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ECR International WML-C Operation And Maintenance Manual

Oil fired warm air furnaces
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Installation, Operation and
Maintenance Manual
Oil Fired Warm Air Furnaces
(Down-Flow or Horizontal Model)
Read this complete manual before
beginning installation. These
instructions must be kept with the
furnace for future reference.
WML-C AND MPL-B
ALL INSTALLATIONS MUST MEET ALL
LOCAL, PROVINCIAL/STATE, AND
FEDERAL CODES WHICH MAY
DIFFER FROM THIS MANUAL
ECR International Limited
OLSEN Division

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Summary of Contents for ECR International WML-C

  • Page 1 ALL INSTALLATIONS MUST MEET ALL Read this complete manual before beginning installation. These instructions must be kept with the furnace for future reference. WML-C AND MPL-B LOCAL, PROVINCIAL/STATE, AND FEDERAL CODES WHICH MAY DIFFER FROM THIS MANUAL ECR International Limited...

  • Page 2: Table Of Contents

    OIL BURNER...9 FURNACE INSTALLATION SET-UP ...10 MAINTENANCE AND SERVICE ...11 OPERATING INSTRUCTIONS ...12 APPENDIX A- WML-C AND MPL-B BURNER SET UP...13 A.1 OIL BURNER AIR ADJUSTMENT...14 A.2 BURNER ELECTRODES...14 A.3 START UP...14 A.4 SPECIAL INSTRUCTIONS FOR UNITS EQUIPPED WITH RIELLO BURNERS...14 TABLE A-6 DIRECT DRIVE BLOWER SET-UP ...15...

  • Page 3: Introduction

    The furnace must be installed and set up by a qualified contractor. Model WML-C is an oil fired forced air multi-positional furnace, with an output capacity range of 58,000 BTU/Hr. to 85,600 BTU/Hr. The MPL-B is also an oil...

  • Page 4: Horizontal Installation

    HORIZONTAL INSTALLATION WML-C AND MPL-B furnaces models are assembled and shipped ready for installation in the down-flow position. The furnace may be installed in either of the horizontal positions; warm discharging left or warm air-discharging right by following these steps: Rotate the furnace 90°...

  • Page 5: Combustion Air

    This problem may be corrected by the use of an appropriately sized chimney liner. If the chimney serves the WML-C furnace only, the vent should be sized at 5-inch minimum. The MPL-B should be 6-inch minimum. The data provided in Table 3 is based on dedicated venting.
  • Page 6 Fig. 2: Common Chimney Problems Table 2: Common Chimney Problems Refer to Figure 2 Trouble Diagnostic Top of chimney lower than Observation surrounding objects Chimney Cap Observation or ventilator. Coping restricts Observation opening. Obstruction in chimney Joist protruding into chimney. Break in chimney lining.

  • Page 7: Optional Side Wall Venting

    OPTIONAL SIDE WALL VENTING Certain WML-C AND MPL-B furnace models are manufactured to be installed as sidewall vented units. Please refer to Direct Venting Instructions, P/N 28888 included with the Vent Kit for details. Sidewall Venting (Direct Venting) requires the use of specific oil burners;...

  • Page 8: Fan Timer Board And Limit Control

    90 seconds at highest input. Longer fan on delay times may result in nuisance limit trips. CIRCULATING AIR BLOWER All WML-C AND MPL-B furnace models are equipped with a direct drive blower system. Direct drive...

  • Page 9: Humidifier

    OIL BURNER NOZZLES WML-C MPL-B certified for multiple firing rates, ranging from approximately 58,000 to 85,600 BTU/hr. on the WML-C and 85,500 to 123,000 BTU/Hr. on the MPL-B By changing the oil burner nozzle within the specific model range, and temperature humidifier rise, the furnace may be fired at an ideal rate for a wide range of structures.

  • Page 10: Stack Temperature

    A) The oil burner must be set up following the procedures outlined above. B) The WML-C models should operate within a temperature rise of 45°F to 75°F. The MPL-B temperature rise range should be 50°F to 80°F. To determine...

  • Page 11: Maintenance And Service

    (lack of fuel, etc.). Be sure that the homeowner knows when to quit trying to start the furnace during these conditions and who to call for emergency service.

  • Page 12: Operating Instructions

    Set the manual switch (if installed) in the Electrical Power Supply Line to "OFF". NOTE: If the furnace is to be shut down for an extended period of time, close the oil supply valve to the oil burner. DO NOT ATTEMPT TO START THE...

  • Page 13: Appendix A- Wml-C And Mpl-B Burner Set Up

    WML-C AND MPL-B furnaces may be used with the following oil burners. Please note: The Beckett AF, and Riello 40F oil burners are for applications using indoor air for combustion only. For sidewall venting applications utilizing outdoor air for combustion, use the Beckett AFII or the Riello 40BF (Balanced Flue) oil burners only.

  • Page 14: Oil Burner Air Adjustment

    13/64 inch. Distance ahead of nozzle: 5/64 to 7/64 inch. A.3 START UP The furnace should be operated for a minimum of 15 minutes to reach steady state conditions before fine tuning combustion. The warm up time is ideal for testing the oil pump pressure.

  • Page 15: Table A-8 Direct Drive Blower Characteristics

    High MPL-130B GT12-10DD High Furnace Blower Motor HP Motor FLA Model WML-C GT10 ½ HP 60 - 90 MPL-B GT12-10DD ¾ HP 90-130 These Formulae will assist with the design of the ductwork and the determination of airflow delivery: Bonnet Output...

  • Page 16: Table A-9 General Dimensions (Inches)

    18 x 18 20-1/2 x 20- 18 x 18 Filter Flue Diameter Type Bottom 18 x 18 Permanent 18 x 18 Permanent WML-C & MPL-B Horizontal Shipping Weight Size 20 x 20 x 1 20 x 20 x 1 30318 R4 9/9/2005...

  • Page 17: Appendix B: Wiring Diagrams

    APPENDIX B: WIRING DIAGRAMS Beckett AF Burner Wiring Diagram 30318 R4 9/9/2005...
  • Page 18 Beckett AFII Burner Wiring Diagram 30318 R4 9/9/2005...
  • Page 19 Riello 40F3 and F5 Burner Wiring Diagram 30318 R4 9/9/2005...
  • Page 20 Riello 40BF3 Burner Wiring Diagram 30318 R4 9/9/2005...

  • Page 21: Operation Of Oil Burner

    Restore electrical power to the furnace. Start the furnace and bleed all air from the fuel oil lines. Close the purge valve and fire the unit. Allow the furnace to warm up to normal operating temperatures.

  • Page 22: Appendix C-R7184 Troubleshooting

    R7184 DETAILED SEQUENCE OF OPERATION (FIGURE 7) Power is applied to unit. The R7184 completes a self-diagnostic procedure. If no light or flame is present, and unit passes its self-diagnostic procedure, the control enters into the idle mode. Thermostat calls for heat: A) Safety check is made for flame (4 second delay).
  • Page 23 R7184 INTERRUPTED ELECTRONIC OIL PRIMARY CONTROL FIGURE 7 ELECTRONIC FAN TIMER BOARD ON CONTROL PANEL FIGURE 8 30318 R4 9/9/2005...
  • Page 24 IDLE STATE THERMOSTAT CALLS FOR HEAT SAFETY CHECK FOR FLAME (5 SEC.) NO FLAME BURNER MOTOR & IGNITOR START 10 SEC. SAFETY CHECK FOR FLAME (5 SEC.) NO FLAME SOLENOID VALVE OPENS TRIAL FOR IGNITION BURNER FLAME MONITORED FLAME CARRYOVER STATE •...

  • Page 25: Table C-1: Electronic Fan Timer Board (Eft) Detailed Sequence Of Operation

    Humidity control is connected. a. EFT closes oil primary control T - T connections). b. Ignition system and R7184 oil primary control start the furnace. Oil flows as long as the oil primary control senses flame. c. Burner motor is energized and heat "fan on" delay timing begins. When timing is complete, the circulator fan is energized at heat speed.

  • Page 26: R7184 Led Diagnostic Light

    R7184 LED DIAGNOSTIC LIGHT The LED diagnostic light has several functions. It indicates the state or mode in which the oil burner is operating. It will also indicate fault conditions, and help determine cad cell resistance while the burner is operating. NORMAL CONDITIONS: The LED diagnostic light will turn on when the burner enters the carryover...

  • Page 27: Table C-3: R7184 Troubleshooting

    Table C-3: R7184 TROUBLESHOOTING Condition: Burner motor does not start when there is a call for heat. Procedure Check that limit switches are closed and contacts are clean. Check for line voltage power at the oil primary control. Voltage should be 120 Vac between the black and white lead wires on the oil primary control.
  • Page 28 Condition: Burner starts then locks out on safety with indicator light flashing at 1/2 second on, 1/2 second off. Procedure Ignition is off Listen for spark after burner Ignition is on. turns on (after 2 second delay). Ignition is on but no oil is being sprayed into the combustion chamber.

  • Page 29: Table C4: System And General Troubleshooting

    Check thermostat and adjust. Also, check thermostat for accuracy; if it is a mercury switch type, it might be off level. Check furnace switch, main electrical panel furnace fuse or circuit breaker. Also look for any other hand operated switch, such as an old poorly located furnace switch, which was not removed during furnace replacement.
  • Page 30 Replace motor if necessary. motor stopping Check burner motor. Replace if necessary. This is not likely to be a furnace problem. Balance duct system. Remedy or lowest practical O content in the flue gases. 30318 R4 9/9/2005...

  • Page 31: Final Check Out

    Where the circuit breaker or fuse is located in the main electrical panel. Where the furnace switch is located, and the switch "on" and "off" positions if not obvious. Where the oil shut-off valve from the oil storage tank is located.

  • Page 32: Parts Listing: Counterflow Horizontal Model: Wml C

    PARTS LISTING: COUNTERFLOW HORIZONTAL MODEL: WML C Ref. No. Right and Left Side Panel Rear Panel Baffle Rear Panel Blower Division Panel Assembly Base Panel Assembly Front Panel Blower Access Door Door Handle – P2-41 Logo Bezel Logo Label End Panel Heat Exchanger Assembly Firepot Retainer Bracket Replacement Combustion Chamber...
  • Page 33 Limit Cover, Right PARTS LISTING: COUNTERFLOW HORIZONTAL DIRECT VENT MODEL: WML CB2U Ref. No. All parts are the same as listed on the previous pages for Model WML-C except where noted below. Oil Burner Mounting Plate Assembly Oil Burner Mounting Plate...
  • Page 34 30318 R4 9/9/2005...
  • Page 35 PARTS LISTING: COUNTERFLOW HORIZONTAL MODEL: MPL Ref. No. Right Side Panel Left Side Panel Side Panel Heat Exchanger Support (2 per unit) Rear Panel Blower Division Panel Assembly Base Heat Exchanger Support Front Panel Blower Access Door Door Handle – P2-41 Logo Bezel Logo Label End Panel...
  • Page 36 PARTS LISTING: COUNTERFLOW HORIZONTAL MODEL: MPL Ref. No Beckett oil Burner AF76XN Burner Motor 1/7 HP 3450 RPM PSC Beckett Clean-cut Oil Pump A2EA6520 Solid State Ignitor FRANCE 10SAY-04 Primary Combustion Control R7184A Air Tube Combination AF76XN Flame Retention Head (MPL 80, to 120) Flame Retention Head (MPL 130) Nozzle 1.00 / 60º...
  • Page 37 30318 R4 9/9/2005...

  • Page 38: Homeowner's Reference Table

    HOMEOWNER’S REFERENCE TABLE Model No. Serial No. Date Installed Contractor Contact Address Postal Code Telephone No. After Hours No. FUEL SUPPLIER Fuel Oil Supplier Contact Telephone No. After Hours No. IF DIFFERENT FROM INSTALLATION CONTRACTOR: Service Tech. Telephone No. After Hours No. 30318 R4 9/9/2005...

  • Page 39: Notes

    NOTES: 30318 R4 9/9/2005...
  • Page 40 6800 Base Line, Wallaceburg, Ontario, N8A 5E5, Can. Tel: (519) 627-0791 Fax: (519) 627-4719 2201 Dwyer Avenue, Utica, New York, 13504, USA. Tel: (315) 797-1310 Fax: (315) 724-9319 85 Middle Road, Dunkirk, New York, 14048, USA Tel: (716) 366-5500 Fax: (716) 366-1209 www.ecrinternational.com 30318 R4 9/9/2005...

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Mpl-b

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