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Olsen HTL-100 Installation, Operation & Service Manual

Oil fired loboy furnace - 83% + efficiency
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Installation, Operation &
Service Manual
OIL FIRED LOBOY FURNACE - 83% + EFFICIENCY
HTL-100
HTL-200
INSTALLATIONS MUST MEET ALL LOCAL AND FEDERAL CODES THAT MAY
DIFFER FROM THIS MANUAL
Please read the manual in its entirety before beginning installation. This
manual must be kept with the boiler for future reference. For maintenance
or question, please refer to your installer – contractor directly.
2023-08-01
5IM-OE-HTL0-00

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  • Page 1 Installation, Operation & Service Manual OIL FIRED LOBOY FURNACE - 83% + EFFICIENCY HTL-100 HTL-200 INSTALLATIONS MUST MEET ALL LOCAL AND FEDERAL CODES THAT MAY DIFFER FROM THIS MANUAL Please read the manual in its entirety before beginning installation. This manual must be kept with the boiler for future reference.

  • Page 2: Table Of Contents

    6.0 FURNACE OPERATION AND SETTINGS 6.1 BOILER SETTING 6.2 FAN TIMER CONTROL BOARD (1158-120) 6.3 (1158-120) CONTROL BOARD SEQUENCE 6.4 SERVICING – FAN TIMER (1158-120) 7.0 SERVICE 8.0 ELECTRICAL / WIRING DIAGRAMS 9.0 EXPLODED PARTS VIEW HTL-100 HTL-200 10.0 START-UP TEST RESULTS...

  • Page 3: Important Saefty Advice

    IMPORTANT SAFETY ADVICE Please read and understand this manual before installing, operating or servicing the furnace. To ensure you have a clear understanding of the operating procedures of the unit please take the time to read the IMPORTANT SAFETY ADVICE section of this manual. FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

  • Page 4: Product Information

    HTL-200 9-1/2" (240 mm) AIR/BLOWER DATA Maximum external static pressure 0.50” WC Maximum cooling unit capacity HTL-100, up to 3.0 tons. HTL-200, up to 5.0 tons. Maximum air temperature rise 85°F MOTOR/BLOWER HTL-100 1/2 hp 4 Speed PSC / G10-8 DD or 1/2 hp 5 speed ECM / G10-8 DD...
  • Page 5 HTL-100 20” x 20” x 2” non-pleated UL approved HTL-200 20” x 25” x 2” non-pleated UL approved PLENUM DIMENSIONS (HTL-100) Cold air return 18” x 18” (460 x 460 mm) Hot air supply 20” x 20” (508 x 508 mm)
  • Page 6 (1372 mm) Width 21-1/2" (546 mm) DIMENSIONS (HTL-200) Depth 29-1/2" (750 mm) Height 60" (1524 mm) Width 24-1/2" (622 mm) 24 1/2" 24 1/2" 54" 47 7/16" 31 3/8" 24 7/8" 10 5/8" 21-5/16" HTL-100 - DIMENSIONS Dimensions are in inches...
  • Page 7 24 1/2" 29 1/2" 60" 54 11/16" 31 1/8" 25 5/8" 10 5/8" 26-5/16" HTL-200 - DIMENSIONS Dimensions are in inches...

  • Page 8: Furnace Installation

    FURNACE INSTALLATION The installation of the appliance shall be in accordance with the regulations of the authorities having jurisdiction. OIL TANK PIPING Tank installation must conform to local requirements. Install according to the applicable code such as CAN/CSA B139 and NFPA 31 in the USA. Minimize number of connections in suction line and make all connections air tight.
  • Page 9 FRONT FLUE FURNACE ILLUSTRATION PLACEMENT & VENTING Furnace installation shall conform to the required installation code for oil-fired equipment (USA: NFPA 31, Canada: CAN/CSA B139). FLOOR SUPPORT If required, support furnace on five (5) concrete blocks. Make sure the center of the furnace base is supported. CHIMNEY/VENT Connect the furnace to a chimney/vent system of size and material required by the NFPA 31 (USA) or CAN/CSA B139 (Canada) code.
  • Page 10 BE AWARE THAT MODIFYING OR REMOVING BAFFLES REDUCES THE UNIT’S EFFICIENCY. Note: See Base temperature definition inside NFPA-31 and CAN/CSA B139 codes. The base temperature of the chimney shall be measured after the unit has been in operation for a minimum of 5 minutes or long enough for the flue gas temperatures to have reached equilibrium.
  • Page 11 Appliance(s) located in a large space Combustion air and additional ventilation from outdoor 12” higher than ground level and snow forecast. The opening shall have a total free-flow area of not less than 4,4 cm2/kW (1 in2/5000 BTU/h) of the total input rating for the appliance(s) located in a large space.

  • Page 12: Accessories Installation

    Appliance(s) located in a limited space Combustion air from outdoors by infiltration and ventilation from inside the building 12’’ higher than ground level and snow forecast. The opening shall have a total free-flow area of not less than 4,4 cm2/kW (1 in2/5000 BTU/h) of the total input rating for the appliance(s) located in a limited space.
  • Page 13 Switch Operation Blocked vent switches are flue gas temperatures safety devices for detecting spillage of flue gases due to a blocked flue or inadequate draft. After detecting a problem, the switch de-energizes the system’s burner control. NEVER reset the switch unless the cause of the blockage has been corrected.
  • Page 14 AIR CONDITIONING An air conditioning coil may be installed on the supply plenum only. Coils installed on the return plenum will cause condensation on the heat exchanger; this will shorten the heat exchanger life and may cause products of combustion to enter the house. Wire as per wiring label and diagram.
  • Page 15 AIR FILTER RACK INSTALLATION Tank installation must conform to local requirements. THE AIR FILTER RACK IS A FIELD INSTALLED COMPONENT. AFTER INSTALLATION THE RACK MUST BE SEALED (WITH DUCT TAPE OR EQUIVALENT) TO MINIMIZE AIR LEAKS. THIS IS THE RESPONSIBILITY OF THE INSTALLER. The air filter rack is shipped uninstalled inside the furnace.
  • Page 16 Step 5: Remove the 4 knockouts on the panel (left side, right side or base panel) where you want to install the air filter Step 6: Cut the panel between the 4 knockouts. Step 7: Using 8 screws, install the air filter rack on the furnace. Seal Properly. Step 8: Slide the air filter inside the air filter rack.

  • Page 17: Burner Installation And Specifications

    Select oil input, nozzle and burner configuration as shown on furnace operating decal. INSTALL NOZZLE Install selected nozzle, check for clean seating and tighten in nozzle adaptor. ELECTRODES See burner manufacturer’s instructions for correct setting HTL-100 6-3/8” HTL-200 9-1/2” INSERTION IMPORTANT: When installing the burner on the furnace MOUNT BURNER make sure that the burner head does not damage the firepot.

  • Page 18: Set Burner For Efficient Operation

    SET BURNER FOR EFFICIENT OPERATION BURNER SETTING Use burner settings in the table on page 20-21 or operating decal as a starting guide to set the burner, particularly for nozzle changes. Those settings are only starting points for the adjustments and are not meant as final settings.
  • Page 19 COMBUSTION TEST All your tests must be done with the burner cover on ADJUSTMENTS After 10 minutes of normal operation, adjust the breech draft with the barometric control to obtain a value of -0.01’’ WC, after proceed to take a smoke test and adjust the burner in order to obtain a reading of ‘1’ on the smoke scale, once achieved take a CO2 reading and note the result.

  • Page 20: Htl Technical Information

    HTL TECHNICAL INFORMATION / BURNER AND BLOWER CONT'D No 2 Fuel Oil Ratings HTL Series HTL-100 HTL-200 Riello Burner* Unit Model HTL-E1-*065-03 HTL-E1-*076-03 HTL-E1-*087-03 HTL-E3-*100-05 HTL-E3-*110-05 HTL-E3-*127-05 Firing Rate (USGPH) 0.55 0.65 0.75 0.85 0.95 1.10 Input (BTU/h) 77,000 91,000...
  • Page 21 B20 Bio-diesel Ratings BCL Series HTL-100 HTL-200 Riello Burner* Unit Model HTL-E1-*065-03 HTL-E1-*076-03 HTL-E1-*087-03 HTL-E3-*100-05 HTL-E3-*110-05 HTL-E3-*127-05 Firing Rate (USGPH) 0.55 0.65 0.75 0.85 0.95 1.10 Input (BTU/h) 74,800 88,400 102,000 115,600 129,200 149,600 Output (BTU/h) 62,000 74,000 85,000 98,200...
  • Page 22 PSC Motor Info Model HTL-065-03 HTL-076-03 HTL-087-03 HTL-100-05 HTL-110-05 HTL-127-05 Temperature Rise (°F) 45-75 45-75 50-80 45-75 45-75 45-75 Blower Speed (0.2" w.c.) Med-Low Med-Low Med-High Med-High Med-High Blower Speed (0.5" w.c.) High Med-High High High ECM Motor Info (0.2" w.c to 0.5" w.c.)

  • Page 23: Furnace Operation And Settings

    FURNACE OPERATION AND SETTINGS SHUTTING FURNACE DOWN POWER OFF Turn off main power breaker or disconnect. FUEL OFF Shut off manual fuel supply valve. Always keep manual fuel supply valve shut off if the burner is shut down for an extended period.
  • Page 24 MODELS WITH ELECTRONIC FAN TIMER CONTROL AND SNAP-DISC LIMIT CONTROL ELECTRONIC FAN TIMER INTEGRATES CONTROL OF BURNER AND CIRCULATOR FAN OPERATIONS. CONTROL IS CENTRAL WIRING POINT FOR MOST OF FURNACE ELECTRICAL COMPONENTS. • United Technologies 1158-120 has an adjustable fan on time set by selecting dipswitch combination displayed in below chart.

  • Page 25: 1158-120) Control Board Sequence

    CONTROL BOARD 1158-120 Electronic Fan Timer Board (EFT) Detailed Sequence Of Operati Mode Action System Response EFT closes the oil primary control T - T connections. Ignition system and the oil primary control start the furnace. Oil flows as long as the Thermostat calls for heat.
  • Page 26 Location of the 1158-120 Electronic Board HTL-100 and 200...

  • Page 27: Servicing - Fan Timer (1158-120)

    SERVICING - FAN TIMER System and General Troubleshooting Problem Possible Cause Remedy Check thermostat and adjust. Thermostat not calling for Check thermostat for accuracy; if mercury switch type, it might be heat off level. Check furnace switch, main electrical panel furnace fuse or circuit breaker.
  • Page 28 System and General Troubleshooting continued Problem Possible Cause Remedy If cad cell is dirty, clean it. Determine why cad cell is getting dirty. If Furnace starts, but cuts cad cell is poorly aimed, realign it. out requiring manually Photo Cell (Cad Cell) NOTE: Photocell should have resistance of 100 KΩ...
  • Page 29 System and General Troubleshooting continued Problem Possible Cause Remedy Insufficient combustion air Adjust oil burner combustion air band and draft regulator to gain adjustment at oil burner, or highest practical CO2 or lowest practical O2 content in flue gases. improper draft pressure. See Burner Set Up.

  • Page 30: Service

    SERVICE / MAINTENANCE REGULAR MAINTENANCE Contact an authorized service representative to check complete operation at least once a year. In Canada see CAN/B139, (Maintenance), in United States refer to NFPA 31, for recommended servicing procedure. Clean flue pipeson a regular basis. Replace flue pipes if there is any sign of corrosion or other problems.
  • Page 31 CHANGING NOZZLE It is recommended that the nozzle be replaced at least once annually. If a new nozzle of a different size is installed, change the blower speed according to section BURNER INSTALLATION AND SPECIFICATIONS or operating decal as required. Verify smoke trace and CO2 reading every time the nozzle is replaced.
  • Page 32 BLOWER REMOVAL This furnace has a blower sealing system, which is designed to be tight and rattle free. Refer to the instructions and pictures below. 1) Shut off oil and power to furnace. 2) Remove the two (2) screws securing the blower door (Figure 1).

  • Page 33: Electrical Wiring Diagrams

    ELECTRICAL WIRING DIAGRAMS HEATING & COOLING RIELLO WIRING DIAGRAM INDOOR BLOWER ventilateur principale MOTOR moteur 120V TRANSFORMER/ transformateur TO TW TO TR TW (T) TR (T) 1158-1/1168-1 CONTROL RIELLO MOTOR 530SEC/24V moteur PRIMARY CONTROL RIELLO 40F BURNER/brûleur (IF AVAILABLE)/(si disponible)
  • Page 34 HEATING & COOLING BECKETT WIRING DIAGRAM INDOOR BLOWER ventilateur principale MOTOR moteur 120V TRANSFORMER/ transformateur TW (T) TR (T) 1158-1/1168-1 CONTROL BECKETT OIL GR BK PRIMARY CONTROL IGNITER (BLUE/WHITE) L2 (WHITE) MOTOR (ORANGE) L2 (WHITE) MOTOR moteur L1 (BLACK) LIMIT (RED) L2 (WHITE) VALVE (VIOLET) L2 (WHITE)
  • Page 35 HEATING & COOLING CARLIN WIRING DIAGRAM INDOOR BLOWER ventilateur principale MOTOR moteur 120V TRANSFORMER/ transformateur TW (T) TR (T) 1158-1/1168-1 CONTROL CARLIN BURNER/brûleur...

  • Page 36: Exploded Parts View

    EXPLODED PARTS VIEW HTL-100 - EXPLODED PARTS VIEW View Detail B View Detail C Detail B Detail C FAN-A0-0002-00 FAN-A0-0002-01 PSC Motor ECM Motor...

  • Page 37: Htl-100

    Electrical Box Assembly 4TF-00-40VA-00 Transformer HTC-01A0BB01 40va 4CB-00-FAN0-01 1158-120 UTEC Electrical Board FAN-A0-0002-00 Fan motor assembly HTL-100 psc motor FAN-A0-0002-01 Fan motor assembly HTL-100 ecm motor 3BU-10-08DD-00 Blower 10" x 8" direct drive (g10-8dd) 3BM-50-4SDD-01 Motor Blower 1/2 Hp Direct Drive 4sp Emerson 4CA-00-705M-00 Capacitor 7.5 Uf 370vac 70c 60 Hz...
  • Page 38 HTL-200 - EXPLODED PARTS VIEW View Detail B View Detail C Detail B Detail C FAN-A0-0004-00 FAN-A0-0004-01 PSC Motor ECM Motor...

  • Page 39: Htl-200

    HTL-200 - PARTS LIST ITEM PART NUMBER DESCRIPTION CAB-A1-9034-00 Lower Front Panel Assembly CAB-A1-9030-00 Top Front Panel Assembly CAB-A1-9028-00 Left Panel Assembly CAB-A1-9027-00 Right Panel Assembly CAB-P1-9037-00 Base Panel CAB-A1-9026-00 Rear Panel HEX-A1-9003-00 Heat Exchanger Assembly HEX-P1-9013-00 Pipe Baffle CAB-P1-9044-00 Front Door Panel CAB-P0-0303-00 Front Flue Collar...

  • Page 40: Start-Up Test Results

    10.0 START-UP TEST RESULTS Model: Serial Number: Hiboy HTL Date of installation: Installer (name & address): START-UP TEST RESULTS Size of unit (Btu/h): Nozzle: Oil Pressure (psi): Chimney Burner adjustments: RIELLO F3 RIELLO F5 Beckett AFG CARLIN EZ-1S Turbulator: Air Gate: *Head Setting: Air band: Air shutter:...
  • Page 41 TEST PROCEDURES External Total Static Pressure Reading A/C Coil Total Resistance Reading Supply Pressure (Ps) + Return Pressure (Pr) Coil Pressure (Pc) - Supply Pressure (Ps) Temperature Rise Reading *** Supply Temp. (Ts) - Return Temp. (Tr) *** Probe must not be in direct sight of heat exchanger.
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  • Page 44 USA Contact Canada Contact Granby Industries L.P. Industries Granby S.E.C. 98 des Industries, 2201 Dwyer Avenue, Utica, NY 13501 Cowansville, Qc. Tel. 800 325 5479 J2K 0A1. Canada. www.ecrinternational.com 450-378-2334 www.granbyindustries.com supporttechnique@granbyindustries.com...

This manual is also suitable for:

Htl-200

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