Kerr Oil Furnace Manual

The Kerr Oil Furnace is a high-efficiency heating system designed for residential and light commercial use, featuring advanced combustion technology, multiple heat settings, integrated safety controls, oil tank compatibility, thermostat connectivity, air filtration system, and energy-saving modes. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Components 7. Operating Procedures 8. Safety Features 9. Maintenance & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Combustion chamber, oil burner assembly, heat exchanger, blower motor, oil pump, filter system, control panel, safety switches.

Feature	Description
Combustion chamber	High-temperature ceramic lining for efficient heat transfer
Oil burner assembly	Single-stage nozzle system with adjustable flame
Heat exchanger	Stainless steel construction for durability
Blower motor	Variable speed for optimized airflow
Oil pump	Positive displacement pump with filter
Filter system	Replaceable cartridge for oil filtration
Control panel	Digital display with temperature settings
Safety switches	High-limit and pressure switches for protection
Thermostat connection	Compatible with standard 24V thermostats
Vent system	Type L vent pipe compatible

Installation

Unpack and inspect all components. Ensure proper location with adequate clearance.

Position furnace: Place on level surface with minimum 18-inch clearance on all sides.
Connect oil supply: Install oil line with shut-off valve and filter.
Install venting: Use approved Type L vent pipe with proper slope.
Electrical connections: Connect to dedicated 120V circuit with proper grounding.
Thermostat wiring: Connect 24V thermostat wires to control board.

WARNING! Installation must be performed by qualified technician. Follow all local codes and regulations.

First-Time Setup

Power on furnace; follow startup sequence.

Purge air from oil line: Open bleed valve until steady oil flow appears.
Set temperature: Adjust thermostat to desired setting.
Test operation: Initiate heating cycle and verify proper ignition.
Adjust flame: Use combustion analyzer to optimize air/fuel ratio.
Program settings: Set clock, temperature limits, and cycle times.

CAUTION! Ensure proper ventilation and carbon monoxide detectors are installed.

Specifications

Heating Capacity: 85,000 - 150,000 BTU/hr
Efficiency: 85% AFUE
Fuel: No. 2 heating oil
Oil Consumption: 0.65 - 1.10 gallons per hour
Electrical: 120V AC, 60Hz, 5 Amps
Airflow: 800 - 1400 CFM
Dimensions: 48" H x 24" W x 30" D
Weight: 285 lbs
Noise Level: < 65 dB
Warranty: 10 years heat exchanger, 5 years parts

Controls and Settings

Access control panel via front cover. Digital display shows status and settings.

Control Panel: POWER, TEMP UP/DOWN, FAN SPEED, RESET, DIAGNOSTIC.

Temperature Settings: Set point adjustment, differential setting, maximum limit. Fan Control: Auto/Manual, speed adjustment, delay settings. System Settings: Cycle rate, purge time, lockout reset. Diagnostic: Error codes, system status, runtime hours.

Connecting Components

Oil Supply: 3/8" copper or steel line. Electrical: Dedicated 120V circuit. Thermostat: 24V connections.

Turn off power and oil supply before making connections.
Match wiring to terminal designations (R, W, G, C).
Use proper pipe dope for oil line connections.
Install sediment trap in oil supply line.

Tip: Label all wires and pipes for future maintenance.

Operating Procedures

Normal operation, seasonal startup, and shutdown procedures.

Startup: Ensure thermostat is set above room temperature.
Normal Operation: Furnace cycles automatically based on thermostat demand.
Fan Operation: Auto mode runs with heat cycle; manual for continuous airflow.
Seasonal Shutdown: Turn off power, close oil valve, clean combustion chamber.
Restart: Open oil valve, restore power, verify proper operation.

WARNING! Never bypass safety controls. Regular maintenance required for safe operation.

Safety Features

High Limit Switch: Shuts off burner if temperature exceeds safe limit. Pressure Switch: Verifies proper draft before ignition. Flame Sensor: Monitors burner flame during operation. Lockout Control: Prevents repeated ignition attempts. Overcurrent Protection: Circuit breaker for electrical protection.

Maintenance & Cleaning

Annual maintenance required by qualified technician.

Clean heat exchanger: Remove soot and debris annually.
Replace oil filter: Change every heating season.
Clean burner assembly: Remove and clean nozzle, electrodes.
Lubricate motor: Oil bearings as specified.
Check safety controls: Test all switches for proper operation.

CAUTION! Disconnect power before performing any maintenance.

Regulatory Information

UL Listed: Meets UL 727 standards for oil-fired furnaces. EPA Compliant: Meets emission standards for residential heating equipment. CSA Certified: Canadian Standards Association approved. For technical support, visit www.kerrfurnace.com or contact 1-800-555-HEAT. Copyright © 2024 Kerr Heating Systems.

Troubleshooting

Symptom	Possible Cause	Corrective Action
No ignition	No fuel/power	Check oil supply and power; reset lockout control.
Furnace locks out	Flame failure	Check ignition system; clean photocell; verify fuel supply.
Excessive smoke	Air adjustment	Adjust air shutter; check nozzle size; clean heat exchanger.
Unusual noises	Motor/bearing wear	Lubricate motor; check blower wheel balance; tighten components.
Poor heating	Filter/airflow	Replace air filter; check ductwork; verify thermostat setting.

Reset Procedure: Press RESET button on control panel once.

Service: 1-800-555-HEAT; www.kerrfurnace.com