INOV8 F240 Manuel utilisateur

INOV8 Model F240 – Edited September 2008

INTERNATIONAL INCORPORATED

ASSEMBLY, INSTALLATION, MAINTENANCE

AND OPERATING INSTRUCTIONS

INOV8 F240 Multi-fueled Unit Heater & Furnace

Save These Instructions! This manual must be kept near the furnace!

Control No. 3120734

INOV8 Model F240 – Edited September 2008

SECTION 1 – GENERAL GUIDELINES...........................................................................................0

Codes & Regulations........................................................................................................................................................ 0

U.S. EPA Regulations & Used oil Burning........................................................................................................................ 0

Listing Agencies ............................................................................................................................................................... 1

Fuels- general information................................................................................................................................................ 1

Special Precautions!......................................................................................................................................................... 1

Warranty is void if … ........................................................................................................................................................ 2

Disposal............................................................................................................................................................................ 2

Unpacking & Inspecting.................................................................................................................................................... 2

Minimum Clearances........................................................................................................................................................ 2

Shipping & parts information ............................................................................................................................................ 3

Figure 1 - Model F240 Dimensions .......................................................................................................................... 4

SECTION 2 – FURNACE INSTALLATION ......................................................................................5

FURNACE LOCATION ................................................................................................................................................ 5

ATTACHING THE BURNER TO THE FURNACE............................................................................................................... 5

Installing the Burner:......................................................................................................................................................... 5

Installing the Electrical Plug.............................................................................................................................................. 6

Electrical Hookup of the Furnace...................................................................................................................................... 6

Attaching the Air Connection ............................................................................................................................................ 7

Attaching the Oil Delivery Line (‘A’ in photo)..................................................................................................................... 6

Attaching the Return Line (‘B’ in photo) ............................................................................................................................ 6

Blocked Vent Switch –supplied with Canadian Furnaces (or optional) ............................................................................. 7

INSTALLATION DETAILS............................................................................................................................................. 7

Air Supply Installation ....................................................................................................................................................... 7

Chimney Installation ......................................................................................................................................................... 8

Installing the Barometric Draft Control.............................................................................................................................. 9

Draft Measurements & Adjustments............................................................................................................................... 10

Installing an Optional Draft Inducer ................................................................................................................................ 10

Installing an Optional Sealed Combustion System ......................................................................................................... 10

Figure 2 - Typical Installation Diagram (without bench tank).................................................................................. 12

Ceiling Mount Installation Considerations....................................................................................................................... 12

Electrical Supply Installation........................................................................................................................................... 12

Fan/Limit control............................................................................................................................................................. 13

TANK &PIPING CONSIDERATIONS........................................................................................................................... 13

Oil Storage Considerations............................................................................................................................................. 13

Additional Oil Storage Consideration.............................................................................................................................. 13

Piping & Fitting Recommendations................................................................................................................................. 13

Tank Filter ...................................................................................................................................................................... 14

Vapor Eliminator Filter / Pressure Relief Assembly ........................................................................................................ 14

Installation of Vent Line from Vapor Eliminator back to the Tank ................................................................................... 14

Vapor Eliminator Filter .................................................................................................................................................... 14

Bench Tank Installation .................................................................................................................................................. 16

Figure 3 - Bench Tank Setup ................................................................................................................................. 16

Boost Pump (optional) .................................................................................................................................................... 18

Figure 4 - Diagram Showing Installation of Suntec Boost Pump, Filter, Check valve, Regulator & Gauges .......... 19

Figure 5 – Burner Diagram .................................................................................................................................... 20

Final Installation Checklist .............................................................................................................................................. 21

SECTION 3 – OPERATING THE FURNACE .................................................................................22

FIRST START-UP OF FURNACE................................................................................................................................22

Priming the Oil System ................................................................................................................................................... 22

Firing up the Furnace the First Time .............................................................................................................................. 22

Ducted Furnace Installation Check (Model F240 SC)..................................................................................................... 23

NORMAL OPERATION OF FURNACE .........................................................................................................................24

FACTORY SETTINGS...............................................................................................................................................25

Figure 6 - Electrode Adjustment Diagram .............................................................................................................. 25

FLAME ADJUSTMENTS ............................................................................................................................................26

Figure 7 – Proper & Improper Flame appearances............................................................................................... 26

MAINTENANCE .......................................................................................................................................................27

INOV8 Model F240 – Edited September 2008 iii

General Information ........................................................................................................................................................ 27

Changing Filters.............................................................................................................................................................. 27

Vacuuming the Combustion Chamber & Heat Exchanger Tubes ................................................................................... 27

Annual Maintenance ....................................................................................................................................................... 28

Chimney Inspection ........................................................................................................................................................ 29

Summer Burner Refurbishing Program........................................................................................................................... 29

SECTION 4 - TROUBLESHOOTING ............................................................................................. 30

General Failure Categories & Potential Causes ............................................................................................................. 30

Using Lights on the Controller to Diagnose Symptoms................................................................................................... 31

SECTION 5 –DETAILED SERVICING PROCEDURES ................................................................. 33

Removing the Module from the Burner ........................................................................................................................... 33

Replacing the Module into the Burner............................................................................................................................. 33

Flushing the Final Delivery.............................................................................................................................................. 33

Checking the Oil Spray ................................................................................................................................................... 34

Checking the Oil System................................................................................................................................................. 34

Checking the Ignition Arc................................................................................................................................................ 35

Checking the Atomizing Air System................................................................................................................................ 35

Checking the Draft & things that can cause it to be wrong.............................................................................................. 36

By-passing the Bimba Cylinder....................................................................................................................................... 36

Replacing the Vapor Eliminator Filter ............................................................................................................................. 37

Cleaning the Nozzle........................................................................................................................................................ 37

Rebuilding the Pump ...................................................................................................................................................... 38

Cleaning the Pump Internal Pressure Regulator............................................................................................................. 39

Oil Temperature Controller: Operation & Settings .......................................................................................................... 39

Oil Temperature & Pressure Settings..................................................................................................................... 40

Adjusting the Temperature Controller..................................................................................................................... 40

Removing Excess Oil from Combustion Chamber.......................................................................................................... 41

PROCEDURE FOR PARTS REPLACEMENT................................................................................................................. 41

ADDENDUM................................................................................................................................... 42

THEORY OF OPERATION......................................................................................................................................... 42

MAIN COMPONENTS &THEIR FUNCTIONS ............................................................................................................... 43

The Fireye Controller ...................................................................................................................................................... 43

The Oil System ............................................................................................................................................................... 44

The Primary (atomizing) Air System ............................................................................................................................... 45

ELECTRICAL DIAGRAMS ......................................................................................................................................... 46

Figure 8 – Basic Wiring Diagram for Furnace with Prop Fan ................................................................................. 46

Figure 9 – Basic Wiring Diagram – for 240v Squirrel Cage Blower ........................................................................ 47

Figure 10 – Burner Electrical Diagram for Prop Fan............................................................................................... 48

Figure 11 – Burner Electrical Diagram for 240v Squirrel Cage Blower................................................................... 49

PARTS LIST &TOOLS............................................................................................................................................. 50

SECTION 6 - GLOSSARY ............................................................................................................. 51

Notations Used in this Manual

RISK OF INJURY OR SYSTEM DAMAGE – Identifies a possible dangerous

situation that can lead to personal injury or physical damage.

NOTICE – This is a tip or notice for optimum use of equipment and

adjustment as well as useful information.

INOV8 Model F240 – Edited September 2008

SECTION 1–GENERAL GUIDELINES

Congratulations on your purchase of this INOV8 Multi-fueled Furnace. You have

selected the highest quality, precision-engineered piece of equipment available,

designed specifically to allow you to fully benefit from the used oils generated in your

business. INOV8 has not compromised in engineering this product for high efficiency,

safety, longevity, operating economy, and to allow you a maximum of fuel choices; all

while providing the highest standards of environmental considerations. This manual was

written for the novice technician with detailed instructions for the installation, start-up,

routine operation and maintenance of this furnace. If these instructions and pertinent

local regulations are followed closely you will be assured full satisfaction.

CODES &REGULATIONS

This manual covers installation, maintenance and service of the INOV8 model F240 unit

heater or F240 SC furnace. Both are referred to using the term “furnace” throughout this

manual that covers the installation of the chimney system, fuel storage and piping

connections and electrical work. All work shall be performed by a qualified contractor in

strict accordance with the requirements of state, provincial and local regulating agencies

and codes pertaining to oil-burning equipment installations. After start-up the owner or its

representative should be instructed about the furnace operation and be given this

manual. This equipment must be installed according to these national standards.

For furnace equipment: ANSI/NFPA # 31 – Standard for the Installation of Oil-

Burning Equipment – 2006 Edition, and in Canada to CSA

Standard B139.

For chimney installation: ANSI/NFPA # 211 – Standard for Chimneys, Fireplaces,

Vents, and Solid Fuel Burning Appliance, 2006 Edition

For oil storage installation: NFPA # 31 – Standard for the Installation of Oil-Burning

Equipment – 2006 Edition

For electrical installation: NFPA # 70 – National Electrical Code – 2005

Cleaning and routine maintenance must be carried out at least quarterly during

operation. This shall include an overall check of the heating system. There should be

periodic inspection of the combustion chamber for possible deterioration. Any

discrepancies must be corrected immediately.

NOTE: This manual is for reference only. The manual does NOT purport to address all

design, installation and safety considerations. It is the responsibility of the user of this

manual to determine the applicability and safety of each individual application and ensure

its compliance with local building codes.

U.S. EPA REGULATIONS &USED OIL BURNING

On August 12, 1992 the U.S. Environmental Protection Agency (EPA) announced that it

would not list nor classify as hazardous waste, used oil destined for recycling. They also

affirmed the long-standing regulatory exemption, which allows the operation of used oil-

fired furnaces. Under this exemption, used oil-fired furnaces may operate without a

regulation so long as the owner burns "on-specification used oil". Used oil exceeding

EPA designated levels of contaminants is classified as "off-specification used oil"

which means the owner must comply with three requirements: the heater does not

exceed 500,000 BTU per hour, it is vented to the outside, and burns oil generated on-site

or collected from do-it-yourself oil changers. After years of careful study the EPA

concluded that used oils that are recycled in this manner do not pose a substantial

present or potential hazard to human health or the environment so long as they are

managed properly. To this end, EPA's regulations are designed to provide safe and

environmentally sound used oil management practices.

INOV8 Model F240 – Edited September 2008 1

LISTING AGENCIES

This equipment is tested and listed by Intertek ETL Semko (ETL) - an internationally

recognized third party test agency to UL 296A - Standard for Safety for Waste Oil

Burning Air-Heating Appliances, Edition 2, Revision 2006/03/08 (the U.S. used oil

standard), and to CSA B140.0 General Requirements for Oil Burning Equipment General

Instruction No 2-4 (R1991) Rev: 1991/01/01and is listed with the European Economic

Community with a CE registration number 3884/97. The INOV8 tanks are also tested

and listed by ETL to UL 80 Standard for Steel Tanks for Oil-Burned Fuel.

FUELS-GENERAL INFORMATION

This product is approved to burn the following oils: crankcase oil, crankcase oil with up to

20% gasoline, fuel oils up to #6 heating oil, jet fuel, mineral spirits and transmission oil.

The following additional oils have been tested and passed combustion analysis

requirements but are not approved as fuels due to a lack of standards to define them:

used and crude vegetable oil, and biodiesel. DO NOT attempt to burn other liquids

without written authorization from INOV8 International, Inc. Only used oil generated on

the premises of the owner may be used in this equipment, unless written authorization is

obtained from the regulatory authority.

Caution – used oils may contain gasoline, heavy metallic compounds and foreign

materials. When burned, these compounds are emitted from or deposited within this

furnace and therefore care should be taken when storing these oils or when using,

cleaning and maintaining this equipment.

SPECIAL PRECAUTIONS!

1. This furnace is listed for commercial or industrial use only. It may not be used for

residential or any other unauthorized purpose.

2. All furnaces must be wired strictly in accordance with wiring diagram and

instructions in this manual.

3. Disconnect the power supply before making wiring connections to prevent

electrical shock and equipment damage.

4. Disconnect the power supply before cleaning the furnace.

5. Do not install furnace or chimney connector closer than 18 inches to combustible

materials in any direction, except the louver side of the furnace, which must be

unobstructed.

6. DO NOT add fluids with the classification of a hazardous waste, or fuels with

flash points below 100oF (such as gasoline) to your used oils. (Check your local

codes for restrictions.)

7. For your protection - DO NOT store or use gasoline or other flammable vapors

and liquids in the vicinity of this or any other appliance.

8. Canadian standards allow only used oil generated on the premises of the owner

to be used as fuel, unless permitted by the regulatory authority.

9. Venting - Failure to provide proper venting could result in death, serious injury,

and/or property damage. Units must be installed with a flue connection, draft

regulator and proper vent to the outside of the building. Safe operation of any

gravity vented heating equipment requires a properly operating vent system,

correct provision for combustion air, and regular maintenance and inspection.

10. Hazardous Atmosphere - The INOV8 products are not designed for use in

hazardous atmospheres containing flammable vapors or combustible dust, or

atmospheres containing chlorinated or halogenated hydrocarbons.

INOV8 Model F240 – Edited September 2008

WARRANTY IS VOID IF …

1. The heater is not installed in accordance with these instructions and applicable

codes and ordinances.

2. The wiring is not in accordance with drawings in this manual.

3. The Furnace or burner is not maintained in accordance with maintenance

requirements – particularly failure to clean the combustion chamber and heat

exchanger on a regular basis.

4. Other than specified fuel is burned.

5. Fuel input capacity is over the rated condition of maximum flow rate of 1.68 US

gallons or 7.63 liters per hour.

Note: Information on the Limited Warranty was sent along with the sales order.

DISPOSAL

Dispose of packaging in an environmentally responsible manner. Dispose of all heating

system components that have to be replaced at an authorized disposal site. Dispose of

ash in a responsible manner.

UNPACKING &INSPECTING

Immediately upon receipt, check the cabinet and burner for any damage that may have

occurred in shipment. If damage is found, INOV8 or the sales representative must be

notified within two days in order to process shipping damage claims. Prior to shipping, all

components were inspected and the burner test fired, so the burner will still have oil in it.

MINIMUM CLEARANCES

Furnaces must be installed so that the following clearances are provided for proper air

movement, service and distance from combustible materials. In addition to walls and

ceilings, combustibles include rags, paper, or any moveable combustibles like gasoline

or other flammable fluid.

Inches Millimeters Purpose

Cabinet Fan Motor: 6 152 air movement

Chimney connector (flue pipe): 18 457 combustible material

Above Furnace: 24 609 combustible material

Below Furnace: 4 101 combustible material

Burner side: 48 1,219 service access

Outlet Louver: Unobstructed air movement

INOV8 Model F240 – Edited September 2008 3

SHIPPING &PARTS INFORMATION

The INOV8 Waste Oil Furnace is shipped on a pallet with strapping and plastic wrap.

This includes the heat exchanger, fan, and fan motor (mounted and wired). The burner is

packed in a separate box that also contains other parts, based on the following list and

what was purchased. Immediately upon receipt of INOV8 products inspect all parts for

possible shipping damage or missing parts and report any problems within 48 hours.

Check for the items shown in the photos, that they are received:

1. Oil Pickup Assembly, includes these parts from the top down:

a. One ¾” check valve

b. 3/4 “ x 2” black nipple

c. One 90ostreet elbow

d. Filter mount

e. One 90ostreet elbow

f. One ¾” x 12” pipe nipple

g. Double tap bushing, 2” with ¾” x ½”

reducing bushing

h. One primary filter, model Gar-Ber

Spin-on Filter #11V-R2000K with Filter

Restriction Indicator

2. Barometric draft control – 8”

(see photo at right)

The following items are shown in the lower photo:

3. Wall Thermostat - 120 volt (line voltage).

4. Other items include:

a. Instruction Manual

b. Spare vapor eliminator filter

c. Spare 10 amp (brown) & 4 amp

(orange) fuses

d. Burner gasket

5. Air regulator Assembly, includes:

a. Air regulator

b. Air gauge, 0 – 160 psig

c. Plastic nut

d. Bracket and screws

e. ¼” air tube

The following items are not shown in the photos:

6. Squirrel-Cage Blower (optional), mounted

7. Bench Tank - (optional), which includes:

a. 300 gallon bench-type tank

b. Optional stands

c. Tank gauge, oil supply and lines with fittings

INOV8 Model F240 – Edited September 2008

Figure 1 - Model F240 Dimensions

INOV8 Model F240 – Edited September 2008 5

SECTION 2–FURNACE INSTALLATION

FURNACE LOCATION

Furnace location and other installation requirements were covered in the “Pre-installation

Considerations” document that was sent along with the confirmation of order. It is

absolutely essential that you have read that document before proceeding with the

installation. If you don’t have it, contact INOV8 and it will be faxed or e-mailed.

The furnace location is important to the efficient operation of the system. These

abbreviated guidelines will insure the most beneficial location. Further details are found

on subsequent pages.

1. The location of the chimney must be considered before other aspects of the

installation. See the section entitled, “Chimney Installation” for further details

2. Select a location as close as possible to the oil storage tank. The burner pump can

suck laterally easier than it can vertically but there are limits. If the distance from the

tank exceeds 30 feet or when the height exceeds 8 feet, a boost pump may be

necessary.

3. Furnaces hung higher than the standard 8 feet are not recommended. The location

should provide easy access to the furnace for routine servicing and

maintenance and for proper heat distribution.

4. DO NOT attach ducting to furnace (unless the furnace was ordered with the ducting

option that includes the squirrel-cage blower).

5. To prevent premature heat exchanger failure, DO NOT locate in areas where

chlorinated, halogenated or acid vapors or other corrosive contaminants may exist.

6. DO NOT install the furnace outdoors or in excessively wet conditions.

7. DO NOT attach air filters to the furnace.

8. In multiple furnace installations, arrange furnaces so that each supports the air

stream of the next furnace, thus creating circulatory air movement in the area. A

large portion of the heated air should be directed toward the side of the building

exposed to prevailing winds. The INOV8 dealer can provide recommendations for

the most efficient installation of multiple furnaces. These installations will vary

depending upon the unique layout of the facilities.

9. Adequate combustion air is required to maintain combustion. The INOV8 furnace will

not operate in a negative building pressure (see section on sealed combustion if this

exists).

10. Minimum clearances from combustible surfaces must be adhered to. See the

section “Minimum Clearances” for more information.

ATTACHING THE BURNER TO THE FURNACE

Carefully remove the burner and components from the shipping box. Be careful when

handling the burner, as the electrodes and the flame retention head are factory set and if

either are bumped or moved, the operation of the burner could be affected. If the

electrodes get out of adjustment, refer to page 25 for a diagram of the proper electrode

settings. The burner has been pre-fired in the factory prior to shipping and will have oil in

it. A plug has been installed in the pump for shipping and should be removed carefully to

avoid spilling oil.

INSTALLING THE BURNER:

1. Place the burner gasket onto the air tube.

2. Remove the three 3/8”-16 nuts from the burner mounting plate studs.

3. Place burner on mounting plate studs.

4. Now tighten the 3/8” nuts that hold the burner to the mounting plate.

INOV8 Model F240 – Edited September 2008

INSTALLING THE ELECTRICAL PLUG

Insert the round burner power plug into the socket provided on the bottom of the

electrical junction box that houses the GFCI outlet.

ELECTRICAL HOOKUP OF THE FURNACE

1. Remove a convenient knock-out from the electrical junction box to allow

connection of your electrical supply conduit.

2. Attach the hot wire (typically black) to the 6” black pigtail that comes off the GFCI

“Line Hot” terminal.

3. Attach the Neutral wire (typically white) to the 6” white pigtail that comes off the

GFCI “Line Neutral” terminal.

4. Attach the earth ground wire to the 6” green pigtail that comes off of the junction

box.

5. If the furnace has a blower fan (like a squirrel cage) hook the other hot wire

(typically red) to the red pigtail that comes off the fan contactor.

ATTACHING THE OIL DELIVERY LINE (‘A’ IN PHOTO)

Specifics on the oil storage and plumbing are covered in the section titled “Tank

& Piping Considerations” starting on page 13. The items in that section must

have been completed in order to have an oil supply line run to the burner at this

time. Assuming the line is in place: the oil supply line will connect to the inlet

port of the pump on the burner. There are two inlet ports: one on the bottom of

the pump and one on the side. Connect to the one on the side. Attach the line

to the pump via a ½” x ¼” NPT flare fitting and use the corresponding female

portion with a barb fitting to attach to a flexible oil line. DO NOT do the

following:

•plumb the line directly into the pump,

•use any compression fittings,

•use rigid line that will be difficult to remove for servicing the burner.

Be sure to seal the ¼” NPT threads of the flare fitting at the pump inlet. ONLY

Use pipe sealant suitable for waste oil, such as Loctite #565.

ATTACHING THE RETURN LINE (‘B’ IN PHOTO)

As noted in the section “Installation of Vent Line from Vapor Eliminator Back to the Tank”

on page 14, a ¼” O.D. (minimum) copper or plastic line must be installed from the burner

back to the tank. This line will connect to the brass elbow on top of the oil pressure

release mechanism via the compression nut and ferrule supplied on that elbow. There

will be no pressure in this line as long as the line is open all the way back to the tank. It

is ABSOLUTELY IMPERATIVE that no valves or other constrictions be placed or allowed

to exist (like crimps) in this line.

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