Baldor GLC40 Portable Generator User Manual
Contents
1. 227 1 RETURN COUNTERFLOW SPECIFICATION 30 5 8 SHEET 8 1 TOP VIEW 5 2 T KNOCKOUT FLUE KNOCKOUT OPTIONAL HIGH VOLTAGE 54 1 4 REAR ENTRANCE CLEANOUT LOW VOLTAGE ENTRANCE 7 VOLTAGE OIL ENTRANCE L D OPTIONAL OIL ENTRANCE a FRESH AIR OPTIONAL KNOCKOUT FRONT VIEW OIL ENTRANCE LEFT SIDE VIEW RIGHT SIDE VIEW SUPPLY OPENING 18 1 8 BOTTOM VIEW 19 1 8 MIS 1826 A Manual 2100 422M Page 7 of 42 INSTALLING THE FURNACE 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 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 F 6 A gauge to measure CO or INSTALLATION A typical installation is shown in Figures 4 and 5 parts of the furnace installation furnace oil tank and piping systems combustion and ventilation air venting etc must comply with NFPA31 Installation of Oil Burning Equipment latest edition This drawin2. I2OHS TIVOTH LOG T3 lt MANIN E 9395 ONNOOD INO ANO 4NIOd NOLLD3NNOO G3ads SNNCOD 016 91 NOLLOHNNOO 409009 1913 40900118 414 5 026 8 2 48 0011 414 026 8 YOLIOWdVO HOLOW 2400 SO ONLLVH TAISNI HUM 1960580 14 3d OL JAV SNLLVH HOLIOVdVO H3MOT18 SIYMUNN I SALON Mov18 H IH 3018 Q3N 39NVHO 888 413 409001 LH 414 10v18 HDIH HDIH GSW MOT 3018 39 0880u 114 2 SNOL 0109 43348 WON LINN 543345 YAMO18 4 6 8 06 09 anr8 06 09 507 474 409004 LH 4 14 xov 18 06 gt 09 4 0114 414 Ov Id a349 75 ANY HOd LuvHO 385 XTANASSV YMO Li dO Nuni3u
3. 38 32 Chart 5 FLF FLR110D48F Data 38 Figure 18 Filter Installation Lo Boy Models 22 33 Chart6 FLF FLR110D60F Data 38 Figure 19 Removal of Burner Only 35 Chart 7 FLR140D60F Data 39 Figure 20 Removal of Entire Combustion Chart 8 FCO85D36F 39 Chamber Mounting System EE 36 Manual 2100 422M Page 20f42 GETTING OTHER INFORMATION and PUBLICATIONS These publications 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 ANSI Z223 1 NFPA54 National Electrical Code ANSI NFPA 70 Standard for the Installation ANSI NFPA 90A of Air Conditioning and Ventilating Systems Standard for Warm Air ANSI NFPA 90B 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
4. 0 HEATING 240 01 PRIMARY T T SECONDS A m 7 az O Bees 3 5 5 31 5 3 4 HUMIDIFIER CONNECTION UNUSED BLOWER MOTOR 5651166 COOL SPEED CONNECTIONS LINE VOLTAGE CONNECTION COM L2 ELECTRIC AIR MIS 1819 CLEANER CONNECTION HEATING BLOWER SPEED CONNECTION COOLING BLOWER SPEED CONNECTION Manual 2100 422M Page 18 of 42 TABLE 4 FURNACE DATA Model Burner Furnace Nozzle Heating Heating Number Type Type Input Output Size Type Pump Pressure BTUH BTUH 0 75 105 000 87 000 FC085D36F AFG Counterflow 0 65 70 Hollow 100 PSIG 91 000 76 000 0 55 77 000 64 000 105 000 87 000 FHO85D36F AFG Hi Boy 0 65 70 Hollow 100 PSIG 91 000 76 000 0 55 77 000 64 000 0 85 140 000 116 000 FH110D48F NX Hi Boy 60 Solid 150 PSIG 0 75 119 000 99 000 0 85 140 000 116 000 FH110D60F NX Hi Boy 60 Solid 150 PSIG 0 75 119 000 99 000 0 75 105 000 87 000 FLF085D36F AFG Lo Boy 0 65 70 Hollow 100 PSIG 91 000 76 000 0 55 77 000 64 000 0 85 140 000 116 000 FLF110D48F NX Lo Boy 60 Solid 150 PSIG 0 75 119 000 99 000 0 85 140 000 116 000 FLF110D60F NX Lo Boy 60 Solid 150 PSIG 0 75 119 000 99 000 075 105 000 87 000 FLR085D36F AFG Lo Boy 0 65 70 Hollow 100 PSIG 91 000 76 000 0 55 77 000 64 000 1 00 140 000 116 000 FLR110D48F AFG Lo Boy 70 Hollow 100 PSIG 0 85 119 000 99 000 1 00 140 000 116 000 FLR110D60F AFG Lo Boy 70 Hollow 100 PSIG 0
5. 2100 422 39 of 42 FH SERIES WIRING DIAGRAM NER ASS Y 1 L2 VALVE BURNER MOTOR IGNITOR OIL VALVE BURNER MOTOR IGNITOR CAD CELL CAD CELL UNIT PRIMARY BACKUP LIMIT LIMIT BLACK BLACK WHITE CONTROL NOTES IF PRIMARY LIMIT WIRES ARE TO BE REPLACED USE WIRE WITH INSUL TEMP RATING OF 200 HEATING SPEED CONNECTION POINT COOLING SPEED CONNECTION POINT ONLY ONE HEATING AND COOLING SPEED CAN BE CONNECTED ALL OTHER TAPS CONNECT TO SPARE TERMINALS DASHED LINES 5 N REPRESENT FIELD WIRING NDANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING HOT gt gt NEUTRAL HEAT EXCHANGER AREA lt LOW VOLTAGE HIGH VOLTAGE FIELD WHITE PLUG 3 BLOWER CAPACITOR RETURN BLOWER ASSEMBLY YELLOW BLUE GREEN PLUG 2 RANSFORME IL 120V COM BLACK SEE CHART FOR HEATING AND COOLING WIRE COLORS GROUND L N WARNING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERI
6. 10 5 10 5 12 5 12 5 12 5 5 6 0 Manual 2100 422M Page 9 of 42 WARNING ALL WIRING MUST CONFORM TO THE NATIONAL ELECTRIC CODE AND ALL LOCAL CODES Left side high voltage unit power entrance Left 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 422M Page 100142 FIGURE 4 TYPICAL UNIT SETUP FLF UNIT SHOWN Right side high voltage unit power entrance Right side oil line entrance 4 x e 3 N low voltage thermostat entrance To thermostat and optional unit power Source S hut off switch if not fused power line must include fuse or circuit breaker Power Wires Black HOT White NEUTRAL Green GROUND 15 1836 FIGURE 5 TYPICAL FLUE INSTALLATION REQUIREMENTS FRONT FLUE LO BOY MODEL SHOWN REPRESENTS ALL MODELS Thimble INSTALLER NOTE Follow all appropriate standards for installing needed venting system Draft Regulator Be sure to follow installation inst supplied with regulator 1 4 inch per 1 foot rise 90 Rotatable Flue Box on front flue mo
7. YOLON SANA c1 TI ASSY Mov18 06 09 _ 06 09 80100 dAaL HAWIS 51H 39209808 474 SONILLAS X3 INVHOVIG Salas 4 73 2100 422M Manual Page 41 of 42 ONMM CT T3IJ 5 S IVNIATHALL lt lt _ TOulLNOD Ov IH amp duvdS OL LOS3NNOO L ONIDINYAS 740434 YAWOd LDJNNODS k XDOHS INOTH LOG V ANO 5 SNNOOD 5 2400 JO ONLY TNSNI HUM HIM C3ov 1ddu OL SJAM UNN ANI Yd SALON H IH 3018 80100 43385 Sa3adS 395998094 SNO AINVTAAINOA YO 1 H IH 395998093 _ SONLLL3S ZLLIHAA SYO IOO JAM 1009 ANY LVH LYVWHD 385 dH D ATANASSV H3MO 18
8. When installing the furnace be sure to provide adequate space for easy service and maintenance Locate the furnace as close to the chimney as practical giving consideration to the accessibility of the oil burner controls and blower for service Allow a minimum of 24 inches at front of furnace for servicing oil burner Allow adequate room for filter and blower maintenance Clearance from combustible material as stated on the furnace and repeated in Table 1 must be maintained For damp basement installations a raised concrete pad 15 recommended This will help keep the bottom of the furnace dry and reduce the risk of rusting An oll burner must have a generous supply of combustion air to operate properly The flow of combustion and ventilating air must not be obstructed from reaching the furnace See Combustion Air 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 FHO85D36F FH110D48F FH110D60F FLFO85D36F FLRO85D36F FLF110D48F FLF110D60F FLR110D48F FLR110D60F FLR140D60F FCO85D36F NNN gt 7 00 r
9. oexez 29 92 58 LX OZ x QL 62916 sceo 92 ez 9 pesn u4n3es Ajiddns 3uBreH f V IPPON 5 jeuiqe 3 SNOISN3WIG S13GON Y 474 318VL SNOISN3MIG 57 4 73 y mom Nna 444 5 NOLLVOIHIDdS OTT H T4 T14 2100 422 Manual Page 5 of 42 YV VIBL SIA MAN ACIS MIA MIN JAIS 14811 LOSE J i A 1 1 SNIN3dO TNNOLLdO RE SR PER RR d A 3ONvuIN3 o 4 35X LIOANNO 1 2 65 G 3ONVHIN3 H ama X j n ONNI LJ3JJHS NOLLVOIJIIDdS S980HJ SNOISN3MIG S TAGOW 2100 422 Page 60142 FIGURE 3 FC085 MODEL DIMENSIONS
10. 1 16x25x1 FH110D48F Hi Boy 1 16x25x1 FH110D60F Hi Boy 1 20x25x1 FLFO85D36F FLRO85D36F 1 16x20 x2 Lo Boys FLF110D48F FLR110D48F FLF110D60F 1 FLR110D60F Lo Boys FLR140D60F Loo 1 20 25 2 FC085D36F 2 Counterflow 20x20x2 16 x 20 x 1 FIGURE 17 TYPICAL INSTALLATION OF FR25 FILTER KIT Optional Filter Box Unit 10 5 16 i MIS 1841 Manual 2100 422M Page 320142 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 FLE FLRO85 16x20x2 FLE FLR110 20x20x2 FLR140 20 x25x2 STEP 3 SLIDE FILTER OUT TOWARDS BLOWER DOOR 2 gt lt gt STEP 2 REMOVE BLOWER DOOR STEP 1 BY PULLING OUT ON UNFASTEN SWELL SWELL LATCHES AND LATCHES BY PULLING MIS 1835 A TILTING OUTWARDS HANDLES OUTWARD Manual 2100 422M Page 33 of 42 MAINTENANCE LUBRICATION No lubrication 15 required for either the burner or the blower motor Both are permanently lubricated INSPECT AIR FILTER Replace filters before each heating s
11. full 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 15 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 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 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
12. 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 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 Manual 2100 422M Page 37 of 42 BLOWER SYSTEM RESISTANCE CHARTS CHART 1 FH085D36F DATA CHART 4 FLF FLRO85D36F DATA as 2 o o so 2 FH110D48F DATA tow oo oe 08 16 zx 32 ign 16 25 24 oz ao a0 so CHART 3 FH110D60F DATA Blower Speed Blower Static CHART 5 FLF FLR110D48F DATA tow os e ss 50 oo 35 zx 35 24 24 42 me oz ao a0 so CHART 6 FLF FLR110D60F DATA Blower Speed Blower Static tow oe a ay 3s 21 20 2 50 2100 422 380f42 7 FLR140D60F DATA Blower Speed Blower Static __ 61 tow CHART 8 FC085D36F DATA __ s 2 e 26 36 a6 4 50
13. 0 14 5 14 0 13 5 13 0 12 5 12 0 11 5 11 0 10 5 10 0 TABLE 6 NO 2 FUEL OIL EFFICIENCY CHART STACK TEMP DEGREES TABLE 7 RECOMMENDED START UP SETTINGS Nozzl Air Model Burner Style oce Air Band Shutter Adjustment Number Part No Setting Setti Plate Size Type Pump Pressure etung Setting 0 75 0 6 FC085D36F AFG 9020 034 0 65 70 Hollow 100 PSIG 0 5 0 55 5 0 75 0 6 FH085D36F AFG 9020 034 0 65 70 Hollow 100 PSIG 0 5 0 55 0 5 0 85 375 FH110D48F NX 9020 039 60 Solid 150 PSIG 0 75 3 0 85 375 FH110D60F NX 9020 039 60 Solid 150 PSIG 0 75 3 0 75 0 6 FLF085D36F AFG 9020 034 0 65 70 Hollow 100 PSIG 0 5 0 55 0 85 Ste FLF110D48F NX 9020 039 60 Solid 150 PSIG 0 75 3 0 85 SWS FLF110D60F NX 9020 039 60 Solid 150 PSIG 0 75 3 0 75 0 6 FLRO85D36F AFG 9020 036 0 65 70 Hollow 100 PSIG 0 0 55 1 00 2 10 FLR110D48F AFG 9020 037 70 Hollow 100 PSIG 0 85 0 8 1 00 2 10 FLR110D60F AFG 9020 037 70 Hollow 100 PSIG 0 85 8 1 25 0 8 FLR140D60F AFG 9020 038 70 Hollow 100 PSIG 1 10 6 Manual 2100 422M Page 24 of 42 Factory Installed Nozzle Also shown are optional approved nozzle size type O 200 250 300 350 40
14. 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 15 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 OVERSIZE Determination of oversizing can be determined prior to your adjustment Ifthe firing rate should be reduced refer to Table 4 Short cycles and low percent time result in higher overall pollutant emissions and lower thermal efficiency An in line oil filter will reduce service problems due to nozzle clogging The filter should be located as close as possible to the oil burner Care should be taken to prevent air leakage in the oil suction line Use continuous runs of copper tubing and use minimum number of joints and fittings Always use
15. 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 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 38 39 for additional information WIRING FIELD WIRING wiring must conform to the National Electrical FACTORY WIRING Code and all local codes A separate fuse or breaker All units are fully factory wired Multispeed blowers should be used for the furnace are factory wired on high speed for cooling 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 is 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 Amps 159 122 14 2 7 3 7 3 12 2 12 2 14 2 14 2 14 2 7 3 Volts HZ PH FLA 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 115 60 1 FHO85D36F FH110D48F FH110D60F FLFO85D36F FLRO85D36F FLF110D48F FLR110D48F FLF110D60F FLR110D60F FLR140D60F FCO85D36F 1 3 1 2 3 4 1 3 1 3 1 2 1 2 3 4 3 4 3 4 1 3 5 6 10 5 12 5 1 7 1 7 1 7 17 17 17 1 7 1 7 1 7 1 7 1 7
16. Low 1225 60 90 Medium High FLR140D60F AFG 70 Hollow 100 PSIG 200 1 10 60 90 Medium Low Factory Set Point Manual 2100 422M Page 31 of 42 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 cutting of the return openings The upflow filter kit part numbers are FR23 for a 16x25x1 filter size and FR24 for a 20x25x1 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 AIR FILTERS TABLE 11 FILTER SIZES FOR OIL FURNACES FH085D36F Hi Boy
17. OUTER AIR BOOT AND SECURE FLANGE TO UNIT MAKE ALL SETTINGS MIS 1833 ACCORDING TO MANUAL FOR AIR BOOT Note This accessory is not currently available for Bard Models FHII0D48F FH110D60F FLF110D48F FLF110D60F with NX Burners Manual 2100 422M Page 260142 APPLIANCES LOCATED IN 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 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 a room 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 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
18. Single Inside Reserve Aif 24 Tank Installation 12 Table 6 No 2 Fuel Oil Efficiency Chart 24 Figure 7 Electronic Blower Control 18 Table 7 Recommended Start Up Settings 24 Figure 8 Typical Smoke CO Characteristic 22 Table 8 Sq Ft Required as Figure 9 Pressure Gauge Connection to Unconfined Space 27 Bleed Pott ee 23 Table9 Minimum Ventilation Openings 28 Figure 10 Electrode Adjustments 25 Table 10 Temperature Rise Ranges Limit Figure 11 Combustion Air Boot Assembly 26 Control Settings and Figure 12 All Air From Inside Building 27 Heating Blower Speeds 31 Figure 13 All Air From Outdoors 28 Table 11 Filter Sizes for Oil Furnaces 32 Figure 14 AIL Air From Outdoors Through Ventilated Attic 29 Figure 15 AIL Air From Outdoors Inlet Air From Ventilated Crawl Space and CHARTS Outlet Air to Ventilated Attic 29 Chart 1 FHO85D36F 38 Figure 16 Typical Installation of FR26 and FR27 Chart2 FH110D48F Data 38 Filter Rack 0 32 Chart 3 FH110D60F Data 38 Figure 17 Typical Installation of FR25 Filter 4 FLF FLRO85D36F Data
19. for cooling speed and one which isolates the signal from the oil primary control NOTE If a jumper wire is placed across and W prior to turning on power to the unit and then power is applied the comfort air blower will start and run for the ignition period and through the entire call for heat Once this call for heat is satisfied the blower will function according to the regular blower on and blower off delay cycles 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 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 Manual 2100 422M Page 17 of 42 FIGURE 7 ELECTRONIC BLOWER CONTROL THERMOSTAT TRANSFORMER 24V CONNECTIONS SECONDARY CONNECTIONS 24 8 W G Y lalelelele 18 18 saw ruse HEATING BLOWER OFF DELAY ADJ USTMENT 7 IN SECONDS e s 150 22
20. 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 10 TEMPERATURE RISE RANGES LIMIT CONTROL SETTINGS AND HEATING BLOWER SPEEDS Model Bumer Nozzle Maximum Heating Rise Ranges Outlet Air Blower Number Type o Size Type Pump Pressure Temp F Speed 0 75 60 90 Medium FC085D36F AFG 0 65 70 Hollow 100 PSIG 70 100 200 Low 0 55 70 100 Low 0 75 60 90 Medium Low FH085D36F AFG 0 65 70 Hollow 100 PSIG 70 100 200 Low 0 55 70 100 Low 0 85 60 90 Medium Low FH110D48F NX 60 Solid 150 PSIG 200 0 75 70 100 Low 0 85 60 90 Medium FH110D60F NX 60 Solid 150 PSIG 200 0 75 60 90 Low 0 75 60 90 Medium FLF085D36F AFG 0 65 70 Hollow 100 PSIG 60 90 200 Low 0 55 60 90 Low 0 85 60 90 Medium High FLF110D48F NX 60 Solid 150 PSIG 200 0 75 60 90 Medium Low 0 85 60 90 Medium High FLF110D60F NX 60 Solid 150 PSIG 200 0 75 60 90 Medium Low 0 75 60 90 Medium FLRO85D36F AFG 0 65 70 Hollow 100 PSIG 60 90 200 Low 0 55 60 90 Low 1 00 60 90 Medium High FLR110D48F AFG 70 Hollow 100 PSIG 200 0 85 60 90 Medium Low 1 00 60 90 Medium High FLR110D60F AFG 70 Hollow 100 PSIG 200 0 85 60 90 Medium
21. of Trouble 37 Beckett R7184B Primary Operational Guide 14 Care of Finish 37 Beckett GeniSys 7505 14 17 Cleaning of the Heat 37 Burner States Reset Button Op Priming the Pump Cad Blower System Resistance Charts 38 39 Cell Resistance Indicator Reset Restricted Lockout Wiring Dlagrams tette ntt 40 42 Burner Set up and Adjustments 19 20 amp 21 Short Form Adjustment Procedure 21 Combustion Air Requirements 25 Louvers and Grilles 30 Venting Options 30 ETT 30 TABLES FIGURES Table 1 Minimum Clearances 4 Figure 1 FLF R Models Dimensions 5 Table 2 Dimensions FLF R Models 5 Figure 2 FH Models Dimensions 6 Table3 Electrical 9 Figure 3 FC Models Dimensions 7 Table A Reset Button Operation 15 Figure 4 Typical Unit Setup FLF 10 Table B Status Lights 15 Figure 5 Typical Flue Installation Table 4 Furnace Data 19 Requirements FLF 11 Table 5 Correlation of of CO and Figure 6 Typical
22. r 34v39v Nuni3u HOLINOI YOLON NOS NOH SALIVA c1 E ASSY V3uv INVHOVIG 531495 24 2100 422 42 0142
23. 0 450 500 550 600 650 700 750 800 1 89 6 88 4 87 3 86 2 85 1 84 0 82 9 817 80 6 79 5 78 4 77 3 76 2 14 7 2 89 4 88 2 87 0 85 9 84 7 83 6 82 4 81 2 80 1 78 9 77 7 76 6 75 4 14 0 3 89 2 87 9 86 7 85 5 84 3 83 1 81 9 80 7 79 4 78 2 77 0 75 8 74 6 13 2 4 88 9 87 7 86 4 85 1 83 8 82 6 81 3 80 0 78 7 77 5 76 2 74 9 73 6 12 5 5 88 7 87 3 86 0 84 6 83 3 82 0 80 6 79 3 77 9 76 6 75 3 73 9 72 6 11 7 6 88 4 87 0 85 5 84 1 82 7 81 3 79 9 78 5 77 0 75 6 74 2 72 8 71 4 11 0 7 88 0 86 5 85 0 835 82 0 80 5 79 0 77 5 76 0 745 73 0 71 5 70 0 10 3 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 Figures 10A amp 10B GUN ASSEMBLY ADJUSTMENT The gun assembly can be adjusted 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 a certain amount of excess air is required as well to ensure complete combus
24. 42 NOTE Each air duct opening shall have a free area of not less than one square inch per 2 000 BTU per hour 70 square inches per gallon per hour of the total input rating of all appliances in the enclosure FIGURE 14 APPLIANCES LOCATED IN CONFINED SPACES ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC CHIMNEY VENTILATION LOUVERS EACH END OF ATTIC NOTE The inlet and outlet air openings shall each have a free area of not less than MET AI DUCT one square inch per 4 000 BTU per hour R DUC ENDS FT ABOVE FLOOR 35 square inches per gallon per hour of the total input rating of all appliances in the enclosure FURNACE WATER HEATER 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 VENTILATION LOUVERS END OF ATTIC NOTE The inlet and outlet air openings shall each have a free area of not less than one square inch per 4 000 BTU per hour 35 square inches per gallon per hour of the total input rating of appliances in the enclosure WATER HEATER ALTERNATE AIR INLET VENTILATION LOVERS FOR UNHEATED CRAWL SPACE MIS 1339 Manual 2100 422M Page 29 of 42 LOUVERS AND GRILLES In calculating free area for ventilation and combustion air requirem
25. 85 119 000 99 000 125 175 000 145 000 FLR140D60F AFG Lo Boy 70 Hollow 100 PSIG 1 10 154 000 127 000 Factory Installed Nozzle Also shown are optional approved nozzle size type 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 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 screwing in pressure gauge See Figure 9 Manual 2100 422M Page 19 of 42
26. AL HAVING A TEMP RATING OF AT LEAST 105 C EXCEPT PRIMARY LIMIT WIRES SEE NOTE 1 COND _ UNIT THERMOSTAT 24V T87F Q539A1220 CONN OR EQUIVELANT OPTIONAL AIR COND SETTING NOM COOLING BLOWER Tong SPEED COLOP 2 LOW RED 21 2 3 HIGH BLACK 212 LOW RED MED LOW ORANGE MED HIGH BLUE 4 HIGH BLACK LOW RED MED LOW ORANGE MID HIGH BLUE HIGH BLACK 50 WC 730 900 1160 1020 1280 FHO85D36F CONTROL FH110D48F FH110D60F FACTORY SETTINGS HEATING BLOWER COOLING BLOWER cpu SPEED COLOR SPEED COLOR LOW RED FHO85D36F LOW RED 702100 0 75 MED BLUE 60 90 0 85 LOW RED HIGH BLACK 70 100 FHTTODAGE MED LOW ORANGE 60 90 0 85 LOW RED 60 90 EM ODGOF 1__ MED LOW ORANGE 60290 BLOWER CAPACITOR RATING UNT MOTOR CAPACITOR 5 36 1 3 5 370 10048 1 2 7 5 370 4047 118 110060 3 4 15 370 2100 422 40 of 42 ql SdNrTO3HSVvG S IVNIATHALL OL LOJNNOO WHIO ONDAS YMOd 1
27. CTION e Any time the burner is running press and hold the reset button to disable the burner The burner will remain off as long as the button is held Burner 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 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 typically 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 QS7100F 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
28. E 6 BOLTS AROUND PERIMETER STEP 4 PULL BURNER ASSEMBLY _ OF BURNER PLATE STRAIGHT OUT TO PREVENT DISCONNECT WIRES POWER CONNECTIONS A R DURING REMONAL BOOT OPTIONAL AND OIL LINES TO BURNER Mis 1837 A Manual 2100 422M Page 36 of 42 COMMON CAUSES OF TROUBLE CAUTION To avoid accidents always open main switch OFF position when servicing the burner BURNER WILL NOT PRODUCE FLAME Check oil level gauge to see that there is sufficient oil in tank or tanks Check the burner mounted relay 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 A STRINGY FLAME Worn tangential grooves in nozzle Replace nozzle BASEMENT TANK HUM Occasionally with a two pipe installation there may be a 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 i
29. 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 3555 Fax 617 984 7057 Manual 2100 422M Page 3 of 42 INSTALLATION and OPERATING INSTRUCTIONS EQUIPMENT SELECTION An accurate heating load calculation must be conducted using American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE or Air Conditioning Contractors of America ACCA manuals Do not add a large safety factor above the calculated value If the calculated heating load requirement exceeds the heating capacity rating of a given model use only the next larger size available Never increase by any more than absolutely necessary based upon available equipment heating capacities Always select based upon heat capacity output never use input capacities NOTE It is the personal responsibility and obligation of the purchaser to contract a qualified installer to assure that installation is adequate and is in conformance with governing codes and ordinances LOCATING THE FURNACE
30. OIL FURNACE INSTALLATION INSTRUCTIONS MODELS FH085D36F FH110D48F FH110D60F FLF085D36F FLF110DA8F FLF110D60F FLRO85D36F FLR110D48F FLR110D60F FLR140D60F 085 6 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 WARRANT Y A WARNING CARBON MONOXIDE POISONING HAZARD FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PERSONAL INJURY OR DEATH Carbon Monoxide is invisible orderless and toxic Bard Manufacturing recommends a carbon monoxide alarm in your home even if you do not own a gas appliance Locate the carbon monoxide alarm in the living area of your home and away from doorways to attached garages Follow the alarm
31. SSEMBLY e A AN eH 1 J 2 Qd Nd 245 A 2x STEP 4 PULL BURNER STRAIGHT OUT TO PREVENT DAMAGE TO CHAMBER DURING REMOVAL STEP 3 ROTATE BURNER COUNTER CLOCKWISE STEP 1 DISCONNECT T T WIRES POWER CONNECTIONS AIR BOOT OPTIONAL AND OIL LINES TO BURNER MIS 1834 Manual 2100 422M Page 35 of 42 TO REMOVE BURNER ONLY TO REMOVE THE ENTIRE COMBUSTION CHAMBER MOUNTING SYSTEM Disconnect fuel line power cord and wires from T T on primary control Loosen 3 1 4 inch bolts securing Disconnect fuel line power cord and wires from T T burner mounting flange Twist burner on primary control Remove 6 5 16 inch bolts from counterclockwise and pull straight back away from the around front plate Next remove 2 5 16 inch nuts furnace See Figure 19 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 NDANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING STEP 3 REMOVE 2 NUTS IN THE TOP LEFT AND RIGHT CORNERS OF BURNER PLATE 72 d BURNER S PLATE 6 4 276 LIA Mf y gt 9 STEP 2 REMOV
32. all appliances shall be provided For combustion air options see Page 25 Combustion Air Requirements FIGURE 12 APPLIANCES LOCATED IN CONFINED SPACES ALL AIR FROM INSIDE THE BUILDING 7 CHIMNEY 2 m WATER OPENINGS HEATER 5 0 15 1330 8 SQUARE FEET REQUIRED QUALIFY AS UNCONFINED SPACE Unconfined Space Minimum Area In Square Feet 8 Ceiling Height 60 000 375 80 000 500 85 000 581 105 000 656 115 000 719 120 000 750 140 000 875 145 000 906 160 000 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 obstructed from reaching the furnace NOTE Each opening shall have a free area of not less than one square inch per 1 000 BTU per hour 140 sq
33. alve to prevent oil spray from accumulating in the combustion chamber during the air bleed procedure Ensure that all bubbles and froth are purged from the oil supply system before tightening the pump air bleed valve Prepare the burner for priming by fully opening the pump bleed port and attaching a clear plastic hose over the bleed port fitting Use a suitable container to collect purged oil Initiate a call for heat After the burner starts press and hold the reset button for 15 seconds until the yellow LED turns on This indicates that the button has been held long enough Release the reset button The yellow LED will turn off and the burner will start up again Manual 2100 422M Page 160f42 5 At burner start up tap the reset button within the first 10 seconds of the ignition cycle This will transition the control to a dedicated Pump Prime mode during which the motor igniter and valve are powered for four minutes The yellow LED will be on 6 Bleed the pump until all froth and bubbles are purged If desired hold the reset button for at least one second to exit Pump Prime mode and return to Standby 7 Atthe end of 4 minutes the yellow LED will turn off and the control will automatically return to standby mode 8 If prime is not established during the four minute pump prime mode return to step 5 to re enter Pump Prime mode Repeat steps 5 through 7 until the pump is fully primed and the oil i
34. aterial 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 Manual 2100 422M Page 300f42 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 NFPA31 latest edition and Standard for Chimneys NFPA211 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 5S for 140 models only This 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
35. button wits below state Button Click Button Hold Button Hold press lt 1 second press gt 1 second press 15 seconds Valve on Delay Trial for Ignition Son Bip Poe see Below Disable the Burner Enables Pump Priming After the reset button has been held for 15 seconds the button can then be tapped during the next ignition sequence to enter Pump Prime mode Ignition Carryover Any time the burner is running Yellow LED flashes to press and hold the reset button to disable the burner The burner will remain off as long as the button is held indicate cad cell resistance Run igniter is shut off See Cad Cell Resistance Indicator for table of resistance values Motor Off Delay Standby No action TABLE B STATUSLIGHTS On Continuously Restricted hard Lockout Soft Lockout Flame Detected Could be flame or stray light Recycle Control is in Pump Prime mode or Cad Cell resistance See Cad Cell Resistance Indicator Reset button currently held for 15 seconds section for table of resistance values Manual 2100 422M Page 15 of 42 PRIMING THE PUMP N WARNING Hot Gas Puff Back amp Heavy Smoke Hazard Failure to bleed the pump properly could result in unstable combustion hot gas puff back and heavy smoke Do not allow oil to spray into a hot combustion chamber while bleeding air from the pump Install a gauge in the nozzle discharge port tubing or fully open the pump bleed v
36. dels remove appropriate cabinet knockout Mounting screws located under flue box cover Flue Box Cover Optional Flue Locations o gt 3 53 O 5 Oil Burner Clean outDoor Fresh keep closed Air Boot remove MIS 1825 P d rect knockout Note This accessory is not currently available for Bard Models 110 48 FH110D60F FLF110D48F FLF110D60F with NX Burners Manual 2100 422M Page 11 of 42 OIL LINE PIPING First determine whether the pipe system 15 to be a single line system or a two line system 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 tank and pipe setups must comply with NFPA31 BECKETT AFG OR NX OIL BURNER This furnace is equipped with a high static Beckett AFG or Beckett NX oil burner which 15 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 a
37. eason 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 1 Determine that all parts ofthe 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 s instructions included with the control Following is the method we recommend in checking the safety switch in this primary c
38. ents 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 Ifthe 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 1s 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 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 15 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 m
39. er 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 if the net stack temperature during steady operation exceeds 600 F N Check Ignition Check operation over repeated cycles to insure prompt ignition on starting O 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 1s 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 shutdown If poor cutoff persists repair or replace pump Also make sure the pump solenoid is working if not replace 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 2 CHECK DRAFT Set draft regulator if necessary Regulator should be adjusted to achieve a 02 W C
40. flare 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 nameplate pump pressure if necessary 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 take a smoke Manual 2100 422M Page 20 of 42 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
41. g 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 verify that the unit is properly sized Refer to Equipment Selection section on Page 4 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 422M Page 80142 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
42. manufacturer s instructions included with the alarm Bard Manufacturing Company Inc Manual 2100 422M Bryan Ohio 43506 Supersedes 2100 422L gt File VOL 1 TAB 3 Since 1914 Moving ahead just as planned Date 11 21 14 CLIMATE CONTROL SOLUTIONS Page 1 of 42 5 Getting Other Information and Publications 3 Filters Lo Boy Models Filter Locations 33 Installation and Operating Instructions Equipment Selection 4 Maintenance Locating the Furnace eater ninos 4 LW FICATION eoo 34 Installing the Furnace 8 Filter toten 34 Dutt m 8 Final Inspection and Test 34 Installing a Cooling 8 Service 34 9 Combination Combustion Chamber Burner Oil Line Piping 12 Mounting System 35 Beckett AFG Oil Burner 12 amp 13 To Remove Burner Only 36 Beckett CleanCut Oil 13 To Remove Entire Combustion Chamber Beckett Solid State 13 Mounting System sss 36 Beckett R7184B Primary Control 13 Common Causes
43. n integral solenoid valve and a Genisys 7505 primary control FIGURE 6 TYPICAL SINGLE INSIDE TANK INSTALLATION Vent Cap 1 1 4 Vent P ipe 01 Tank 2 2 Fill Pipe Return Line Guage Bushing 2 x 1 1 2 or 1 1 4 Gate Valve 3 8 X 4 nipple 3 8 x 3 8 Adapter 3 8 O D Copper Fuel Tubing Legs either 1 1 4 x10 or 1 1 2 x10 nipples Manual 2100 422M Page 120f42 Bushing P F ilter MIS 1823 These controls were selected for their proven high quality dependability and serviceability With proper maintenance this burner assembly will provide many years of reliable service All units 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 ZAWARNING 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 Beckett AFG Oil Burner how each operates how to set up the burner and how to troubleshoot problems
44. n 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 ofthe building Relieving this strain may eliminate noise 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 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 15 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 ANWARNING 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
45. ol possesses the latest technology is avery simple control to operate and provides additional troubleshooting features to ease service and reduce down time The operational guide for the Genisys 7505 primary control is provided following on Page 14 Manual 2100 422M Page 13 of 42 BECKETT GENISYS MODEL 7505 MIS 2491 PRIMARY OPERATIONAL GUIDE BECKETT GENISYS 7505 Sequence of Operation Pump prime Standby e Valve on Trial for dela ianition BURNER STATES 1 Standby The burner is idle waiting for a call for heat 2 Valve On Delay Prepurge The igniter and motor are on while the control delays turning on the oil solenoid valve for the programmed time 3 Trial for Ignition The fuel valve is opened A flame should be established within the factory set trial for ignition time lockout time 4 Lockout The control has shut the burner down for one of the following safety reasons The trial for ignition lockout time expires without flame being established The cad cell detects flame during Valve On Delay The Recycle mode 30 second time budget expires see Recycle section for complete explanation of recycle time budget Manual 2100 422M Page 140f42 If the control locks out three times without completing a successful call for heat the control enters Restricted Hard Lockout and must be reset by a technician Hold the reset button for 15 seconds until the red light shuts off to
46. ontrol 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 on 1 2 second off Ignition and motor stop and oil valve closes Manual 2100 422M Page 340f42 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 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 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 95 Make sure electrical supply to furnace is on and fuses are not blown or circuit breakers tripped 4 Reset safety switch of burner
47. over fire condition The more restricted and lengthy the flue the higher the draft necessary to obtain the accepted over fire conditions 3 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 4 CO TEST Check CO levels This level should be between 10 and 12 Manual 2100 422M Page 21 of 42 FIGURE 8 TYPICAL SMOKE CO CHART WITH ADJUSTMENT RANGE High Air Settings Low 8 CO Curve from plotted points Plotted point 5 adjustment 4 Tolerance to knee Best air 2 setting Plotted point Plotted point Knee 0 6 8 10 12 14 Percent CO in Flue Gas Technician s plotting area 6 4 2 0 6 8 10 12 14 Percent CO in Flue Gas MIS 1827 Manual 2100 422M Page 220f42 FIGURE 9 PRESSURE GAUGE CONNECTION BLEED PORT Remove Bleed Portto attach pressure guage Pressure Gauge MIS 1660 TABLE 5 CORRELATION OF PERCENT OF CO AND RESERVE AIR Reserve Air Approx 0 0 0 0 Carbon Dioxide 15 4 15
48. primary control N 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 5 Make sure air filters are in place and are clean 6 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 COMBINATION COMBUSTION CHAMBER BURNER MOUNTING SYSTEM 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 designed to remove the burner assembly independently from the mounting system to perform basic annual 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 ANWARNING The procedures described in Figures 19 and 20 should be conducted only by a qualified service technician Improper servicing could cause electric shock hazard fires or explosion resulting in damage injury or death FIGURE 19 REMOVAL OF BURNER ONLY NDANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING STEP 2 LOOSEN 3 BOLTS ENOUGH TO ROTATE BURNER A
49. reset from Restricted Lockout 5 Ignition Carryover Once flame is established the igniter remains on for 10 additional seconds to ensure flame stability 6 Run The flame is sustained until the call for heat is satisfied The burner is then sent to Motor Off Delay Postpurge if applicable or it is shut down and sent to Standby 7 Recycle If the flame is lost while the burner is firing the control shuts down the burner enters a 60 second recycle delay and then repeats the ignition sequence The control will continue to Recycle each time the flame is lost until the accumulated oil flow without flame time reaches 30 seconds at which point the control will go into lockout This feature prevents excessive accumulation of oil in the appliance firing chamber 8 Motor Off Delay If applicable the fuel valve is closed and the control delays turning the motor off for the set motor off delay time before the control returns to standby 9 Pump Prime The igniter and motor are on with the oil valve open for up to 4 minutes During Pump Prime mode the cad cell is disregarded allowing the technician to prime the pump without having to jumper the cad cell RESET BUTTON OPERATION Table A explains what action the control will take when the reset button is pressed for different lengths of time during the various burner operating states RESET BUTTON OPERATION Pushing the Reset button will ein the Reset
50. s free of bubbles 9 Terminate the call for heat and the control will resume normal operation CAD CELL RESISTANCE INDICATOR During the burner Run state tap the reset button less than 1 second to check the cad cell resistance range The yellow LED will flash 1 to 4 times depending on the amount of light detected by the cad cell See chart below Flame Detection Range Normal 0 400 ohms Normal 400 800 ohms Normal 800 1600 ohms Limited 1600 ohms Lockout RESETTING FROM RESTRICTED LOCKOUT f the control locks out three times without a satisfied call for heat or due to other significant events such as a relay contact weld the Lockout becomes restricted in order to prevent repetitious resetting by the homeowner CAUTION Before resetting the control from restricted lockout state troubleshoot the heating system for the root cause s of lockout and make necessary repairs or adjustment to ensure a safe start condition Then to reset hold the button down for 15 seconds until the red light turns off and the yellow LED turns on Observe at least one full control sequence of operation from startup to shutdown Simulate a flame failure lockout by following the procedure within this manual If the operation is erratic or not to specifications then replace the control Always verify the control functions according to all specifications before leaving the installation site DISABLE FUN
51. 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 All installation and set up instructions are outlined in the Oil Pump Specification section of the installation 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 GENISYS 7505 PRIMARY CONTROL The Genisys 7505 Interrupted Electronic Oil Primary is a line voltage safety rated interrupted ignition oil primary control for residential oil burners The Genisys 7505 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 contr
52. 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 the 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 A 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 four 4 inches above the top of the furnace cabinet
53. tion 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 15 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 NOTE This accessory is not currently available for Bard Models FH110D48F FH110D60F FLF110D48F and FLF110D60F with NX burners FIGURE 10A ELECTRODE ADJUSTMENTS AFG BURNERS 1 8 9 32 ELECTRODE NOZZLE FIGURE 10B MIS 160 ELECTRODE ADJUSTMENTS NX BURNERS A 114 Above 7 ALL nozzle center gt N lt J PATS LA m 3 32 Nozzle to tip spacing Manual 2100 422M Page 25 of 42 FIGURE 11 COMBUSTION AIR BOOT ASSEMBLY AFG BURNER COMBUSTION AIR BOOT ASSEMBLY USE THIS KNOCKOUT E FOR OIL LINE AFG BURNER ASSEMBLY REMOVE PUMP TO ASSEMBLE INNER AIR BOOT REMOVE KNOCKOUT IN LEFT SIDE Hmc
54. uare inches per gallon per hour of the total input rating of all appliances in the enclosure Manual 2100 422M Page 27 of 42 TABLE 9 MINIMUM VENTILATION OPENINGS Recommended Min Ventilation 2 Opening 3 Square Inch Size Sq In FLF110D48F FLR110D48F FIGURE 13 ALL VENTILATION AIR FROM OUTDOORS A The confined space shall be provided with two permanent openings one in or near the top of the enclosure and one in or near the bottom The openings shall communicate directly or by means of ducts with outdoors or to such spaces crawl or attic that freely communicate with outdoors See Figures 13 14 amp 15 When directly communicating with outdoors or by means of vertical ducts each opening shall have a free area of not less than one square inch per 4 000 BTU per hour 35 square inches per gallon per hour of total input rating of all appliances in the enclosures If horizontal ducts are used each opening shall have a free area of not less than one square inch per 2 000 BTU per hour 70 square inches per gallon per hour of total input of all appliances in the enclosure APPLIANCES LOCATED IN CONFINED SPACES ALL AIR FROM OUTDOORS CHIMNEY N OUTLET AIR DUCT g INLET AIR DUCT MIS 1337 Manual 2100 422M Page 28 of
55. ue 2 24 24 24 24 24 24 24 24 24 24 24 D For the first three 3 feet from plenum After three 3 feet no clearance required C Combustible flooring NC Noncombustible floor Maintained on 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 Manual 2100 422M 40142 SISLSIA MENA 3015 XCIIS 14571 1 m 5 EH HS3uJ Ow uaria TNNOLLdO i SONVHINJ 3OV LIOA HOIH SONVYLLNA H 3OV ILIOA WO SONVuIN3 TNNOlLdO 3 mom 3OV LIOA s VNOlLdO sSq3dOW 414 NO 1 NODON anas d i iar v 4 d 9 gt aN ana 7 sseuxoluj WOU BdA 3 JjO9GdOLLM 14 48 011414 4090011414 474 I Seis 62916 rpm
56. 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 Airleaks 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 1 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 test The inspection door hole should be sealed when not being used to avoid leakage of air through it See Step H 2 Ifthe CO level of 10 cannot be reached without exceeding No 2 smoke poor mixing of air and fuel 15 likely It may be necessary to replace the combustion head or try different settings 4 FINAL CHECKS M Measure Stack Temperature Operating the 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 exchang
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