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ECR International HML-C User Manual

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Installation, Operation and
Maintenance Manual
Oil Fired Warm Air Furnaces
HML-C (Up-Flow Model)
HMLV-C (Up-Flow Model with ECM)
ALL INSTALLATIONS MUST MEET ALL
LOCAL, PROVINCIAL/STATE, AND
FEDERAL CODES WHICH MAY
DIFFER FROM THIS MANUAL
ECR International Limited
Read this complete manual before
beginning installation. These instructions
must be kept with the furnace for future
reference
30173 Rev B 4/29/2008
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ECR International HML-C Specifications

General IconGeneral
BrandECR International
ModelHML-C
CategoryFurnace
LanguageEnglish

Summary

Introduction and Furnace Setup Basics

Models HML-C and HMLV-C Overview

Details the specific furnace models covered in the manual, their type, and capacity range.

Installation Safety and Location Guidelines

Covers general safety warnings, heat loss calculation, unit placement, and required clearances.

Air Conditioning Application Considerations

Outlines integration requirements when the furnace is used with air conditioning systems.

Heat Exchanger Access Screw Guidance

Specific instruction on removing heat exchanger support screws for improved accessibility.

Combustion Air and Chimney Venting Requirements

Combustion Air Supply Specifications

Details the necessary air openings for proper combustion in various room types and construction.

Chimney Venting Installation Standards

Specifies proper installation and safety requirements for chimney and flue pipe connections.

Flue Draft Pressure and Measurement

Notes the recommended flue draft pressure and methods for checking over-fire draft.

Venting, Control Systems, and Electrical Connections

Barometric Damper and Sidewall Venting

Covers draft regulators for chimney venting and specific requirements for sidewall venting applications.

Fan Timer and Limit Control Board Functions

Describes the electronic fan timer boards and their role in blower operation and safety limits.

Electrical Connection Standards and Requirements

Outlines wiring requirements conforming to CSA, NFPA, and local electrical codes.

Ancillary Systems and Burner Adjustment

Humidifier Installation and Fuel Piping

Instructions for installing optional humidifiers and the fuel system, including filters and piping.

Oil Burner Nozzle Selection and Adjustment

Guides on selecting nozzles and adjusting the fuel-to-air ratio for optimal combustion efficiency.

Burner Electrode Positioning for Ignition

Emphasizes correct electrode placement for smooth ignition and efficient combustion.

Burner Controls and Blower System Details

Burner Primary Control and Combustion Chamber

Details the safety control, cad cell maintenance, and combustion chamber inspection and alignment.

Circulating Air Blower Systems (HML-C/HMLV-C)

Explains the direct drive blower systems for HML-C (PSC) and HMLV-C (ECM) models.

Furnace Maintenance, Service, and HML-C Operation

Homeowner Maintenance and Inspections

Outlines homeowner responsibilities including air filter maintenance and visual inspections.

Annual Professional Service Tasks

Details tasks performed by a professional service technician during annual maintenance.

HML-C Operating Instructions

Step-by-step guide for starting and operating the HML-C model furnace.

HMLV-C Operation and ECM Blower Motor Features

HMLV-C Operating Instructions

Step-by-step guide for starting and operating the HMLV-C model furnace.

ECM Blower Motor Operational Modes

Details on ECM motor features like soft start, soft stop, dehumidification, and continuous fan operation.

Appendix A: Burner Set-Up Specifications

Beckett AF Series Oil Burner Setup

Table providing specifications for Beckett AF series oil burners used with chimney venting.

Beckett AFII Series Oil Burner Setup

Table detailing specifications for Beckett AFII series oil burners for sidewall or chimney venting.

Appendix A: Riello Burner Specs and Air Adjustment

Riello 40F Series Oil Burner Setup

Table of specifications for Riello 40F series burners used with chimney venting.

Riello Balanced Flue Series Burner Setup

Table of specifications for Riello BF series burners for sidewall venting.

Oil Burner Air Adjustment Procedures

Guides for adjusting combustion air for Beckett and Riello oil burners.

Appendix A: Electrode Specs, Startup, and Riello Notes

Burner Electrode Adjustment Specifications

Specific gap and distance settings for Beckett and Riello burner electrodes.

Furnace Startup and Combustion Tuning

Steps for initiating operation, fine-tuning combustion, and testing oil pressure.

Special Instructions for Riello Burners

Notes on factory settings and consulting Riello installation manuals for specific adjustments.

Appendix A: Blower Set-Up and Characteristics Tables

PSC Motor Blower Set-Up Table

Table detailing PSC blower speed configurations for different models and static pressures.

PSC Motor Blower Characteristics Table

Table showing PSC blower performance (CFM) at various static pressures.

Appendix A: General Dimensions Table

Furnace General Dimensions

Table listing cabinet dimensions, plenum openings, and filter sizes for HML-C/HMLV-C.

Appendix A: ECM Blower Control Settings

ECM Blower DIP Switch Adjustment Chart

Detailed chart for setting DIP switches on the ECM blower control board for various inputs.

Appendix B: Wiring Diagrams - Chimney Vent

Wiring Diagram Legend and Symbols

Explanation of symbols and color codes used in the wiring diagrams.

Chimney Vent Burner Wiring Diagram

Wiring diagram for chimney vented HML-C and HMLV-C models.

Beckett AF Burner Wiring Diagram

Specific wiring diagram for Beckett AF burners.

Appendix B: Wiring Diagrams - Direct Vent

Direct Vent Burner Wiring Diagram

Wiring diagram for direct vent HML-C and HMLV-C models.

Beckett AFII Burner Wiring Diagram

Specific wiring diagram for Beckett AFII burners.

Oil Burner Operation, Testing, and Safety Notes

Oil Burner Startup and Operation Procedure

Steps for starting the burner, bleeding lines, setting pressure, and checking temperature rise.

Limit Switch and Fan Off Delay Testing

Procedures to verify the proper operation of safety controls and fan off delay settings.

Critical Operational and Venting Safety Notes

Important reminders for safe operation, full cycle testing, and venting system checks.

Appendix C: Oil Primary Control Sequence Details

Oil Primary Control Sequence Overview

Detailed breakdown of the oil primary control's operation from idle to run states.

Flame Monitoring and Carryover Logic

Explains control logic for flame sensing, spark ignition, and carryover timers.

Thermostat Satisfied and Recycle Mode Logic

Describes control actions upon thermostat satisfaction or loss of flame.

Control Board Illustrations

Figure 4: United Technologies 1158-120 Fan Timer Board

Visual representation of the fan timer board used in HML-C models.

Figure 5: United Technologies 1168-1 ECM Tap Board

Visual representation of the ECM tap board used in HMLV-C models.

Oil Primary Control Sequence Flowchart

Oil Primary Control Operational States Flowchart

Illustrates the sequence of states: Idle, Trial, Carryover, Run, Lockout, and Recycle.

Control State Transition Logic

Shows how the control transitions between states based on system conditions and flame presence.

Electronic Fan Timer Board Detailed Sequences

EFT Mode Sequences Table

Table detailing system responses for HEAT, COOL, FAN, and LIMIT modes of the Electronic Fan Timer.

Thermostat Input LED Indicator Functions

Explanation of EFT LEDs and their corresponding thermostat signal inputs.

Oil Primary Control LED Diagnostics and Troubleshooting

LED Diagnostic Light Interpretation Guide

Explains LED meanings for normal operation and fault conditions.

Cad Cell Resistance Testing Procedures

Details testing cad cell resistance using LED flash codes and necessary equipment.

Preliminary Troubleshooting Checks

Initial checks for power, limit switches, electrodes, and igniter before control diagnosis.

Thermostat Wire Disconnection Caution

Warning about disconnecting thermostat wires to prevent damage to controls.

Oil Primary Control Troubleshooting - Burner Start Issues

Burner Motor Failure to Start Diagnosis

Troubleshooting steps when the burner motor does not start during a call for heat.

Burner Lockout with Flashing Light Diagnosis

Diagnosing safety lockouts indicated by a flashing light on the primary control.

Oil Primary Control Troubleshooting - Lockout and Cad Cell Issues

Troubleshooting Safety Lockout Conditions

Continued steps for diagnosing safety lockouts and indicator light flashing issues.

Cad Cell Functionality and Sighting Checks

Procedures for testing the cad cell's response to flame and ambient light.

System and General Troubleshooting Introduction

Oil Primary Control and Thermostat Troubleshooting

Further steps for oil primary control faults, including thermostat and wiring checks.

General System Troubleshooting Overview

Introduces a table for diagnosing common system-wide problems and their remedies.

General System Troubleshooting - Startup Failures

Furnace Startup Failure Diagnosis

Troubleshooting steps for when the furnace does not start, including fuel supply, motor, and filter issues.

Burner Start/Stop and Sputtering Issues

Diagnosing problems where the burner starts but repeatedly shuts down or sputters at the nozzle.

General System Troubleshooting - Performance Issues

Fuel Oil Consumption and Smoke Problems

Diagnosing high fuel usage, excessive smoke, and soot buildup from poor combustion or alignment.

Furnace Heating Performance Issues

Troubleshooting lack of heat, uneven heating, and temperature regulation problems.

Final Checks and Homeowner Information

Supply Air Temperature Troubleshooting

Diagnosing issues with supply air being too hot, too cool, or fluctuating during operation.

Final Operational and Safety Checks

Ensuring all safety devices, components, and electrical connections are correctly set and secure.

Key Homeowner Information Points

Essential knowledge for homeowners regarding operation, maintenance, and service contact.

Homeowner's Reference Table

Installation Contractor and Fuel Supplier Details

Space for recording installation contractor, fuel supplier, and service technician contact information.

Parts Listing - Highboy Models

HML-80C and HMLV-80C Parts List

Detailed list of replacement parts for highboy models with reference and part numbers.

Parts Listing - Direct Vent Models

HML-80CB2U and HMLV-80CB2U Parts List

Lists specific replacement parts for direct vent highboy models.

Model HML-C and HMLV-C Component Diagram

Furnace Component Identification Diagram

A visual diagram illustrating the location of various components within the furnace.

Notes and Manufacturer Contact Information

General Notes Section

Blank space provided for user-added notes and remarks.

ECR International Contact Details

Provides addresses, phone numbers, and fax numbers for the manufacturer for support.