steel liners, such as stainless types 430, 304,or for the toughest corrosion problems, type 316. Ifthe chimney is the correct size for the unit andcondensing still occurs, then insulating the ventconnector and/or reducing the efficiency of thefurnace may have to be done to raise the chimneytemperature.More detailed information may be obtained from thelatest edition of the ASHRAE HVAC Systems andEquipment Handbook.Should the previous recommendations and theinformation obtained from the ASHRAE Handbookfail to resolve a condensation problem, anotheralternative to consider is power side wall venting.

DRAFT REGULATORA barometric-type, draft regulator is supplied with thefurnace. Installation or operating conditions that pro-duce excess amounts of draft can reduce the heating ef-ficiency of the furnace. The purpose of the regulator isto adjust and control the flow of flue gases from the fur-nace by stabilizing the amount of chimney draft towhich the furnace is subjected.Generally, install the barometric draft regulator in thevent connector as close as possible to the flue outlet col-lar of the furnace. However, always refer to the draftregulator manufacturer’s installation instructions forapplication specific recommendations.

POWER (SIDE-WALL) VENTING▲ CAUTION!

The manufacturer will NOT assume responsibility fordamage to, and deterioration of, exterior building mate-rials, e.g. brick, siding, clapboards, and etc., in closeproximity to the vent terminal due to operation of apower vented, oil furnace. This policy is applicable re-gardless of the cause of sooting.

PREVENTION OF CHIMNEY CONDENSING:

▲ WARNING!PROPER VENTING REQUIRED!Improper venting may lead to condensation in thechimney. This may result in property damage, injury,or loss of life. To prevent condensation refer to NFPA31 Section 6 and Appendix E.

Stack gas may do one of two things as it escapes upthe chimney:A. Remain entirely in a gaseous state if the internalchimney wall temperature is above the dew point, orB. Condense water vapor on the chimney walls if theyare chilled below the dew point.Condensing will always occur on chimney walls whosetemperatures are below the dew point, but thecondensate may evaporate when the walls warmabove the dew point. If the chimney wall temperaturedoes not exceed the dew point during the heatingcycle of the furnace, the moisture may accumulate inlarge enough quantities to cause problems such ascorrosion of a metal chimney (especially plain steel orgalvanized steel), erosion and break up of a tile linerin a masonry chimney and, in severe cases, corrosionof the heat exchanger. Condensate also could enterthe home through cracks or joints in the chimney ina worse case situation.Condensation most likely will not occur at the bottomof the chimney because the stack gas heats thechimney walls as it rises and the bottom will beheated first. This heating of the walls will cause thestack gas temperature to drop, which in turn mayreduce the stack gas temperature below dew point,causing condensation to appear on the upper part ofthe chimney first. This condensation may then rundown inside the chimney and drip back as far as theflue pipe and heat exchanger, where corrosion mayoccur, if not treated.

18-DE01D1-8 17

Installer’s GuideTwo (2) problems typically arise when power ventingany oil fired appliance:

1) Soot buildup may occur at an accelerated rate oncritical components of the furnace oil burner, e.g.the primary control flame sensor (“cad cell”), theburner head, and oil nozzle.

2) Severe damage may occur to external surfaces ofthe structure in the event the furnace continuallyproduces a high level of smoke in the flue gases.Excess smoke and soot can be produced for manyreasons, some of which cannot be successfully con-trolled by the installer and the appliance manufac-turer.

NOTICE: The manufacturer recommends the use of achimney to vent residential oil furnaces. If a power ven-ter must be used, it is the responsibility of the installerand power venter manufacturer to design, assemble,and demonstrate proper operation of the power vent-ing system with the furnace.

DUCT WORK AND AIR CONDITIONINGAir duct systems should be installed in accordancewith standards for air conditioning systems, NationalFire Protection Association Pamphlet No. 90. Theyshould be sized in accordance with ACCA Manual Dor whichever is applicable.All furnaces are tested over a range of external staticpressure that simulates the airflow resistance of theductwork, fittings, and diffusers connected to the fur-nace for a typical (average) duct system. The furnaceblower and blower motor have been selected to worksuccessfully against the following range of duct systemresistance.Recommended range of duct system resistance for allmodels: 0.2 to 0.5 in. W.G. external static pressure.Due to the need to maintain an adequate supply of com-bustion and ventilation air, the furnace shall not be in-stalled in a small room without a return air duct sys-tem.A duct the full size of the furnace return air openingshall extend to a location outside the furnace room.If the furnace is used in connection with cooling/ heatpump systems, a 3 " minimum long transition must beinstalled between the furnace supply air outlet and theevaporator coil supply air inlet to prevent overheatingof the evaporator coil drain pan. See page 10 for specificlayout and dimensions.

▲ WARNING!OVERHEATING HAZARD!Failure to maintain a minimum of 3" separation fromthe furnace heat exchanger and the evaporator coildrain pan may cause drain pan damage.

If the furnace is used in connection with summer airconditioning (cooling), the furnace should be installed inparallel with, or on the upstream side of, the evaporatorcoil to avoid water vapor condensation in the furnaceheat exchanger.If the cooling unit is installed in a parallel flow arrange-ment, dampers (or other means used to control airflow)should be provided to prevent chilled air from enteringthe furnace. If such a damper is manually operated, itmust be equipped with a means to prevent operation ofeither unit, unless the damper is placed in either thefull heat or full cool position.

NOTICE: Return air grilles and supply registers in theair distribution system should never be obstructed.

AIR FILTER MOUNTING

▲ CAUTION!POSSIBLE CASING DAMAGE!If cutting openings in the furnace casing is required,DO NOT cut any supporting clips or angles. Cut asclose to the scribed line as possible, but DO NOT cutthe base clip or blower pan support angle.

Lowboy furnaces are factory-equipped with cleanable-type, air filters located above the blower compartment,in the rear of the furnaces. Highboy furnaces ship withan external filter rack & cleanable-type filter.

NOTICE: Downflow/ horizontal furnaces are not factory-equipped with an air filter or filter rack.

Furthermore, the furnace blower compartment doesnot contain enough free space to permit an air filter tobe mounted within the furnace casing. The installershould supply, or fabricate, a filter rack and mount anair filter in the return air plenum above, or upstreamof, the furnace blower compartment.

w

Cutaway view of fan section ofa typical highboy furnace.

On the highboy furnace, it is necessary to cut the re-turn air opening in the lower side, or rear, of the casingdepending upon the needs of the specific installation, re-fer to Figure 12.

18 18-DE01D1-8

Installer’s GuideThe oil burner was installed in the furnace at the fac-tory. In the field, if it is necessary to adjust the heatingcapacity of the furnace by changing the oil burnernozzle, refer to the following instructions. Also, consultthe oil burner manufacturer’s operating instructions(included with the burner) for detailed instructions onthis procedure.1) The oil nozzle is factory installed in the oil burner.

The gun/electrode assembly with nozzle may be re-moved from the rear of the burner assembly with-out removing the oil burner from the furnace.To access the gun/ electrode assembly, loosen two(2) machine screws and clamps holding the burnerignition transformer in position. Rotate the trans-former forward and out of the way.

2) Install an appropriate replacement nozzle of the cor-rect size, spray angle, and spray type.

3) The furnace may have been handled roughly whilein transit. Under some conditions, the combustionchamber can shift out of position. Check for properalignment of the burner air tube with the circularopening in the combustion chamber and trial fit theburner to check the insertion depth of the oilburner into the combustion chamber.The end of the burner air tube should be insertedno farther than 1/4 inch back from the inside sur-face of the combustion chamber, refer to Figure 13 .Do not allow the burner tube/ end cone to physi-cally touch or protrude into the chamber.High temperatures in the combustion chamber canresult in damage to the tube, the end cone, or both.A distance greater than 1/4 inch back from the in-side chamber wall may cause flame impingementon the combustion chamber wall and subsequentsooting or carbon char buildup.

The side casings have each been pre-punched with four(4), square, knockout openings for use in locating theproper position for the return air filter rack. On theside of the furnace, where the return air duct will at-tach, scribe a line connecting the outside edges of theknockout openings to form a rectangle.Using a punch, or a large screwdriver, and a hammer,remove the knockouts and cut the return air openingin the casing.Sheet metal shears, or a power metal cutting tool, willbe required to cut the casing.Position the open end of the filter rack to the front ofthe furnace to permit access for filter replacement.Align the filter rack with the rectangular hole andmark the locations on the casing of the pre-punchedmounting holes in the filter rack flange. Drill pilotholes in the casing and permanently attach the filterrack to the furnace with screws, or pop-rivets (thesefasteners are not included). Connect the return air ple-num to the filter rack and slide the air filter into posi-tion.

OIL BURNER AND NOZZLE INSTALLATION▲ CAUTION!

FUEL REQUIREMENT!This oil furnace is designed to use No. 2 distillatefuel (home heating) oil only.

This furnace is designed to utilize the following spe-cially modified, oil burner:- R.W. Beckett Corp. model AF burner, specification

#EFL-101.

NOTICE: NO other burners may be used in this appli-cation.

The heat output from the furnace is fixed, based on thesize of nozzle installed in the oil burner. Four (4) heatinput rates are permissible: 84,000, 105,000, 119,000,and 140,000 BTUH.Nozzle selection (i.e. heating capacity of the furnace)shall be based on a rate of heat loss (heating load) cal-culation for the building. These calculations should bemade according to the manuals provided by the AirConditioning Contractors of America (ACCA) or theAmerican Society of Heating, Refrigeration and AirConditioning Engineers, Inc. (ASHRAE).Refer to the Residential Load Calculation, Manual J,from the ACCA, and the ASHRAE Handbook Funda-mentals volume, from ASHRAE, for the recommendedprocedure to compute the design heating load of a resi-dence.

e

Side view of correct burner insertion intocombustion chamber.

The oil burner provided with this furnace requires ini-tial inspection, set-up, and proper adjustment. Refer tothis manual and the oil burner manufacturer’s operat-ing instructions for detailed information on the follow-ing items:- Initial firing of burner- Adjusting the burner combustion air

18-DE01D1-8 19

Installer’s Guide- Adjusting the fuel pump pressure- Setting the draft control

NOTICE: This oil furnace must be installed and ad-justed by qualified oil heating dealers using calibratedcombustion test instruments to ensure safe and reli-able operation of the furnace.

FUEL SYSTEM INSTALLATIONIn situations where the oil storage tank is installed atthe same level with, or above, the burner, a single oilsupply line run from the oil tank to the burner will usu-ally be adequate. No return line will be required. If theoil tank is installed below the burner and the lift ex-ceeds approximately 8-ft., an oil supply line and an oilreturn line are necessary. See Figure 14 and 15.Refer to the Standard for the Installation of Oil-BurningEquipment, NFPA 31-2001, and the oil burner operatinginstructions for detailed information on oil storage tank& oil supply/ return line installation.

NOTICE: We recommend installing a high effi-ciency oil filter, in the oil supply line, capable of fil-tering 10 to 20 micron diameter (or preferablysmaller) particles from the fuel.

If available, the use of ultra-low or low sulfur (lessthan 0.0015% S and 0.0015 - 0.05% S, by weight, re-spectively), no. 2 fuel oil is highly recommended.Low sulfur fuel oil can help to significantly reduce in-stances of blockage and corrosion of the oil burner fueldelivery system (especially the nozzle), the furnace heatexchanger, and the flue gas venting system. Air pollut-ants emitted by the furnace and the typical malodoroussmell of oil combustion will be reduced.Connect fuel linesCarefully follow the fuel unit manufacturer’s literatureand the latest edition of NFPA 31 for oil supply systemspecifications.Fuel units with automatic bypass do not require a by-pass plug. The burner fuel unit is shipped without thebypass plug installed. You must install this plug on two-pipe oil systems.

▲ WARNING!DO NOT install the bypass plug in the fuel unit if con-nected to a one-pipe oil system.Failure to comply could cause fuel unit seal failure, oilleakage and potential fire and injury hazard.

Fuel supply level with or above burner –The burner is factory equipped with a single-stage fuelunit. Connect the fuel supply to the burner with asingle supply line if you want a one-pipe system(making sure the bypass plug is NOT installed inthe fuel unit.)

Manual venting of the fuel unit is required on initialstart-up. If connecting a two-pipe fuel supply, install thefuel unit bypass plug.The oil supply inlet pressure to the fuel unit cannotexceed 3 psi. Install a pressure-limiting device inaccordance with NFPA 31. Example: Burner is at samelevel or below the level of the oil tank. WARNINGFuel supply below the level of the burner –When the fuel supply is below the level of the burner, atwo-pipe fuel supply system is required. See Figure 15.Depending on the fuel line diameter and horizontal andvertical length, the installation may also require a two-stage pump. Consult the fuel unit literature for lift andvacuum capability.Fuel line installation –• Continuous lengths of heavy wall copper tubing are

recommended. Always use flare fittings. Neveruse compression fittings.

• Always install fittings in accessible locations. Fuellines should not run against the appliance or the ceil-ing joists (to avoid vibration noise).

Never use Teflon tape on any fuel fitting. Tapefragments can lodge in fuel line components and fuelunit, damaging the equipment and preventing properoperation. WARNINGFuel line valve and filter –• Install two high quality shutoff valves in accessible

locations on the oil supply line. Locate one close tothe tank and the other close to the burner, upstreamof the filter.

Some states require these valves to be fusible-handledesign for protection in the event of fire. Werecommend this as good industry practice for allinstallations.

r

20 18-DE01D1-8

Installer’s Guide

• Install a generous capacity filter inside the build-ing between the fuel tank shutoff valve and theburner, locating both the filter and the valve close tothe burner for ease of servicing. Filter should berated for 50 microns or less.

The following table and graph explain the delay-off settings:

COOLING OFF - DELAY OPTIONS

SWITCH SETTINGS SELECTION NOMINALAIRFLOW

5 - OFF 6 - OFF NONE SAME

5 - ON 6 - OFF 1.5 MINUTES 100% *

5 - OFF 6 - ON 3 MINUTES 50%

5 - ON 6 - ON ** 50 - 100%

TABLE 1

SINGLE STAGE, TWO PIPEMAXIMUM LINE LENGTH

( H + R )

3450 RPM

Lift"H"

3/8" Tubing 1/2" Tubing

3 GPH 7 GPH 3 GPH 7 GPH

0' 84' 71' 100' 100'

1' 78' 66' 100' 100'

2' 73' 62' 100' 100'

3' 68' 57' 100' 100'

4' 63' 53' 100' 100'

5 57' 48' 100' 100'

6' 52' 44' 100' 100'

7' 47' 39' 100' 100'

8' 42' 35' 100' 100'

9' 36' 31' 100' 100'

10' 31' 27' 100' 100'

11' 26' 22' 100' 87'

12' 21' 18' 83' 70'

13' - - 62' 52'

14' - - 41' 35'

VARIABLE SPEED DIP SWITCH SETTING FOR COOLING

TWO-PIPE SYSTEM

t

SEE TABLE 10N PAGE 18

ELECTRICAL CONNECTIONS

NOTICE: All field wiring must conform to local, state,and national installation codes.

A disconnect switch equipped with overcurrent protec-tion (e.g. a time delay-type fuse or inverse time, circuitbreaker) should be installed in the service line for shut-ting down and protecting the furnace and electrical sys-tem.Since the furnace is entirely pre-wired at the factory, itis only necessary to connect the building electrical ser-vice lines to the two (2) pigtail wires extending from thefan center junction box. The fan center is mounted in-side the furnace burner compartment or mounted onthe front exterior of the furnace, in the case of thedownflow / horizontal model. The service lines to thefurnace should be no smaller than 14 Ga., insulated cop-per wire with a temperature rating of 60ºC, or greater.Connect an equipment ground wire to the furnace atthe fan center junction box. If wiring is run throughmetal electrical conduit, it may not be necessary to runa separate equipment ground wire. Consult local codesand authorities for specific minimum requirements.

* - This setting is equivalent to BAY24X045 relay ben-efit.

** - This selection provides ENHANCED MODE, whichis a ramping up and ramping down of the blowerspeed to provide improved comfort, quietness, andpotential energy savings. See Service Facts forcooling and heating air flow dip switch settings1,2,3,4,7,8. The graph which follows, shows theramping process.

OFF

50%50%

80%

Dehumidify

EfficiencyFast Cooling

1

minute

3

minutes

7.5

minutes

100% if necessary

OFF

See Service Facts for dip switch settingfor complete setup for Enhanced Mode.

18-DE01D1-8 21

Installer’s Guide

LOW VOLTAGE HOOK UP DIAGRAMS FOR OIL FURNACE WITH PSC MOTOR(SINGLE STAGE COOLING)

Using 18 gauge control wire, connect control wiring tothermostat as shown in the following illustrations. Ifthe thermostat does not have an isolated heating circuit(RH), then install a pilot duty rated, 24 volt, relay(RLY00975, field supplied). This relay is shown as R1 inthe illustrations. Consult the National Electrical Code,ANSI/NFPA 70-2002, for guidelines for proper wiringmethods and materials for this circuit.

R1

R1

B/C

THERMOSTAT

AIRCONDITIONER

FURNACEFAN CENTER

OIL BURNER PRIMARY

u SINGLE STAGE HEAT/ COOL WITH 24V RELAY

NOTE:Thermostat "R" terminal may be labeled as "RC" or"RH".

SINGLE STAGE HEAT/ COOL WITH RH/ RC CIRCUIT

NOTE:Thermostat "R" terminal may be labeled as "RC" or"RH".

RCRC

B/C

THERMOSTAT

AIRCONDITIONER

FURNACEFAN CENTER

OIL BURNER PRIMARY

y

22 18-DE01D1-8

Installer’s GuideVARIABLE SPEED OIL FURNACE CONNECTION LOCATIONS AND LOW VOLTAGE

HOOK UP DIAGRAMS (SINGLE STAGE COOLING) WITH 24V RELAY

Low VoltageTerminal BoardMAKE LOW VOLTAGECONNECTIONS HERE

Oil BurnerPrimary Control

DO NOT MAKE ANY CONNECTIONS HERE

Route electrical power circuit through outside furnace wall and into junction box and make high voltage connections inside box according to the NEC and local codes.

VARIABLE SPEED V3, V5 LOW VOLTAGE WIRINGCONNECTIONS LOCATIONS

R

G

Y/ Y1

W1

B

THERMOSTAT

VARIABLE SPEED OIL FURNACE SINGLE STAGE COOLING

R

G

W1

W2

Y1/YLO

B

SINGLE STAGE AIR CONDITIONER

ONE STAGE VS OIL FURNACE

BC

BK

Y/Y2 Y

W3

O

R1

R1

"R" to "O" and "R" to "BK" are Factory Installed Jumpers

R1

OIL BURNER PRIMARY

18-DE01D1-8 23

Installer’s GuideLOW VOLTAGE HOOK UP DIAGRAMS FOR VARIABLE SPEED OIL FURNACE

(TWO STAGE/ STEP COOLING)

R

G

Y/ Y1

W1

B

THERMOSTAT

VARIABLE SPEED OIL FURNACE TWO STAGE COOLINGWITH 24V RELAY

R

G

W1

W2

Y1/YLO

Y1

B

TWO STAGE AIR CONDITIONER

ONE STAGE VS OIL FURNACE

BC

Y2

BK

Y/Y2 Y2

R

O

W3

R1

"R" to "O" and "R" to "BK" are Factory Installed Jumpers

R1

OIL BURNER PRIMARY

R

G

Y/ Y1

W1

B

THERMOSTAT

VARIABLE SPEED OIL FURNACE TWO STEP COOLING WITH 24V RELAY

R

G

W1

W2

Y1/YLO

B

TWO STEPAIR CONDITIONER

ONE STAGE VSOIL FURNACE

BC

Y2 BK

Y/Y2 Y1

O

Y2

Note A - Cut/remove the factory installed "R" to "BK" jumper at the indoor unit.

W3

R1

Note A

"R" to "O" and "R" to "BK" are Factory Installed Jumpers

R1

OIL BURNER PRIMARY

02/09

Since the manufacturer has a policy of continuous product and product data improvement, it reserves the rightto change design and specifications without notice.

Trane6200 Troup HighwayTyler, TX 75707

For more information contactyour local dealer (distributor)

BAYSUB10ABASEAA DIMENSIONSDownflow Furnace Combustible

Surface-Mounting Base