ICP 445 02 4054 01, Installation Instructions And Use & Care Manual

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Do not tamper with the unit or controls. Call your service
technician.
Before calling for service, check the following.
a. Check oil tank gauge and check if the oil tank valve in oil is open.
b. Check fuse or circuit breaker.
c. Check if shut-off switch is “ON”.
d. Reset thermostat above room temperature.
e. If ignition does not occur turn off the disconnect switch and call
your qualified service technician.
When ordering replacement parts, specify the complete furnace
model number and serial number.
1.1) Heat exchanger cleaning:
Ordinarily, it is not necessary to clean the heat exchanger or flue pipe
every year, but it is advisable to have your oil burner serviceman
check the unit before each heating season to determine whether
cleaning or replacement of parts is necessary.
If cleaning is necessary, the following steps should be perfomed:
1. Turn “OFF” all utilities upstream of the furnace.
2. Disconnect the flue pipe.
3. Remove the flue collar panel located in the rear part of the warm
air furnace.
4. Remove the radiator baffle.
5. Disconnect the oil line and remove the oil burner from the
furnace.
6. Clean the secondary tubes, and the primary cylinder with stiff
brush and vacuum cleaner.
7. Before reassemble, the heat exchanger and combustion
chamber should be inspected to determine if replacement is
required.
8. After cleaning, replace the radiator baffle, flue collar plate and oil
burner.
9. Readjust burner for proper operation.
Soot will have collected in the first sections of the heat exchangers
only if the burner was started after the combustion chamber was
flooded with fuel oil, or if the burner has been operating in a severely
fouled condition.
1.2) Refractory fire pot:
Remove the burner and check the fire pot.
IMPORTANT
Use extreme care if cleaning of the pot is required. After
firing, the pot becomes very fragile. Do not use any
commercially available soot remover. This furnace has
a fiber type refractory combustion chamber. Normal
servicing of this unit does not require cleaning of the
combustion chamber.
IMPORTANT
Do not vacuum the ceramic chambers—they are easily
damaged.
If the pot is damaged, it must be replaced. A damaged pot could lead
to premature heat exchanger failure. Cracking of the fire pot is normal,
however, replace the pot if the cracks have propagated more than 2/3
the way through the wall thickness. The average wall thickness of the
firepot is 3/4”.
Flooding of the fire pot:
Flooding can occur when the oil primary control has been reset a
number of times in a no-heat situation. Each time oil is fired into the
pot and does not ignite, it is absorbed in the pot. Even if the burner is
removed and the pot is felt for wetness, it is difficult to assess the
degree of oil absorption by the pot.
There is only one way to properly service a flooded fire pot, and that is
to change it.
CAUTION
If you observe the red warning light on the burner, push
once ONLY to try and restart. If the burner will not start,
phone your authorised service agent. Do not press the
button again.
1.3) Burner drawer assembly:
Remove the drawer assembly. Clean all foreign matter from the
retention head and electrodes. If a Beckett AFG burner has been
installed, the burner will have to be removed to check the retention
head and to check for proper “Z” dimension with the Beckett “T” gauge
supplied with every burner. Check for any sign of oil boiling out of the
nozzle and caulking - the solenoid valve could be leaking (if
applicable).
1.4) Nozzle:
Replace the nozzle with the one specified in table # 3.1 to # 3.5.
1.5) Oil filter:
Tank filter:
The tank filter should be replaced as required.
Secondary filter:
The 10 micron (or less) filter cartridges should be replaced annually.
1.6) Air filters:
Air filters are the disposable types. The disposable filters should be
replaced on at least an annual basis. Dusty conditions, presence of
animal hair etc. may demand much more frequent filter changes. Dirty
filters will impact furnace efficiency and increase oil consumption.
1.7) Motor lubrication:
Do not lubricate the oil burner motor or the direct drive blower motor
as they are permanently lubricated.
1.8) CAS-2B combustion air kit :
If used, check the CAS-2B combustion air kit for proper operation.
Check to see that the inlet screen is not plugged. Block the air inlet
completely and ensure that a zero smoke reading results. If a zero
smoke reading is not obtained, set up the burner as indicated on table
# 3.1 to # 3.5.