Boyertown Furnace RSM 500 Installation, Operation And Maintenance Manual Download Page 1

Page: 1 / 36

Regal Star Series

RSM 500/600/750

Installation, Operation and Maintenance Manual

Keep these instructions with the furnace at all times

for future reference

Boyertown Furnace Co.

PO Box 100

Boyertown, PA 19512

610-369-1450

www.boyertownfurnace.com

9-1-15

Summary of Contents for RSM 500

Page 1: ...0 600 750 Installation Operation and Maintenance Manual Keep these instructions with the furnace at all times for future reference Boyertown Furnace Co PO Box 100 Boyertown PA 19512 610 369 1450 www boyertownfurnace com 9 1 15 ...

Page 2: ...oil fired furnace is designed to burn No 1 and No 2 heating oil only DO NOT START THE BURNER UNLESS THE BLOWER ACCESS DOOR IS SECURED IN PLACE Do not store gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance The area around the furnace should be kept free and clear of combustible materials NEVER BURN GARBAGE OR REFUSE IN THE HEATING SYSTEM AND NEVER LEAVE ...

Page 3: ...ining Chimney Connector Power Venting Vent Dampers 11 VENTILATION AND COMBUSTION AIR 14 BURNER INSTALLATION 15 WIRING Power Thermostat 15 OIL TANK AND PIPING 22 START UP Start Up Equipment Burner Adjustments 24 OPERATING AND MAINTENANCE Cleaning the Furnace Oil Burner Blowers Direct Drive Vent System Fuel Oil System Filters 26 PARTS BREAKDOWN LISTS 28 TROUBLE SHOOTING GUIDE 29 WARRANTY 34 INSTALLA...

Page 4: ... Rise 60 F 60 F 60 F Flue Size 5 Frt Rear 5 Frt Rear 5 Frt Rear Filter Size 16 x 20 16 x 20 16 x 20 Motor PSC 3 4HP 3 Spd 10 0 FLA 3 4HP 3 Spd 10 0 FLA 3 4HP 3 Spd 10 0 FLA Motor ECM 3 4Hp Var 8 5 Amp 3 4Hp Var 8 5 Amp 3 4Hp Var 8 5 Amp RSM 600 Highboy Configuration RSM 600 Horizontal Configuration Left or Right Hand Discharge Permitted Rotate Burner Accordingly ...

Page 5: ...M 600 2 2 Closet 18 6 Combustible 6 2 RSM 750 2 2 Closet 18 6 Combustible 6 2 Table 1 Standard Installation Clearances Horizontal Configuration MODEL Sides A Top B Front C Rear D Flooring Chimney Connector E Plenum Top Sides RSM 500 2 2 Closet 18 6 Combustible 6 2 RSM 600 2 2 Closet 18 6 Combustible 6 2 RSM 750 2 2 Closet 18 6 Combustible 6 2 Furnaces are permitted to be installed in rooms with le...

Page 6: ...ure does not exceed 0 5 WC If the cooling unit is installed with a parallel flow arrangement dampers or other means used to control flow of air should be provided to prevent chilled air from entering the furnace If such a damper is manually operated it must be equipped with a means to prevent operation of either unit unless the damper is in the full heat or cool position NOTE When a return registe...

Page 7: ...2 54 43 36 27 22 400 96 72 58 48 36 29 500 120 90 72 60 45 36 750 180 135 108 90 68 54 1000 240 180 144 120 90 72 1250 300 225 180 150 113 90 1500 360 270 216 180 135 108 1750 420 315 252 210 158 126 2000 480 360 288 240 180 144 Note For Systems not over 100 feet equivalent length Do not apply this table to duct systems which exceed 100 equivalent feet in length For longer systems refer to ACCA Ma...

Page 8: ...ting of the DIP switches in the nrgMax 9103i Standby Mode The thermostat inputs are being continuously monitored by the Nidec 16 x 4 Wire Box The motor will respond to the 24 volt AC input signal from the thermostat Fan Mode When a call for fan operation is received from the thermostat G line is energized the blower will operate at a reduced speed as determined by the position of the cooling DIP s...

Page 9: ...n figure 2 When wiring your ECM the pin locations are crucial in assuring that no damage is done to the motor or the control Figure 1 Power Connector Cooling Speed Selection AC Tons Cool Switch 1 Position Cool Switch 2 Position Prog Air Flow CFM Y2 Air Flow CFM Y1 Air Flow CFM G 4 Tons OFF OFF A 1600 1200 800 3 Tons ON OFF B 1200 900 600 2 5Tons OFF ON C 1000 750 500 2 Tons ON ON D 800 600 500 Hea...

Page 10: ...4 Y Y2 3 C2 7 ADJUST 11 HEAT 15 G 4 DELAY 8 OUT 12 R 16 OUT PSC Motor Air Flow Heating set the blower motor speed to give the specified air temperature rise Fan on time after the burner starts is fixed by the nrgMax control at 45 seconds Fan off time can be adjusted by using the delay DIP switches to regulate the outlet air temperature at the end of a heating cycle During a call for heat the elect...

Page 11: ...n ECM motor to PSC motor remove the ECM motor power cable 16 pin control cable and 4 pin control cable Attach the PSC motor speed leads to the proper output terminals for heating cooling and or continuous fan and any unused motor speed wires to the Unused terminals Attach the motor capcitor to the blower housing and connect the motor capacitor to the appropriate motor leads When changing from a PS...

Page 12: ...ler and determined to be in good condition All joints of the chimney must be tightly sealed The inside of the chimney should be free of all obstruction such as loose brick broken pieces of tile or corroded metal If chimney flues are divided or there are multiple flues within one chimney make sure there are no openings in the partition separating the divided or individual flues When a new appliance...

Page 13: ...ize flue pipe for your model furnace Any reduction in size required for the chimney must be made at the chimney connector The vent connector pipe must be made of corrosion resistant steel The vent connector pipe should be as short as possible and installed so that it has a continuous rise from the furnace to the chimney Long horizontal vent runs can result in the possibility of condensation in the...

Page 14: ...ce entering at the highest possible level consistent with clearances to combustible materials Two or more connectors shall not be joined together unless the common connector manifold and chimney are properly sized Adequate draft must be available to safely remove all products of combustion simultaneously without leakage or back flow Power Venting The furnace may be power vented through a side wall...

Page 15: ...the confined space shall be fitted with two openings one 6 inches from the top of the enclosure and one 6 inches from the bottom of the enclosure Each opening shall have a free area of at least 1 square inch per 2000Btu Hr of the total input of the appliances in the enclosure In calculating free area consideration must be given to the blocking effect of louvers screens or grills protesting the ope...

Page 16: ...o the factory wired burner harness as shown in the electrical diagrams Provide electrical ground at the furnace as required by codes Emergency Power Switches Oil burner emergency switches are to be installed as required by code The homeowner should be made aware of the location and proper operation of all emergency shut off switches Thermostat and Wiring Connections Thermostats are to be non power...

Page 17: ... Conventional System 1 Stage Heat 1 Cool PSC Motor Conventional System 1 Stage Heat 1 Cool ECM Motor O Terminal to be energized for Cooling Only Humidistat breaks on high humidity Jumper R DH if not used ...

Page 18: ...onal System 1 Stage Heat 2 Cool ECM Motor O Terminal to be energized for Cooling Only Humidistat breaks on high humidity Jumper R DH if not used Heat Pump 1 Stage Heat 1 Stage Cool PSC Motor Furnace Auxiliary Heat ...

Page 19: ...eating do not connect to NRG Max O terminal Humidistat breaks on high humidity Jumper R DH if not used Heat Pump 2 Stage Heat 2 Stage Cool ECM Motor Furnace Auxiliary Heat O Terminal on NRG Max terminal is to be energized on cooling If thermostat O B terminal energizes for heating do not connect to NRG Max O terminal Humidistat breaks on high humidity Jumper R DH if not used ...

Page 20: ...20 Furnace Wiring PSC Motors ...

Page 21: ...21 Furnace Wiring Nidec ECM Motors ...

Page 22: ...across ceiling or floor joists Piping shall be supported and protected from physical damage and where necessary protected against corrosion as per code Piping systems shall be maintained liquid tight A piping system that has leaks constitutes a hazard which must be repaired in an approved manner All oil feed lines to burners must be air tight The slightest air leak caused by loose fittings bad gas...

Page 23: ...um must not exceed 10 inches of mercury for single stage pumps and 15 inches for two stage pumps It is preferable to stay below these limitations When the suction line is tight and properly installed the pump will hold its vacuum for a minimum of 60 minutes after shutdown Outside Buried Tank Lift System Inside Tank Gravity Feed System ...

Page 24: ...l oil lines valves 10 Set room thermostat to call for heat 11 Turn service switch on Burner should start On one pipe fuel system only you may have to bleed the oil system To bleed attach a clear plastic tube to the oil pump bleed port and allow oil to run until all the air is out of the oil suction line feeding the oil burner If air is still evident in the bleed line you must check the oil lines a...

Page 25: ...y be altered to obtain the above results Lock the air band and head setting screws in place The above procedure will give a built in margin to ensure clean operation throughout the heating season Should draft conditions vary lint accumulate in the fan heavier oil delivered or other adverse conditions be encountered you will have a reasonable margin of built in protection before smoke generation be...

Page 26: ...of the heat exchanger must be done yearly by a qualified service technician It is important to inspect and clean the heat exchanger once annually or as necessary to remove any build up of soot A layer of soot on the inside surface of the heat exchanger will result in reduced efficiency 1 Turn off all power to the furnace 2 Remove clean out covers and the flue pipe 3 Remove the burner 4 With access...

Page 27: ...ou to remove Clean inspect blower wheel annually Lubricate blower motor as per the motor manufacturer s recommendations Vent System Clean and inspect the flue pipe draft regulator and chimney annually as outlined in this manual Fuel Oil System Check oil tank and piping for leaks annually replacing the oil filter to avoid contamination of the fuel unit and nozzle Filters Air filters should be inspe...

Page 28: ... 2 SIDE AIR BAFFLE 17185 12 1 JACKET REAR PANEL 17015 13 1 HEAT EXCHANGER 17255 14 1 HIGH LIMIT 552315 15 1 BLOWER PARTITION 17040 16 1 MOTOR PSC 712490 16 1 1 1 1 1 MOTOR ECM NIDEC ECM POWER CABLE 31 ECM 16 X 4 WIRE BOX ECM 16 PIN CONTROL CABLE 27 ECM 4 PIN CONTROL CABLE 36 712497 15050 712498 15052 15040 17 1 CONTROL MOUNTING BRACKET 17246 18 1 BLOWER 100 10T 710401 19 1 TRANSFORMER 40VA 552200 ...

Page 29: ... Burner Manual Replace Nozzle Nozzle Clean and Matches Preliminary Settings Air Settings Match Preliminary Settings Adjust Air Settings Refer to Burner Manual for Control Trouble Shooting Check All Fitting Connections No No No No No No No No Yes Yes Yes Yes Yes No Yes No No Yes Yes Yes Yes No Troubleshooting Guide This equipment must be serviced adjusted and started only by a qualified service age...

Page 30: ... Volts at Burner Control Adjust Thermostat Check Supply Fuses and Disconnects Fan and Limit Operational Refer to Burner Manual Burner Off on Safety Refer to Burner Manual No No No No Yes Yes Yes Yes Check all Wiring Replace Fan and Limit No Yes Burner Will Not Start ...

Page 31: ...er Verify a jumper wire is installed between positions 1 and 2 of the power cord connector 3 Disconnect power cord from connector on the control unit Inspect power cord for bent damaged or recessed wires and terminals 4 Restore or turn on power to the furnace Electrical Checkout 16 x 4 Wire Box 1 With power applied to the furnace both the RX and TX lights should be flashing during normal operation...

Page 32: ...it Inspect for bent damaged or recessed wires and terminals inside of connector Replace control unit if the three pin connector contains bent damaged or recessed terminals 4 Inspect the NTC thermistor inside of control unit for any cracks or breakage Replace control unit if NTC thermistor is cracked or broken 5 Inspect capacitors inside of control unit for bulging or swelling Replace control unit ...

Page 33: ... steps 2 and 3 3 Inspect connector on back side of motor for bent damaged or recessed wires Replace motor if connector contains bent damaged or recessed wires or terminals 4 Check phase to phase resistance between each of the three phase terminals in the motor connector Resistance levels between any two contacts should be equal If resistance is equal motor is functioning properly Replace motor if ...

Page 34: ...Proof of purchase will be required of the original purchaser when the claim is made The purchaser must pay all other costs of warranty services including labor costs involved in diagnostic calls or in removing servicing or replacing warranty parts and or freight charges Any Implied warranty relating to the heat exchanger covered by this warranty including that of merchantability and fitness for a ...

Page 35: ... furnace air flow and ACCA Manual D All ducts sealed and insulated as required Burner Operation Burner Model __________________ Nozzle _______GPH _______Deg _______Type_______ Burner Pump Pressure ______________ Fuel filter and fuel lines installed and inspected as per burner manual Air bled from oil piping Piping checked for leaks Burner started adjusted and tested per burner manual Furnace Opera...

Page 36: ..._______________________ Cut and Return This Form or Register Online at www boyertownfurnace com Boyertown Furnace Co P O Box 100 Boyertown PA 19512 Date Installed ___________________________ Furnace Model __________________________ Serial Number ________________________ Name of Purchaser _________________________________________________________________________ Purchaser s Address _________________...

Search results

Summary of Contents for RSM 500

Reviews:

Related manuals for RSM 500

Brands by name

Popular brands

Boyertown Furnace RSM 500, Installation, Operation And Maintenance Manual

Search results

Summary of Contents for RSM 500

Reviews:

Related manuals for RSM 500

Brands by name

Popular brands