321 Studios FH110D60E Owner's Manual
Contents
1. j E SUPPLY OPENING 30 1 2 8 ae TOP VIEW ae 23 KNOCKOUT FLUE 54 1 4 REAR CLEANOUT SEH Low VOLTAGE HIGH VOLTAGE ENTRANCE FRONT VIEW OPTIONAL OIL ENTRANCE RIGHT SIDE VIEW 18 1 8 19 1 8 e MIS 1826 Manual 2100 422 Page 5 INSTALLING THE INSTRUMENTS REQUIRED FOR PROPER SETUP OF THE FURNACE It is important that a set of instruments capable of the following requirements be used for the setup of this furnace to ensure proper and safe operation 1 Oil pump pressure gauge that measures up to 150 PSI 2 Smoke gun to pull smoke samples from flue 3 Draft gauge that will measure 02 water column W C 4 Duct static pressure gauge 0 1 0 W C range 5 Temperature gauge that can read from 50 F up to 700 6 A gauge to measure CO or O INSTALLATION A typical installation is shown in Figures 4 and 5 All parts of the furnace installation furnace oil tank and piping systems combustion and ventilation air venting etc must comply with NFPA31 Installation of Burning Equipment latest edition This drawing shows the typical connecting parts needed to correctly install this furnace Make sure that all parts of the heating system comply with the local codes Check the furnace and your load calculation to veri2. Percent in Flue Gas High Air Settings Low CO Curve from plotted points Plotted point Normal adjustment range Tolerance to knee Best air setting Plotted point Plotted point 6 8 10 12 14 Percent in Flue Gas Technician s plotting area 6 8 10 12 14 MIS 1827 FIGURE 9 PRESSURE GAUGE CONNECTION BLEED PORT Remove Bleed Port to attach pressure guage Pressure Gauge MIS 1660 5 CORRELATION PERCENT O RESERVE AIR Carbon Reserve Air Dioxide yg Approx 0 0 0 0 15 4 15 0 0 6 3 0 14 5 1 2 6 0 14 0 2 0 10 0 13 5 2 6 15 0 13 0 3 3 20 0 12 5 4 0 25 0 12 0 4 6 30 0 11 5 5 3 35 0 11 0 6 0 40 0 10 5 6 7 45 0 10 0 7 4 50 0 TABLE 6 NO 2 FUEL OIL EFFICIENCY CHART NET STACK TEMP DEGREES F TABLE 7 RECOMMENDED START UP SETTINGS Factory Installed Field Installed Option Furnace Burner Style Model No Part No Nozzle Setting Setting 2 gt gt A 2 gt 2 gt 2 gt 70 degree hollow pattern 100 PSIG pump pressure Manual 2100 422 Page 19 SPACING OF ELECTRODES The electrodes should be spaced 5 32 apart They should extend 1 16 beyond the end and 5 16 above the center of the nozzle tip as shown in Figure 10 GUN ASSEMBLY ADJUSTMENT The gun assembly can be adjusted
3. INSTALLATION INSTRUCTIONS MODELS FHO85D36E FH110D48E FH110D60E FLFO85D36E FLF110D48E FLF110D60E FLRO85D36E FLR110D48E FLR110D60E FLR140D60E FCO85D36E A WARNING READ ALL INSTRUCTIONS CAREFULLY BEFORE BEGINNING THE INSTALLATION THIS INSTALLATION MUST COMPLY WITH THESE INSTRUCTIONS AND THE REQUIREMENTS OF ALL GOVERNING CODES AND ORDINANCES FOR THE INSTALLATION LOCATION IT IS THE RESPONSIBILITY OF INSTALLER TO KNOW AND UNDERSTAND ALL OF THESE REQUIREMENTS FAILURE TO DO SO COULD CREATE A HAZARD RESULTING IN PROPERTY DAMAGE BODILY INJURY OR DEATH FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE IMPORTANT NOTICE THIS FURNACE IS NOT INTENDED FOR USE AS A CONSTRUCTION HEATER USE OF THIS FURNACE DURING CONSTRUCTION AND FINISHING PHASES OF A STRUCTURE IS CONSIDERED AS OPERATION IN A CORROSIVE ATMOSPHERE AND UNUSUAL NEGLIGENT OR IMPROPER USE AND AS SUCH ARE CONSIDERED EXCLUSIONS BY THE BARD MANUFACTURING COMPANY LIMITED WARRANTY 4 CLIMATE CONTROL SOLUTIONS Bard Manufacturing Company Manual 2100 422B Bryan Ohio 43506 Supersedes 2100 422 File 1 TAB 3 Since 1914 Moving ahead just as planned Date 09 23 03 Copyright 2003 5 Getting Other Information and Publications 1 Filters Upflow amp Counterflow Filter Information 237 Instal
4. gt Manual 2100 422 Page 2 enuen 6 001 aren 085 110 AND FIGURE 1 FLF R MODELS DIMENSIONS TABLE 2 FLF R MODELS DIMENSIONS INCHES SPECIFICATION SHEET penina Cabinet Openings Flue Conection Air Filters DxE RETURN TOP VIEW SUPPLY Number Depth Height Supply Location J yas FLFO85D36E 23 48 125 36 625 22 20 22x14 Front 31 625 5 125 16 x 20 x 1 1 FLRO85D36E 23 48 125 36 625 22 20 22x14 Rear 31 625 5 125 16 x 20 x 1 1 23 FLF110D48E 48 125 40 625 22x20 6 35 625 5 125 20 20 1 FLF110D60E 48 125 40 625 22 20 35 625 5 125 20 x 20 x 1 FLR110D48E 48 125 40 625 22x20 FLR110D60E Washable type filter 1 nom thickness 3 FLF FLUE KNOCKOUT G m E Lg FLF FLUE REAR FLUE KNOCKOUT M ON FLR MODELS HIGH VOLTAGE ENTRANCE boss LOWVOLTAGE OPTIONAL LOW VOLTAGE ENTRANCE HIGH VOLTAGE OIL ENTRANCE OPTIONAL B OIL EON ENTRANCE FRESH AIR KNOCKOUT bel LEFT SIDE VIEW
5. 32 Combustion Air 20 Blower System Resistance Charts 33 34 Louvers Grilles 25 Wiring 35 37 Venting 25 ul a 25 5 FIGURES Table 1 Minimum Clearances 2 Figure 1 FL R Models Dimensions 3 Table2 Dimensions FLF R Models 3 Figure 2 FH Models Dimensions 4 Table3 Electrical Data 7 Figure 3 FC Models Dimensions 5 Table A Furnace Data 14 Figure 4 Typical Unit Setup FLF 8 Table 5 Correlation of of CO and Figure 5 Typical Flue Installation tecnica 19 Requirements FLF 9 Table 6 No 2 Fuel Oil Efficiency Chart 19 Figure 6 Typical Single Inside Table 7 Recommended Start Up Settings 19 Tank Installation 10 Table8 Sq Ft Required as Figure 7 Electronic Blower Control 13 Unconfined 22 Figure 8 Typical Smoke CO Characteristic 17 Table9 Minimum Ventilation Openings 23 Figure 9 Pressure Gauge Connection to Table 10 Temperature Rise Ranges Limit Pressure Gaug
6. 1 I E 3 5 160 FIGURE 11 COMBINATION AIR BOOT ASSEMBLY COMBUSTION ASSEMBLY USE THIS KNOCKOUT FOR OIL UNE BURNER ASSEMBLY REMOVE PUMP TO ASSEMBLE INNER AIR BOOT REMOVE KNOCKOUT IN LEFT SIDE WS INSERT OUTER AIR BOOT AND SECURE FLANGE TO UNIT MAKE ALL SETTINGS MIS 1833 ACCORDING TO MANUAL FOR AIR BOOT Manual 2100 422 Page 21 APPLIANCES LOCATED CONFINED SPACES In unconfined spaces in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of unusually tight construction additional air shall be provided using the method described under All Air From Outdoors in Figure 13 An unconfined space such as an open basement must have a minimum volume of 50 cubic feet per 1 000 BTUH of total of all appliances in area Adjoining rooms may be counted as one area only if there are not doors between the rooms Shown in Table 8 are the required minimum areas in square feet to qualify as an unconfined space for various total BTUH input ratings The table is based on aroom s with 8 foot ceiling heights If the unconfined space is within a building having insufficient air because of tight construction the air for combustion and ventilation shall be obtained from outdoors or from spaces freely communicating with the outdoors Under these conditions a permanent
7. MIS 1841 Manual 2100 422 Page 27 LO BOY MODELS FILTER LOCATIONS Lo boy models have the filter installed in the return air cabinet section of the furnace It is accessible from the rear of the furnace by removing the blower filter access door The electrical switch should be turned off prior to removing the access door Refer to Figure 18 below FIGURE 18 FILTER INSTALLATION LO BOY MODELS UNIT FILTER SIZE FLF FLRO85 16 x 20 x1 FLF FLR110 20 x 20 x FLR140 20 x25 x 1 STEP 3 SLIDE FILTER 0UT TOWARDS BLOWER m STEP 2 REMOVE BLOWER DOOR BY PULLING OUT ON UNFASTEN SWELL SWELL LATCHES AND LATCHES BY PULLING TILTING OUTWARDS HANDLES OUTWARD Manual 2100 422 Page 28 LUBRICATION No lubrication is required for either the burner or the blower motor Both are permanently lubricated INSPECT AIR FILTER Replace filters before each heating season begins It is recommended that filters also be replaced at least twice during the heating season Be sure the new filters are set securely in the filter rack so there can be minimal leakage around them FINAL INSPECTION AND TEST Final inspection and test of an installation shall be made to determine that the work has been done in full accordance with regulations and according to the highest standards for safety performance and appearance Such an inspection and test should indicate the following as a minimum
8. NEUTRA gt GREEN BLACI GROUND gt gt ALL OTHER 5 CONNECT SPARE TERMINALS DASHED LINES REPRESENT FIELD WRING 4047 120 B
9. 1 Determine that all parts of the oil storage and circulating system including tank piping and burner are free from oil leaks Be sure that no oil discharges from the nozzle when burner is not operating 2 Be sure that the suction line and pump have been entirely vented of air so that the burner has instantaneous oil shutoff at the nozzle and so that the pump operates without an air noise 3 Check the flame adjustment to determine that the flame is clear quiet free of odor and oil nozzle is of proper size for the furnace 4 Test operation of burner by operating the thermostat First set the thermostat above room temperature Burner should start Second set thermostat below room temperature Burner will stop 5 Check operation of burner primary control in accordance with manufacturer 5 instructions included with the control Following is the method we recommend in checking the safety switch in this primary control A Flame Failure Simulate by shutting off oil supply manual valve while burner is on Within 9 seconds the control will shut the burner down and flash a diagnostic code of 1 2 second 1 2 second off Ignition and motor stop and oil valve closes MAINTENANCE B Ignition Failure Test by closing oil supply while burner is off Run through starting procedure The primary control will attempt three trials for ignition After three attempts the control will lockout C Power Failure Turn
10. These controls were selected their high quality dependability and serviceability With proper maintenance this burner assembly will provide many years of reliable service Allunits are shipped with the oil burner installed and with high rate oil nozzle installed designed for use with No 1 or No 2 fuel oil Inspect firepot refractory before firing to be sure it has not been jarred out of position in shipment Burner air tube must not extend beyond inside surface of firepot Burner head should be centered on the combustion chamber opening See Figures 19 and 20 Never attempt to use gasoline in your furnace Gasoline is more combustible than fuel oil and could result in a serious explosion causing damage injury or death The following is a detailed explanation of each control included in the Becket AFG Oil Burner how each operates how to set up the burner and how to troubleshoot problems should they occur BECKETT CLEANCUT OIL PUMP This oil pump is equipped with an oil solenoid valve installed in the pump housing This feature provides quick cutoffs resulting in reduction in smoke after the burner shuts down This is a time proven pump design and is capable of both one and two pipe systems This pump requires a pre purge style primary control such as the R7184B primary All installation and set up instructions are outlined in the Oil Pump Specification section of the in
11. alarm the security agency will notify the dealer of choice based upon information supplied by the home owner The system will also be capable of being connected to a phone line that will contact the dealer directly with the alarm This alarm will typical sound 3 to 5 days prior to the primary control going into lockout giving the service agency a prior notice before a sooting condition or other failure can occur resulting in untold savings This monitor system is available through your local distributor under the Honeywell part no QS7100F blower on and off timings for both heating and cooling speeds are timed automatically The heating blower off delay can be selected from four different timings by moving the selection jumper The timings are as follows Heating Blower ON delay 75 seconds from a call for heat Heating Blower OFF delay Selectable in seconds 150 180 210 or 240 Factory shipped at 240 Cooling Blower ON delay 6 seconds from a call for cooling Cooling Blower OFF delay 60 seconds FIGURE 7 ELECTRONIC BLOWER CONTROL THERMOSTAT TRANSFORMER 24V CONNECTIONS SECONDARY w CONNECTIONS O aG lg 18 FUSE HEATING BLOWER OFF DELAY ADJ USTMENT ld IN SECONDS 4 hr 240 1 HEATING OIL PRIMARY T T SECONDS CONNECTIONS 49 LINE VOLTAGE sik ei Wu CONNEC
12. eae NOTE Each air duct opening shall have a KZ free area not less than one square ES NLET AIR DUCT inch per 2 000 BTU per hour 70 square inches per gallon per hour of the total input rating of all in the enclosure MIS 1337 Manual 2100 422 Page 23 FIGURE 14 APPLIANCES LOCATED CONFINED SPACES ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC CHIMNEY VENTILATION LOUVERS gt a EACH END OF ATTIC leg x NOTE The inlet and outlet air openings shall each free area less than square inch INLET AIR DUC 4 000 BTU per hour 35 square FURNACE ENDS 1 FT ABOVE FLOOR inches per gallon per hour of the total input rating of all appliances in the enclosure MIS 1338 FIGURE 15 APPLIANCES LOCATED IN CONFINED SPACES ALL AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACE AND OUTLET AIR TO VENTILATED ATTIC CHIMNEY ATION LOUVERS EACH END OF ATTIC NOTE The inlet and outlet air openings shall each have a free area of not nee Se less than square inch 4 000 GE 35 22 hour 35 square
13. FRONT MEW RIGHT SIDE MEW MIS 1815 A enuen r 001 FIGURE 2 MODELS DIMENSIONS sey SPECIFICATION SHEET OPENING 19 7 8 FLUE KNOCKOUT g KNOCKOUT FLUE KNOCKOUT OPTIONAL HIGH VOLTAGE REAR CLEANOUT ENTRANCE DOOR 7 7 HIGH ENTRANCE VOLTAGE ENTRANCE r OPTIONAL OIL ENTRANCE 53 FHO85 59 FH11O OIL ENTRANCE LOWVOLTAGE E 19 1 4 BEE FRESH AIR Kee KNOCKOUT OPTIONAL OIL 1 RETURN OPENING Bag OPENING i CUT OUT VESTIBULE CUT OUT 1 DOOR 9 ER 9 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW MIS 1814A 085 SPECIFICATION SHEET FLUE OPTIONAL HIGH VOLTAGE ENTRANCE OPTIO CA LOW VOLTAGE 2 ENTRANCE OIL ENTRANCE OPTIONAL OIL ENTRANCE FRESH AIR KNOCKOUT LEFT SIDE VIEW RETURN OPENING BOTTOM VIEW FIGURE 3 085 MODEL DIMENSIONS 19 7 8 21 7 3 m
14. THE COIL TO MAKE SURE IT IS ACCEPTABLE FOR USE WITH THESE OIL FURNACES HAVING MAXIMUM OUTLET AIR TEMPERATURE OF 200 F See CFM versus static pressure curves on pages 33 36 for additional information WIRING FIELD WIRING All wiring must conform to the National Electrical FACTORY WIRIN S Code all local codes A separate fuse Allunits are fully factory wired Multispeed blowers should be used for the furnace are factory wired on high speed for cooline manual fan operation Heating speeds are wired for the largest input and may need lower speed for field installed low input nozzle If replacement wire 15 necessary use 105 degrees C minimum See electrical data Table 3 TABLE 3 ELECTRICAL DATA Max Time Burner Motor Minimum Delay Fuse Circuit Blower Motor Total Volts HZ PH Amps 115 60 1 9 2 115 60 1 12 2 115 60 1 14 2 115 60 1 17 3 115 60 1 17 3 115 60 1 12 2 115 60 1 12 2 115 60 1 14 2 115 60 1 14 2 115 60 1 14 2 115 60 1 7 3 FH085D36E FH110D48E FH110D60E FLF085D36E FLR085D36E FLF110D48E FLR110D48E FLF100D60E FLR100D60E FLR140D60E FC085D36E 1 3 1 2 3 4 1 3 1 3 1 2 1 2 3 4 3 4 3 4 1 7 1 7 1 7 1 7 1 7 1 7 1 7 Manual 2100 422 Page 7 FIGURE A TYPICAL UNIT SETUP FLF UNIT SHOWN ALL WIRING MUST CONFORM TO THE NATIONAL ELECTRIC CODE AND ALL LOCAL WARNING CODES Left side high voltage unit power entrance Le
15. burner requires technical knowledge and the use of combustion test instruments The following procedure must be followed to correctly adjust the burner to match the specific characteristics of the installation IMPORTANT Always use combustion test instruments when making burner adjustments and draft gauge when setting the barometric damper It is virtually impossible to make accurate and reliable adjustments using the eyeball method Check all oil lines and connections for leaks Connect pressure gauge by removing bleed fitting and 1 PREPARATION STEPS A Calibrate and Check Operation of Measuring Equipment Follow manufacturer s recommended procedures for calibration and equipment check out Prepare Heating Unit for Testing Drill two 1 4 inch holes in the flue between the heating plant and the barometric draft regulator If space permits the holes should be located in a straight section of the flue at least two flue diameters from the elbow in the flue pipe and at least one diameter from the draft regulator The purpose of the two holes in the flue pipe is to speed up testing and reduce instrument handling Clean and Seal Heating Plant Make sure the burner blast tube fan housing and blower wheel are clear of dirt and lint Seal any air leaks into the combustion chamber Nozzle Inspection Annual replacement of nozzle is recommended The nozzle size should match the design load DO NOT OVER
16. in the slot inside of fan housing by loosening screw holding slot cover in position Nozzle tip should ordinarily be located 1 1 8 behind the front face of the cone REMOVING GUN ASSEMBLY Disconnect the oil line at the fan housing and remove lock nuts on copper tube fitting Loosen igniter hold down clamps then swing igniter up and backward Gun assembly can now be removed through this opening COMBUSTION AIR REQUIREMENTS This furnace must be installed in a location where a sufficient supply of combustion air is available for the complete combustion of the fuel oil Keep in mind that certain amount of excess air is required as well to ensure complete combustion of the fuel oil When structures are constructed too tightly to supply sufficient combustion air air from outside the structure is required to be brought in directly to the furnace This furnace has been conveniently designed to accept a combustion air boot which is attached directly to the outdoors by means of a 4 pipe This pipe can be rigid or flexible but it is recommended that a metallic material be used Refer to Figure 11 The air boot used for this design is a Field Controls model number CAS 2B 90E that can be purchased through your local distributor Follow all installation procedures as specified in the instructions packaged with the air boot kit FIGURE 10 ELECTRODE ADJUSTMENTS 1 1 8 Manual 2100 422 Page 20
17. inches gt per gallon per hour of the total Ca input rating of appliances the 3 enclosure HSN 7 VENTILATION LO UNHEATED Manual 2100 422 Page 24 LOUVERS AND GRILLES In calculating free area for ventilation and combustion air requirements consideration shall be given to the blocking effect of louvers grilles or screens protecting openings Screens used shall not be smaller than 1 4 inch 6 3 mm mesh and shall be readily accessible for cleaning If the free area through a design of louver or grille is known it shall be used in calculating the size Opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will have 30 35 percent free area and metal louvers and grilles will have 60 75 percent free area VENTING OPTIONS This furnace is designed to be vented conventionally into a vertical chimney or horizontally through a side wall with an optional Field Controls side wall power venting system Note that the FH FC and FLF series furnaces have been designed to allow for bringing the vent system through the cabinet side for increased venting flexibility To take advantage of this feature simply remove the desired knockout from either side or top of unit and rotate flue box accordingly by removing four 4 screws under cleanout plate as shown in Figure 4 Make sure smoke pipe gasket is in place before
18. limit control setting It may be that flame is not allowed to stay on long enough to generate sufficient heat in furnace to heat the house properly If the proper size furnace has been selected according to house requirements and satisfactory heat is not obtained recheck the heating plant for size and capacity in relation to house Check for clogged filters Check and make sure the heat anticipator on the thermostat is set correctly CARE OF FINISH This furnace cabinet is made with a very durable and corrosion resistant finish With normal cleaning it will last for many years ZAWARNING Under no circumstance should a soot deterioration device be used in the combustion chamber These products known as soot busters or soot sticks are comprised of chemicals that burn at very high temperatures which may exceed the temperature rating of the combustion chamber material Use of these products are detrimental to the life expectancy of the combustion chamber and will destroy the chamber Refer to the Cleaning of Furnace section for proper cleaning methods CLEANING OF THE HEAT EXCHANGER All of these units have four clean out plugs for easy cleaning of the heat exchanger They are accessible from the front and back of these units by removing the clean out access cover in the burner compartment and at the back of unit The furnace should be checked annually by a qualified service technician BLOWER SYSTEM RESISTA
19. off power supply while burner is on When burner goes out restore power and burner will restart D If operation is not as described check wiring and installation first If trouble appears to be in the control circuit replace the flame detector If trouble still persists refer to Common Causes of Trouble section on page 28 SERVICE HINTS Preventive maintenance is the best way to avoid unnecessary expense inconvenience and retain operating efficiency of your furnace It is advisable to have your heating system and burner inspected at periodic intervals by a qualified serviceman If trouble develops follow these simple checks before calling the serviceman 1 Make sure there is oil in tank and valve is open 2 Make sure thermostat is set above room temperature 3 Make sure electrical supply to furnace is on and fuses are not blown or circuit breakers tripped 4 Reset safety switch of burner primary control CAUTION Reset three 3 times only More than three resets can cause excessive oil to be pumped into combustion chamber which could result in explosion upon ignition Press thermal protector button of burner motor Make sure filters place and clean 7 Make sure all air openings in furnace all ventilation and combustion air openings all return air grilles and all warm air registers are unobstructed and open Manual 2100 422 Page 29 COMBINATION CO
20. out or in restricted mode hard lockout Flashing 2 seconds 2 seconds off control is in recycle mode soft lockout CAD cell is sensing flame OFF CAD is not sensing flame Ignition Trials any given call for heat the control will allow three ignition trials After the three trials the control will go into a soft lockout mode The LED will flash 2 seconds on and 2 seconds off when in this recycle mode The control may then be reset by pressing the RED reset button on the control If within the same original call for heat the control will again allow three ignition trials followed by another soft lockout and 2 second 2 second off LED code The control my be reset one additional time by pressing the red reset button This will allow three final ignition trials If all three of the final ignition trials fail then the control goes into a hard lockout or Restricted Mode This series of ignition failures must all occur with the original call for heat in order to reach the Restricted Mode The LED will now flash 1 2 second 1 2 second off indicating the restricted mode The control can be resurrected from the restricted mode only by pressing and holding the red reset button for approximately 30 seconds until the LED flashes twice Removing unit power or resetting the thermostat will not reset the control Checking CAD Cell With a call for heat and the burner ignited press and re
21. than necessary on the lower portion of the curve below the knee The characteristic curve for some burners may not yield a distinct knee in the curve In such cases the setting should be made near the minimum smoke using judgement Lock the air adjustment and repeat draft CO and smoke measurements to make sure the setting has not shifted 3 COMBUSTION DIAGNOSIS L Check Performance A well matched and 2 COMBUSTION ADJUSTMENT STEPS H Set Draft Check the draft reading over the fire with a draft gauge through a hole in the inspection door The hole is above the flame level Adjust the barometric draft regulator on the flue to give the over fire of 02 W C Check Smoke Readings After burner has been operating 5 or 10 minutes make a smoke measurement in the flue following the smoke tester instructions Oily or yellow smoke spots on the filter paper are usually a sign of unburned fuel indicating very poor combustion and likely high emissions of carbon monoxide and unburned hydrocarbons This condition can sometimes be caused by too much air or by other factors If this condition cannot be corrected major renovation or even burner replacement may be necessary Develop Smoke CO2 Curve Record measurements of smoke and CO from the flue Then establish the smoke CO curve by taking readings over a range of air settings as shown in Figure 8 To do this start with the air gate set at nearly full
22. venter can be purchased through your local distributor Follow all installation instructions packaged with the venter system THERMOSTAT These furnaces are designed to be controlled with any 24V heating or heating cooling thermostat The heat cool thermostats must be designed for independent heat cool transformer circuits to assure that the 24V transformer built into the oil primary control does not conflict with the main furnace 24V transformer The heat anticipator should be set at 0 20A This is a nominal setting The thermostat circuit should be checked to verify setting Manual 2100 422 25 TABLE 10 TEMPERATURE RISE RANGES LIMIT CONTROL SETTINGS AND HEATING BLOWER SPEEDS Maximum Outlet Heating Blower Nozzle Rise Ranges Temp Speed 55 FH085D36E 65 75 85 70 100 200 Low 85 60 90 200 Low 60 90 200 Low FLF085D36E 65 60 90 200 Low 60 90 200 Med 85 60 90 200 Med Low 85 60 90 200 Med Low 60 90 200 Low FLR085D36E 60 90 200 Low 60 90 200 Med 85 60 90 200 Med Low 85 60 90 200 Med Low 1 10 60 90 200 Med Low 55 FCO85D36E 70 degree hollow cone spray pattern 100 PSIG pump pressure Manual 2100 422 Page 26 AIR FILTERS Only Lo Boy models are shipped with air filters Filter kits are available from your local distributor for Upflow and Counterflow models Knockouts are provided in the sides of the FH series models to facilitate the cuttin
23. 0 FH110D48E 3 MED LOW 1280 ft MED HIGH BLUE EE eee WIRE COLORS 3 LOW RED 1300 H MED LOW ORANGE b iyisi reg BLUE SES 5 HIGH BLACK 1970 FACTORY SETTINGS INPUT TEMP u UNIT BATE BLOWER COOLING BLOWER oer 3 5 COLOR SPEED COLOR RANGE Oh 0 55 LOW RED 70 100 FHO85D36E 0 65 LOW RED 70 100 0 75 MED BLUE 60 90 0 85 LOW RED HIGH BLACK 7021002 UE ORANGE 60 90 0 85 LOW RED 60 90 THT ODS0E 1 _ MED LOW ORANGE 60 90 BLOWER CAPACITOR RATING UNIT MOTOR CAPACITOR FHO85D36E 1 3 5 370 BLOWER ASSEMBLY FH110D48E 1 2 7 5 370 4047 118 110060 3 4 15 370 2100 422 35 Manual enuen 96 001 SERIES WIRING DIAGRAM FACTORY SETTINGS HTG BLWR SPD TEMP COLING BLWR COLOR RISE SPEED 0 55 LOW RED 602 904 HIGH BLACK FLF R085D36E 0 65 LOW RED 60 90 _HIGH BLACK 0 75 MED BLUE 602 9024 HIGH BLACK FLF R110D48E 0 85 MED HIGH BLUE 60 90 _ HIGH BLACK FLF R110D60E 1 MED HIGH BLUE 60 90 HIGH BLACK 11 HIGH BLUE 60 90 HIGH BLACK HIGH BLUE 60 90 HIGH BLACK BAC PRIMARY LIMIT UNIT GPH INPUT HEAT EX AREA FLR140D60E BURNER ASS Y od 12 OIL VALVE OR EQUIVELA
24. 55 Fax 617 984 7057 Manual 2100 422 Page 1 INSTALLATION and OPERATING INSTRUCTIONS EQUIPMENT SELECTION LOCATING THE FURNACE An accurate heating load calculation must be conducted When installing the furnace be sure to provide adequate using American Society of Heating Refrigeration and space for easy service and maintenance Locate the Air Conditioning Engineers ASHRAE or Air furnace as close to the chimney as practical giving Conditioning Contractors of America ACCA manuals consideration to the accessibility of the oil burner Do not add a large safety factor above the calculated controls and blower for service Allow a minimum of value If the calculated heating load requirement 24 inches at front of furnace for servicing oil burner exceeds the heating capacity rating of a given model Allow adequate room for filter and blower use only the next larger size available Never increase maintenance Clearance from combustible material as by any more than absolutely necessary based upon stated on the furnace and repeated in Table I must be available equipment heating capacities Always select maintained For damp basement installations a raised based upon heat capacity output never use input concrete pad is recommended This will help keep the capacities bottom of the furnace dry and reduce the risk of rusting NOTE It is the personal responsibility and An oil burner must have a generous supply of obligation of the purcha
25. ING SPEED CONNECTION PO COOLING SPEED CONNECTION POINT ONLY ONE HEATING AND COOLING SPEED CAN BE CONNECTED ALL OTHER TAPS A NT HEAT EXCHANGER ARI CONNECT TO SPARE TERMINALS DASHED LINES REPRESENT FIELD WIRING DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING gt N lt PLUG 2 1 2 LOW VOLTAGE HIGH VOLTAGE FIELD WHITE PLUG 3 BLOWER CAPACITOR N WARNING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST REPLACED IT MUST REPLACED WITH WIRING MATERIAL HAVING A TEMP RATING LEAST 105 C EXCEPT PRIMARY LIMIT WIRES SEE NOTE 1 Esas Ee sisa BEE 1 s m Se OO ONOMA SH COND Er Oty UNIT THERMOSTAT 4 24V T87F Q539A1220 E CONN OR EQUIVELANT T R AN 5 0 R M E R KS 5 OPTIONAL AIR COND SETTINGS om igi erg COLOR 50 WC 2 LOW RED 730 8 FH085D36E 21 2 MED 900 LAC 3 HIGH BLACK 1160 21 2 LOW RED 102
26. MBUSTION CHAMBER BURNER MOUNTING NG The furnace has been designed with a combustion chamber mounting system that enables service personnel to remove the combustion chamber its mounting system and burner assembly as one unit for inspection and or service on the bench It has also been Improper servicing could cause electric shock designed to remove the burner assembly independently hazard fires or explosion resulting in damage from the mounting system to perform basic annual injury or death service and inspection The mounting system is completely adjustable so exact alignment between the burner tube and combustion chamber may be assured prior to installation into the furnace See Figure 19 and 20 The procedures described in Figures 19 and 20 should be conducted only by a qualified service technician FIGURE 19 REMOVAL OF BURNER ONLY DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING STEP 2 LOOSEN 3 BOLTS ENOUGH TO ROTATE BURNER ASSEMBLY d K 245 N K i RY STEP 3 ROTATE BURNER COUNTER CLOCKWISE PULL BURNER STRAIGH SC ULL BURNER STRAIGHT or SEET Gamme CHAMBER DURING REMOVAL BOOT OPTIONAL AND OIL LINES BURNER MIS 1834 Manual 2100 422 Page 30 REMOVE BURNER ONLY Disconnect fuel line power cord and wires from T T on primary control Loosen 3 1 4 inch bolts securi
27. NCE CHARTS CHART 1 FHO85D36E DATA Blower Static Blower See 2 FH110D48E DATA __ 4 8 3 FH110D60E DATA Blower Static 21 Hon 2 CHART 4 FLF FLR085D36E DATA ae as a hn 2 3 a 0 CHART 5 FLF FLR110D48E DATA low o 46 23 18 24 22 o 2 0 50 6 FLF FLR110D60E DATA Static aja 10 21 20 2 a 0 Manual 2100 422 Page 33 7 FLR140D60E DATA Blower Speed Blower Static oo 22 me 2 ao a so Manual 2100 422 Page 34 CHART 8 FC085D36E DATA Blower Speed Blower Static tow 2 2 a6 egene 20 win 2 a a oo SERIES WIRING DIAGRAM OO L1 L2 VALVE NER ASS Y BURNER MOTOR IGNITOR OIL VALVE BURNER MOTOR IGNITOR CAD CELL CAD CELL UNIT PRIMARY BACKUP LIMIT LIMIT CONTROL a a n BLACK NOTES IF PRIMARY LIMIT WIRES ARE REPLACED USE WIRE WITH INSUL TEMP RATING OF 200 C HEAT
28. NT BURNER MOTOR MOTOR COOLING BLOWER SPEEDS IGNITOR IGNITOR i NOM A C UNIT SPEED COLOR TONS 50 WC 2 LOW RED 775 FLF R085D36E 2 5 MED BLUE 1070 3 HIGH BLACK 1275 2 5 LOW RED 1065 3 MED LOW ORANGE 1235 3 5 MED HIGH BLUE 1415 4 HIGH BLACK 1525 3 LOW RED 1190 FLF R110D60E 3 5 MED LOW ORANGE 1400 FLR140D60E 4 MED HIGH BLUE 1640 5 HGH 2250 5 L BLOWER CAPACITOR IF PRIMARY LIMIT WRES BLOWER CAPACITOR RATING ARE TO BE REPLACED BRO UNIT MOTOR CAPACITOR TEM HATING OF FLF RO85D36E 1 3 5 370 FLF R110D48E 1 2 7 5 370 CONNECTION POINT lt BRO FLF R110D60E PAES FLR140D60E 3 4 15 370 CONNECTION POINT ONLY ONE HEATING AND COOLING SPEED BE CONNECTED DANGER ALL OTHER TAPS CONNECT TO SPARE TERMINALS FLF R110D48E RETURN AREA ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE DASHED LINES SEE CHART FOR SERVICING REPRESENT FIELD WRING HEAT AND COOL BLOWER ASSEMBLY WARE COLORS 4047 119 C enuen Ze 001 SERIES PRIMA
29. RY LIMIT WIRING DIAGRAM HEAT AREA BURNER ASS Y OO EE 12 OIL VALVE BURNER MOTOR MOTOR IGNITOR IGNITOR BACKUP LIMIT DOOR SWITCH RETURN AREA 2 IERTE BLACKk S gt BLOWER CAPACITOR BLACk BLACK n 2 5 370 lt 7 BROWN BLOWER ASSEMBLY 1 3 HP SEE CHART FOR HEAT AND COOL WARE COLORS WHITE FACTORY SETTINGS UNIT GPH INPUT BLWR SPD TEMP COLING BLWR COLOR RISE SPEED 0 55 LOW RED 60 90 HIGH BLACK FCO85D36E 0 65 LOW RED 70 100 HIGH BLACK 0 75 MED BLUE 60 90 HIGH BLACK THERMOSTAT 7 1220 OR EQUIVELANT COOLING BLOWER SPEEDS UNIT NOM A C CFM SPEED COLOR TONS 50 WC FC085D36E 2 LOW RED 775 2 5 MED BLUE 1070 3 HIGH BLACK 1230 NOTES IF PRIMARY LIMIT WRES ARE TO BE REPLACED USE WIRE WTH INSUL TEMP RATING OF 200 C Z N DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING HEATING SPEED CONNECTION POINT COOLING SPEED CONNECTION POINT ONLY ONE HEATING AND COOLING SPEED
30. SIZE Determination of oversizing can be determined prior to your adjustment If the firing rate should be reduced refer to Table 4 Short cycles and low percent on time result in higher overall pollutant emissions and lower thermal efficiency An in line oil filter will reduce service problems due to nozzle clogging screwing in pressure gauge See Figure 9 Manual 2100 422 Page 14 It should located as close possible oil burner Care should be taken to prevent air in the oil suction line Use continuous runs of copper tubing and use minimum number of joints and fittings Always use fittings Adjustment of Electrodes Adjust ignition electrodes as specified in Figure 10 Operate Burner Operate burner adjust air setting for good flame by visual observation and run for at least 10 minutes or until operation has stabilized Check Burner Pressure Bleed air from pump and nozzle piping Check pump pressure and adjust to 100 psi if necessary K Adjust Air Setting Examine the smoke CO plot and keeping in mind the curve of Figure 6 note the location of the knee where the smoke number begins to rise sharply Noting the air gate position marks adjust the air setting to a CO level 1 2 to 1 percent lower than the CO level at the knee This provides a tolerance against possible shifts in the setting over a period of time Do not increase the air setting any more
31. TION 3 al 5 3 5 5 SEN HUMIDIEIER UNUSED BLOWER MOTOR COOL SPEED CONNECTIONS LINE VOLTAGE CONNECTION COM L2 ELECTRIC AIR MIS 1819 CLEANER CONNECTION HEATING BLOWER SPEED CONNECTION COOLING BLOWER SPEED CONNECTION Manual 2100 422 Page 13 4 FURNACE DATA Field Installed Options Furnace Installed Furnace Installed Standard Heating Heating Heating SC Input Capacity Nozzle Input Capacity Nozzle Input Capacity Model Number Size BTUH BTUH Size BTUH BTUH Size BTUH BTUH 70 degree hollow spray pattern 100 PSIG pump pressure Annual fuel utilization efficiency and heating capacity based upon U S Government standard test using D O E isolated combustion rating procedure BURNER SETUP AND ADJUSTMENT PROCEDURES All oil burner installations should be performed by a qualified installer in accordance with regulations of the National Fire Protection Standard for Oil Burning Equipment NFPA31 latest edition and in complete compliance with all local codes and authorities having jurisdiction A qualified installer is an individual or agency who is responsible for the installation and adjustments of the heating equipment and who is properly licensed and experienced to install oil burning equipment in accordance with all codes and ordinances The proper installation and adjustment of any oil
32. anual 2100 422 Page 9 OIL LINE PIPING First determine whether the pipe system is to be a single line system or a two line system All connections must be absolutely air tight or you will have a malfunction of the burner When installing the piping a good oil filter should be installed close to the burner A single line system is recommended for gravity feed A typical single inside tank installations shown in Figure 6 For installation details for this and other tank configurations refer to NFPA31 latest edition All tank and pipe setups must comply with NFPA31 BECKETT AFG OIL BURNER This furnace is equipped with a high static Beckett AFG oil burner which is designed to produce adequate draft in nearly any vertically vented application The burner employs the latest time tested controls of the highest quality The controls consist of a high voltage Beckett solid state igniter a Beckett CleanCut oil pump with an integral solenoid valve and a Beckett R7184B primary control FIGURE 6 TYPICAL SINGLE INSIDE TANK INSTALLATION Vent Cap 1 1 4 Vent Pipe 01 Tank _ 2 Cap 2 Fill Pipe Return Line Guage Bushing 2 1 1 2 1 1 4 Gate Valve 3 8 X 4 nipple 3 8 x 3 8 Adapter 3 8 0 D Copper Legs either 1 1 4 x10 or 1 1 2 x10 nipples Manual 2100 422 Page 10 Fuel Tubing Bushing Ka Filter MIS 1823
33. bstructed from reaching the furnace Wm gt OPENINGS NOTE Each opening shall Dee area not less than one square inch per 1 000 BTU per hour 140 square inches per gallon per hour of the total input rating of all appliances in the enclosure TABLE 9 ALL VENTILATION AIR FROM OUTDOORS The confined space shall be provided with two Recommended permanent openings one in or near the top of the Opening enclosure and one in or near the bottom The Min Ventilati maen raon 2 Required openings shall communicate directly or by means Opening Square Inch Size Sq In of ducts with outdoors or to such spaces crawl or attic that freely communicate with outdoors See ER When directly communicating with outdoors by means of vertical ducts each opening shall FLF085D36E free area of not less than one square inch per 4 000 FLR085D36E BTU per hour 35 square inches per gallon per hour of total input rating of all appliances in the FLF110D48E enclosures If horizontal ducts are used each FLF110D60E opening shall have a free area of not less than one FLR110D48E square inch per 2 000 BTU per hour 70 square FLR110D60E inches per gallon per hour of total input of all FLR140D60E appliances in the enclosure FIGURE 13 APPLIANCES LOCATED IN CONFINED SPACES ALL AIR FROM OUTDOORS CHIMNEY OUTLET AIR DUCT WATER
34. e Port 18 Control Settings and Figure 10 Electrode 20 Heating Blower Gpeecs 26 Figure 11 Combination Air Boot Assembly 21 Table 11 Filter Sizes for Gas Furnaces 27 Figure12 All Air From Inside Building 22 Figure 13 A Air From Outdoors 23 Figure 14 Air From Outdoors Through Ventilated Attic 24 5 Figure 15 All Air From Outdoors Inlet Air Chart 1 FHO85D36E Data 33 From Ventilated Crawl Space and Chart 2 FH110D48E Data 33 Outlet Air to Ventilated Attic 24 Chart 3 FH110D60E Data 33 16 Installation of 16 25 1 Chart4 FLF FLR085D36E Data 33 27 5 FLF FLR110D48E 33 Figure 17 Typical Installation of 20x25x1 Chart6 110060 Data 33 GIE 27 Chart 7 FLR140D60E 34 18 Filter Installation Lo Boy Models 28 Chart 8 FCO85D36E Data 34 19 Removal of Burner Only 30 Figure20 Removal of Entire Combustion Chamber Mounting System 31 OTHER INFORMATION PUBLICATIONS These publicatio
35. e space containing the furnace This is to prevent drawing possible hazardous combustion products into the circulated air INSTALLING A COOLING UNIT When the furnace is used in connection with a cooling unit the furnace shall be installed parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element With a parallel flow arrangement the dampers or other means used to control flow of air shall be adequate to prevent chilled air from entering the furnace and if manually operated must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position cooling unit is an air conditioning coil heat pump coil or chilled water coil When installing a cooling unit above an FH or FL below on an FC series furnace the coil must be spaced far enough from the furnace outlet to assure proper operation of the furnace Bard supplied coils when used with Bard supplied coil cabinets are automatically positioned For top discharge FH and FL models when coils are installed without using Bard coil cabinets or coils of another brand are used the coil drain pan should be located a minimum of two 2 inches above the top of the furnace cabinet If a greater clearance is specified by the coil manufacturer then it would apply NOTE IF DRAIN PAN IS ANYTHING OTHER THAN A STEEL PAN PARTICULAR ATTENTION MUST BE GIVEN TO THE INSTALLATION INSTRUCTIONS FOR
36. elay control Do not adjust this control Check position of electrodes incorrect position will cause slow or delayed ignition Clean electrodes and nozzle Check and clean strainer in pump If oil line filter is used check filter condition If burner runs but there is no flame the fuel pump may be air bound Follow instructions for bleeding fuel pump Check and make sure the solenoid valve on the oil pump is being energized and opening BURNER STARTS OR STOPS TOO OFTEN Check heat anticipator setting on thermostat NOZZLE PRODUCES STRINGY FLAME Worn tangential grooves in nozzle Replace nozzle BASEMENT TANK HUM Occasionally with a two pipe installation there may be low return line hum Eliminate hum by installing a special anti hum valve in the return line near pump HEAVY FIRE OR PULSATING FLAME These may occur after burner starts It may be caused by a slight oil leak in the fuel pump and cannot be corrected except by replacing the pump This happens only when the burner is started CHATTERING SOUND OR HIGH PITCH NOISE This noise from motor can usually be traced to where a conduit or BX cable is fixed rigidly or attached to some part of the building Relieving this strain may eliminate noise Manual 2100 422 Page 32 PUMP SQUEALS OR CHATTERS This may be caused by air in pipes Check all joints in the oil supply pipe for leaks Check strainer in pump if dirty clean INSUFFICIENT HEAT Check
37. est The inspection door hole should be sealed when not being used to avoid leakage of air through it See Step 2 Ifthe CO level of 10 cannot be reached without exceeding No 2 smoke poor mixing of air and fuel is likely It may be necessary to replace the combustion head or try different settings Manual 2100 422 Page 15 4 FINAL 5 Measure Stack Temperature Operating unit at an excessive firing rate will generate more heat than the heat exchanger can utilize and result in unnecessary heat loss up the chimney Other causes of excessive heat loss are badly sooted heat exchanger surfaces and excessive draft The temperature of the flue gas provides an indication of these heat losses Measure flue temperature by subtracting the room air temperature from the thermometer reading Excessive stack loss is indicated of the net stack temperature during steady operation exceeds 600 F Check Ignition Check operation over repeated cycles to insure prompt ignition on starting Check Pump Cutoff Slow pump cutoff at the end of a firing cycle can cause smoke and other pollutant emissions Check for prompt pump cutoff by observing flame or by testing smoke at shutdown If poor cutoff is observed make sure air is purged from the pump and nozzle line Air trapped in the pump or nozzle line will expand when heated thus causing oil to drip into the combustion chamber after s
38. ft side low voltage thermostat entrance Left side oil line entrance for opt air boot Left side oil line entrance Oil line see burner pump inst for hookup info Air Boot knockout optional Control panel junction box in FH units Manual 2100 422 Page 8 low voltage thermostat entrance thermostat and optional AIC unit power source ee tT ee E 2 A Shut off switch if not fused power line must Include fuse or circuit breaker 7 Power Wires Right side Black HOT high voltage White NEUTRAL unit power Green GROUND entrance Right side oll MIS 1836 entrance FIGURE 5 TYPICAL FLUE INSTALLATION REQUIREMENTS FRONT FLUE LOWBOY MODEL SHOWN REPRESENTS ALL MODELS 3 5 DS Thimble INSTALLER NOTE Follow all appropriate standards for installing needed venting system Draft Regulator Be sure to follow 1 4 inch per 1 foot rise installation inst Supplied with regulator 90 Rotatable Flue Box on front flue models remove appropriate cabinet knockout Mounting screws located under flue box cover Optional Flue Locations Oil Burner Clean out Door keep closed Fresh Air Boot remove MIS 1825 rect knockout M
39. fy that the unit is properly sized Refer to Equipment Selection section on Page 2 The correct size of unit needed may be substantially smaller than the unit being replaced due to home improvements and technology advancements since the initial installation INADEQUATE SUPPLY AIR and or RETURN AIR DUCT SYSTEMS Short cycling because of limit control operation can be created by incorrectly designed or installed supply and or return air duct systems The duct systems must be designed using ASHRAE or ACCA design manuals and the equipment CFM and external static pressure ratings to insure proper air delivery capabilities On replacement installations particularly if equipment is oversized the duct systems can easily be undersized Modifications may be required to assure that the equipment is operating within the approved temperature rise range when under full rated input conditions and that no short cycling on limit controls is occurring Manual 2100 422 Page 6 DUCT WORK The air distribution system should be designed and installed in conformance with manuals published by Air Conditioning Contractors of America ACCA as set forth in Manual D or ASHRAE publications IMPORTANT When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air must also be handled by a duct s sealed to the furnace casing and terminating outside th
40. g of the return openings The upflow filter kit part numbers are FR23 for a 16x25x1 filter size and FR24 for a 20 25 1 filter size These filter kits come complete with the filter and all necessary brackets for installing on the furnace Each comes with a washable aluminum mesh filter When installing a five ton AC unit on the furnace one FR24 or Two FR23 must be used due to the high airflow requirements It is important to note that a minimum of one inch spacing is required between the filter and the unit side Do not exceed 400 fpm for fiberglass disposable type filters and 575 fpm for washable type filters See Figure 16 The counterflow filter kit part number FR25 comes with two washable filters If not installing the FR25 kit remember not to exceed 400 fpm for fiberglass disposable type filters and 575 for washable type filters See Figure 17 See Table 11 for filter sizes and quantities FIGURE 16 TYPICAL INSTALLATION OF FR26 AND FR27 FILTER RACKS 2 Filter MIS 1839 A TABLE 11 FILTER SIZES FOR OIL FURNACES FHO85D36E Hi Boy 1 16x25x1 FH110D48E Hi Boy 1 16x25x1 FH110D60E Hi Boy 1 20x25x1 FLFO85D36E FLRO85D36E 1 16 x20 x 1 Lo Boys FLF110D48E FLR110D48E FLF110D60E 1 20 20 1 FLR110D60E Lo Boys FLR140D60E 1 20 25 1 FC085D36E 0 16 20 1 FIGURE 17 TYPICAL INSTALLATION OF FR25 FILTER KIT Optional Filter _ L Unit 70 5 16
41. hutdown If poor cutoff persists repair or replace pump Also make sure the pump solenoid is working If not replace 2100 422 16 SHORT FORM ADJUSTMENT PROCEDURE Some burner service organizations may wish to perform a shorter procedure for the adjustment of oil burners The following is an example of such a short form prepared by the National Association of Oil Heat Service Managers 1 SERVICE AND CLEAN BURNER Follow company procedure to complete the cleaning and servicing Operate burner for ten minutes while tools are gathered and are cleaned CHECK DRAFT Set draft regulator if necessary Regulator should be adjusted to achieve a 02 W C over fire condition The more restricted and lengthy the flue the higher the draft necessary to obtain the accepted over fire conditions SMOKE TEST Follow the instructions of the manufacturer of the smoke tester and take a smoke sample Adjust the air to obtain a preliminary reading of about No 3 spot Then readjust the air to obtain the lowest possible reading but do not open the air adjustment more than absolutely necessary to obtain a trace or No 0 spot CO TEST Check levels This level should be between 10 and 12 Bacharach Smoke Number Bacharach Smoke Number FIGURE 8 TYPICAL SMOKE CO CHART WITH ADJUSTMENT RANGE
42. lation and Operating Instructions Lo Boy Models Filter Locations 28 Equipment Selection 2 Locating the Furnace 2 Maintenance Installing the Furnace 6 29 D ct Work EE 6 Inspect Air 29 Installing a Cooling Unit 6 Final Inspection 29 De 7 Service Hints 29 Oil Line Piping BEE 10 Combination Combustion Chamber Burner Beckett AFG Oil Burner 10 Mounting System u u u L uu Sa sz 30 Beckett CleanCut Oil PUMP 11 Remove Burner Only 31 Beckett Solid State Igniter 11 To Remove Entire Combustion Chamber Beckett R7184B Primary Control 11 Mounting System a 31 Beckett R7184B Primary Operational Guide 12 Common Causes Of Trouble 32 Burner Set up and Adjustments 14 Care of 32 Short Form Adjustment Procedure 16 Cleaning of the Heat Exchanger
43. lease the red reset button The LED will go out and then flash 1 2 3 or 4 times before returning to the run mode The CAD cell resistance must be below 1600 ohms for proper operation 1 flash 2 3flashes 4 Option Flame Quality Monitor This control is trained to recognize and remember a good flame based on initial burner set up Control then monitors the flame via the CAD cell signal for deviation in the combustion characteristics of the burner If the control senses a deviation on the high side or on the low side from the original set up condition for three consecutive cycles it will trigger an alarm circuit which can be tied to an audible local device to signal the home owner or into the home security system Upon being notified of the of the Electronic Blower Control Board EBC This furnace is equipped with an Electronic Blower Control EBC which controls all comfort air blower operations This EBC has three relays one for heating speed one for cooling speed and one which isolates the T T signal from the oil primary control This EBC is designed to be very simple and dependable This basic control allows for easy troubleshooting and maintenance As illustrated in Figure 7 all connections are well marked The Manual 2100 422 Page 12 Less than 400 ohms More than 400 and less than 800 ohms More than 800 and less than 1600 ohms More than 1600 and less than 5000 ohms
44. ng burner mounting flange Twist burner counterclockwise and pull straight back away from the furnace See Figure 19 TO REMOVE THE ENTIRE COMBUSTION CHAMBER MOUNTING SYSTEM Disconnect fuel line power cord and wires from T T on primary control Remove 6 5 16 inch bolts from around front plate Next remove 2 5 16 inch nuts from upper right and left hand corners of the front plate Pull entire assembly straight back away from furnace BE CAREFUL NOT TO TIP ASSEMBLY UP OR DOWN AS IT MAY DAMAGE THE COMBUSTION CHAMBER See Figure 20 FIGURE 20 REMOVAL OF ENTIRE COMBUSTION CHAMBER MOUNTING SYSTEM DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING 5 3 REMOVE 2 NUTS IN THE TOP LEFT AND RIGHT CORNERS OF BURNER PLATE IRR EN 7 fs 2 STEP 4 PULLBURNER ASSEMBLY STRAIGHTOUTTOPREVENT DAMAGE TO CHAMBER DURING REMOVAL CHAMBER BURNER PLATE 5 2 STEP 2 REMOVE 6 BOLTS AROUND PERIMETER OF BURNER PLATE STEP 1 DISCONNECT WIRES POWER CONNECTIONS AIR BOOT OPTIONAL AND OIL LINES TO BURNER MIS 1837 Manual 2100 422 31 CAUSES TROUBLE A CAUTION avoid accidents always open main switch OFF position when servicing the burner BURNER WILLNOT PRODUCE FLAME Check oil level gauge to see that there is sufficient oil in tank or tanks Check the burner mounted r
45. ns can help you install the furnace You can usually find these at your local library or purchase them directly from the publisher Be sure to consult current edition of each standard National Fuel Gas Code ANSIZ223 1 NFPA54 National Electrical Code ANSI NFPA 70 Standard for the Installation ANSI NFPA 90A of Air Conditioning and Ventilating Systems Standard for Warm Ar ANSI NFPA 90 Heating and Air Conditioning Systems Standard for Chimneys Fireplaces Vents NFPA 211 and Solid Fuel Burning Appliances Load Calculation for ACCA Manual J Residential Winter and Summer Air Conditioning Duct Design for Residential ACCA Manual D Winter and Summer Air Conditioning and Equipment Selection FOR MORE INFORMATION CONTACT THESE PUBLISHERS ACCA ANSI ASHRAE NFPA Air Conditioning Contractors of America 1712 New Hampshire Ave N W Washington DC 20009 Telephone 202 483 9370 Fax 202 234 4721 American National Standards Institute 11 West Street 13th Floor New York NY 10036 Telephone 212 642 4900 Fax 212 302 1286 American Society of Heating Refrigerating and Air Conditioning Engineers Inc 1791 Tullie Circle N E Atlanta GA 30329 2305 Telephone 404 636 8400 Fax 404 321 5478 National Fire Protection Association Batterymarch Park P O Box 9101 Quincy MA 02269 9901 Telephone 800 344 35
46. open and then take smoke and CO readings at progressively lower air settings as necessary to visualize the general shape of the curve The CO readings will increase as the air setting is decreased unless combustion is incomplete Do not set the air gate to give a smoke reading above No 4 or No 5 Plot the points on graph paper as in Figure 8 Usually 3 or 4 readings are enough to establish the curve In adjusting each air setting it is helpful to note the various positions of air gate at which measurements are made so that the final setting can be located quickly well tuned burner should be capable of operation with smoke not greater than No 2 and at a CO level not less than 10 If this cannot be reached check the following 1 Air leaks into the combustion chamber or heat exchanger can dilute the combustion gases and prevent normal CO readings Such leaks should be sealed with furnace cement or other high temperature sealant To check for dilution by leakage measure the CO at as high a point as possible over the fire using a stainless steel tube inserted through the fire door sample hole as described earlier for overfire draft measurements and compare this with the CO measured in the flue A difference of more than percent CO between the flue and overfire reading usually indicates air entry through leaks that have not been properly sealed Seal between the probe and inspection door sample hole during t
47. opening or openings have a total free area of not less than one square inch per 5 000 BTU per hour 28 square inches per hour of total input rating of all appliances shall be provided For combustion air options see Page 20 Combustion Air Requirements FIGURE 12 APPLIANCES LOCATED IN CONFINED SPACES ALL AIR FROM INSIDE THE BUILDING CHITIN HEATER MIS 1336 Manual 2100 422 22 TABLE 8 SQUARE FEET REQUIRED QUALIFY AS UNCONFINED SPACE Unconfined Space Minimum Area In Square Feet 8 Ceiling Height 60 000 375 80 000 500 85 000 531 105 000 656 115 000 719 120 000 750 140 000 875 145 000 906 160 000 1000 200 000 1250 ALL AIR FROM INSIDE BUILDING The confined space shall be provided with two permanent openings one near the top of the enclosure and one near the bottom Each opening shall have a free area of not less than one square inch per 1 000 BTU per hour 140 square inches per gallon per hour of the total input rating of all appliances in the enclosure freely communicating with interior areas having in turn adequate infiltration from the outside See Figure 12 Also see Table 9 on the following page for specific ventilation opening requirements for the furnace only The flow of combustion and ventilating air must not be o
48. reinstalling flue box screws VERTICAL VENTING If the unit is to be vertically vented make sure the flue pipe from the furnace to the chimney is the same size diameter as the flue outlet of the furnace which is 6 The flue pipe must have no reductions in diameter be made of a corrosion resistant material having an upward pitch of 1 4 for every foot of horizontal run and be made of material capable of handling temperatures up to 1800 F A barometric damper is supplied with the furnace and must be installed in the flue pipe observing the instructions packaged with the damper control The barometric damper opening must be located in the same atmospheric pressure zone as the combustion air inlet to the furnace The furnace must not be vented into the same chimney with any solid fuel burning appliance such as a wood burner or pellet burner Masonry chimneys must be lined with a listed system or other approved material that will resist corrosion softening or cracking from flue gas temperatures up to 1800 F See Standard for Installation of Oil Burning Equipment 31 latest edition and Standard for Chimneys 21 1 latest edition for additional information HORIZONTAL VENTING This furnace is designed to be horizontally vented through a side wall with an optional side wall power vent The recommended side wall venter is the Field Controls model number SWG 4HDS for 085 and 110 models and SWG SS for 140 models only This
49. ser to contract a combustion air to operate properly The flow of qualified installer to assure that installation combustion and ventilating air must not be obstructed is adequate and is in conformance with from reaching the furnace See Combustion Air governing codes and ordinances Requirements section The furnace area must be kept clear and free of combustible materials gasoline and other flammable vapors and liquids This unit is not designed for mobile home or trailer installations Always install furnace in a level position TABLE 1 MINIMUM CLEARANCES Minimum Installation Clearnaces Inches Minimum Service FH085D36E FH110D48E FH110D60E FLF085D36E FLR085D36E FLF110D48E FLF110D60E FLR110D48E FLR110D60E FLR140D60E FC085D36E 2 Front 24 24 24 24 24 24 24 24 24 24 24 For the first three 3 feet from plenum After three 3 feet no clearance required C Combustible flooring Noncombustible floor Maintained one side or the other to achieve filter access and or blower service Floor must be noncombustible For furnace only installation can be installed on combustible flooring only when installed on special base part no CFB7 available from factory When air conditioning coil cabinet DCB23 22 is used then use special base part no CFB23 NN N N N 24 24 24 24 24 24 24 BEER TORN
50. stallation instructions manual BECKETT SOLID STATE IGNITER This igniter differs from the traditional iron core transformer in that it produces a 14 000 volt spark instead of a 10 000 volt spark of the iron core transformer This hotter spark provides for cleaner faster ignitions Being solid state technology this igniter is less susceptible to problems caused by voltage variations It also has a greater ability to ignite cold and or inconsistent oil The solid state igniter is wired to the primary control the same as an iron core transformer BECKETT R7184B PRIMARY CONTROL The R7184B Interrupted Electronic Oil Primary is a line voltage safety rated interrupted ignition oil primary control for residential oil burners The R7184B used with a cad cell flame sensor operates the oil burner and oil valve The primary controls fuel oil senses flame controls ignition spark and is designed to notify a remote alarm circuit before going into lockout when equipped with a flame monitoring system This primary control possesses the latest technology is a very simple control to operate and provides additional troubleshooting features to ease service and reduce down time The operational guide for the R7184B primary control is provided following on Page 12 Manual 2100 422 Page 11 BECKETT R7184B PRIMARY OPERATIONAL GUIDE Pre Purge Delay 15 seconds on delay LED Codes Flashing 1 2 second on 1 2 second off system is locked
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