Baldor GLC40 Portable Generator User Manual

OIL FURNACE
INSTALLATION INSTRUCTIONS
MODELS
FH085D36F
FLF085D36F
FLR085D36F
FLR140D60F
FH110D48F
FLF110D48F
FLR110D48F
FC085D36F
FH110D60F
FLF110D60F
FLR110D60F
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.
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 manufacturer’s instructions included with the alarm.
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Manual:
Supersedes:
File:
Date:
2100-422M
2100-422L
VOL. I, TAB 3
11-21-11
Manual 2100-422M
Page
1 of 42
CONTENTS
Getting Other Information and Publications ........ 3
Installation and Operating Instructions
Equipment Selection ............................................. 4
Locating the Furnace ............................................ 4
Installing the Furnace ........................................... 8
Duct Work ............................................................. 8
Installing a Cooling Unit ........................................ 8
Wiring
.............................................................. 9
Oil Line Piping ..................................................... 12
Beckett AFG Oil Burner .............................. 12 & 13
Beckett “CleanCut” Oil Pump .............................. 13
Beckett Solid State Igniter ................................... 13
Beckett R7184B Primary Control ........................ 13
Beckett R7184B Primary Operational Guide ...... 14
Beckett GeniSys 7505 ................................ 14 – 17
Burner States, Reset Button Op., Priming the Pump, Cad
Cell Resistance Indicator, Reset Restricted Lockout
Filters
Lo-Boy Models – Filter Locations ...................... 33
Maintenance
Lubrication .......................................................... 34
Inspect Air Filter .................................................. 34
Final Inspection and Test .................................... 34
Service Hints ....................................................... 34
Combination Combustion Chamber/Burner
Mounting System ................................................ 35
To Remove Burner Only ..................................... 36
To Remove Entire Combustion Chamber
Mounting System ................................................ 36
Common Causes of Trouble ............................... 37
Care of Finish ..................................................... 37
Cleaning of the Heat Exchanger ......................... 37
Blower System Resistance Charts ................. 38-39
Wiring Diagrams ............................................ 40-42
Burner Set up and Adjustments ............ 19, 20 & 21
Short Form Adjustment Procedure ..................... 21
Combustion Air Requirements ............................ 25
Louvers and Grilles ............................................. 30
Venting Options .................................................. 30
Thermostat .......................................................... 30
TABLES
Table 1
Table 2
Table 3
Table A
Table B
Table 4
Table 5
Minimum Clearances ............................. 4
Dimensions FLF/R Models ................... 5
Electrical Data ........................................ 9
Reset Button Operation ....................... 15
Status Lights ........................................ 15
Furnace Data ....................................... 19
Correlation of % of CO2, O2 and
Reserve Air .......................................... 24
Table 6 No. 2 Fuel Oil Efficiency Chart ............. 24
Table 7 Recommended Start-Up Settings ........ 24
Table 8 Sq.Ft. Required as
Unconfined Space ............................... 27
Table 9 Minimum Ventilation Openings ............ 28
Table 10 Temperature Rise Ranges, Limit
Control Settings, and
Heating Blower Speeds ....................... 31
Table 11 Filter Sizes for Oil Furnaces ................ 32
FIGURES
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
CHARTS
Chart 1
Chart 2
Chart 3
Chart 4
Chart 5
Chart 6
Chart 7
Chart 8
FH085D36F Data ................................. 38
FH110D48F Data ................................. 38
FH110D60F Data ................................. 38
FLF/FLR085D36F Data ....................... 38
FLF/FLR110D48F Data ....................... 38
FLF/FLR110D60F Data ....................... 38
FLR140D60F Data ............................... 39
FC085D36F Data ................................. 39
Manual 2100-422M
Page
2 of 42
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
FLF/R Models Dimensions ................ 5
FH Models Dimensions ..................... 6
FC Models Dimensions ..................... 7
Typical Unit Setup - FLF .................. 10
Typical Flue Installation
Requirements - FLF ........................ 11
Typical Single Inside
Tank Installation ............................... 12
Electronic Blower Control ................ 18
Typical Smoke-CO2 Characteristic .. 22
Pressure Gauge Connection to
Bleed Port ....................................... 23
Electrode Adjustments ..................... 25
Combustion Air Boot Assembly ....... 26
All Air From Inside Building ............. 27
All Air From Outdoors ...................... 28
All Air From Outdoors Through
Ventilated Attic ................................. 29
All Air From Outdoors - Inlet Air
From Ventilated Crawl Space and
Outlet Air to Ventilated Attic ............. 29
Typical Installation of FR26 and FR27 .
Filter Rack ....................................... 32
Typical Installation of FR25 Filter
Kit .................................................... 32
Filter Installation - Lo-Boy Models ... 33
Removal of Burner Only .................. 35
Removal of Entire Combustion
Chamber Mounting System ............. 36
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.
FOR MORE INFORMATION, CONTACT THESE
PUBLISHERS:
ACCA
Air Conditioning Contractors of America
1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: (202) 483-9370
Fax: (202) 234-4721
ANSI
American National Standards Institute
11 West Street, 13th Floor
New York, NY 10036
Telephone: (212) 642-4900
Fax: (212) 302-1286
ASHRAE
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
NFPA
National Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: (800) 344-3555
Fax: (617) 984-7057
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
Manual 2100-422M
Page
3 of 42
INSTALLATION and OPERATING INSTRUCTIONS
EQUIPMENT SELECTION
LOCATING THE FURNACE
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.
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 is recommended. This will help keep the
bottom of the furnace dry and reduce the risk of rusting.
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.
An oil 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 Installatio n C learnaces — Inches
Furnace
P lenum
Minimum Service
C learances
Fro nt
B ack
Sides
To p
Sides
1
D uct
Flue
P ipe
Flo o r
Fro nt
B ack
Sides
FH085D 36F
FH110D 48F
FH110D 60F
4
4
4
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
9
9
9
C
C
C
24
24
24
—
—
—
—
—
—
F LF 085D 36F
FLR085D 36F
FLF110D 48F
FLF110D 60F
6
6
6
6
0
18
0
0
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
9
9
9
9
NC
NC
NC
NC
24
24
24
24
24
24
24
24
18
18
18
18
FLR110D 48F
FLR110D 60F
FLR140D 60F
F C 085D 36F
6
6
6
6
18
18
18
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
9
9
9
9
NC
NC
NC
NC **
24
24
24
24
24
24
24
—
18 *
18 *
18 *
—
Mo del
1
C
NC
*
**
For the first three (3) feet from plenum. After three (3) feet, no clearance required.
Combustible flooring
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
Page
4 of 42
*
*
*
*
Manual 2100-422M
Page
5 of 42
H
D
F
G
FILTER
DOOR
E
LEFT SIDE VIEW
FRESH AIR
KNOCKOUT
OPTIONAL
OIL
ENTRANCE
OIL
ENTRANCE
OPTIONAL
LOW VOLTAGE
ENTRANCE
OPTIONAL
HIGH VOLTAGE
ENTRANCE
"FLF" FLUE
KNOCKOUT
TOP VIEW
REAR FLUE
ON "FLR" MODELS
RETURN
DUCT
SUPPLY
DUCT
J
FLF/FLR 085, 110 AND 140
SPECIFICATION SHEET
23
23
23
23
FLF110D 48F
FLF110D 60F
FLR110D 48F
FLR110D 60F
"FLF" FLUE
KNOCKOUT
FRONT VIEW
A
26
23
23
FLR140D 60F
P lenum
Openings
40.625
40.625
40.625
40.625
1
25x20
22x20
22x20
22x20
22x20
22x20
22x20
25x16
22x14
22x14
22x14
22x14
22x14
22x14
Rear
Front
Front
Rear
Rear
Front
Rear
C
6
6
6
6
6
6
6
RIGHT SIDE VIEW
OPTIONAL
OIL ENTRANCE
HIGH VOLTAGE
ENTRANCE
LOW VOLTAGE
ENTRANCE
"FLF" FLUE
KNOCKOUT
B
Washable type filter 1” nom. thickness
50.250 47.625
48.125
48.125
48.125
48.125
48.125 36.625
48.125 36.625
J
Siz e
Air Filters
---
5.125
5.125
5.125
5.125
MIS-1815 A
42.125
35.625
35.625
35.625
35.625
x 20
x 20
x 20
x 20
x1
x1
x1
x1
20 x 25 x 1
20
20
20
20
31.625 5.125 16 x 20 x 1
31.625 5.125 16 x 20 x 1
H
Flue C o nectio n
A
B
C
DxE
DxF
G
Width D epth H eight Supply R eturn Lo catio n D ia.
F LF 085D 36F
FLR085D 36F
Mo del
N umber
C abinet
TABLE 2
FLF/R MODELS DIMENSIONS (INCHES)
FIGURE 1
FLF/R MODELS DIMENSIONS
1
1
1
1
1
1
1
1
No.
U sed
Manual 2100-422M
Page
6 of 42
16"
LEFT SIDE VIEW
RETURN
OPENING
(CUT OUT)
19 1/4"
VESTIBULE
DOOR
FRESH AIR
KNOCKOUT
OIL
ENTRANCE
OPTIONAL
OIL
ENTRANCE
OPTIONAL
LOW VOLTAGE
ENTRANCE
OPTIONAL
HIGH VOLTAGE
ENTRANCE
FLUE
KNOCKOUT
FLUE
KNOCKOUT
19 7/8"
TOP VIEW
FRONT VIEW
23"
21 7/8"
HIGH
VOLTAGE
ENTRANCE
OPTIONAL
OIL
ENTRANCE
LOW VOLTAGE
ENTRANCE
RIGHT SIDE VIEW
RETURN
OPENING
(CUT OUT)
MIS-1814 A
FH085 AND FH110
SPECIFICATION SHEET
REAR CLEANOUT
DOOR
FLUE
KNOCKOUT
53" (FH085)
59" (FH110)
30 1/2"
SUPPLY
OPENING
FIGURE 2
FH MODELS DIMENSIONS
FIGURE 3
FC085 MODEL DIMENSIONS
22"
COUNTERFLOW
SPECIFICATION
SHEET
RETURN
OPENING
20"
30 5/8"
TOP VIEW
23"
FLUE
KNOCKOUT
FLUE
KNOCKOUT
FLUE
KNOCKOUT
OPTIONAL
HIGH VOLTAGE
ENTRANCE
54 1/4"
OPTIONAL
LOW VOLTAGE
ENTRANCE
REAR
CLEANOUT
DOOR
LOW VOLTAGE
ENTRANCE
OIL ENTRANCE
HIGH VOLTAGE
ENTRANCE
OPTIONAL
OIL ENTRANCE
FRESH AIR
KNOCKOUT
FRONT VIEW
OPTIONAL
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
DUCT WORK
INSTRUMENTS REQUIRED FOR PROPER
SETUP OF THE FURNACE
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.
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° F.
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 the space containing the
furnace This is to prevent drawing possible
hazardous combustion products into the
circulated air.
6. A gauge to measure CO2 or O2.
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 Oil
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 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
8 of 42
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. 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.
FIELD WIRING
WIRING
All wiring must conform to the National Electrical
Code and all local codes. A separate fuse or breaker
should be used for the furnace.
FACTORY WIRING
All units are fully factory wired. Multispeed blowers
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
B lo wer Mo to r
B urner Mo to r
Max. Time
D elay Fuse
o r H AC R
C ircuit B reaker
Mo del
Vo lts-H Z-P H
To tal
Amps
HP
FLA
HP
FLA
Minimum
C ircuit
Ampacity
FH085D 36F
115-60-1
7.3
1/3
5.6
1/7
1.7
9
15
FH110D 48F
115-60-1
12.2
1/2
10.5
1/7
1.7
15
20
FH110D 60F
115-60-1
14.2
3/4
12.5
1/7
1.7
18
20
F LF 085D 36F
115-60-1
7.3
1/3
5.6
1/7
1.7
9
15
FLR085D 36F
115-60-1
7.3
1/3
5.6
1/7
1.7
9
15
FLF110D 48F
115-60-1
12.2
1/2
10.5
1/7
1.7
15
20
FLR110D 48F
115-60-1
12.2
1/2
10.5
1/7
1.7
15
20
FLF110D 60F
115-60-1
14.2
3/4
12.5
1/7
1.7
18
20
FLR110D 60F
115-60-1
14.2
3/4
12.5
1/7
1.7
18
20
FLR140D 60F
115-60-1
14.2
3/4
12.5
1/7
1.7
18
20
F C 085D 36F
115-60-1
7.3
1/3
5.6
1/7
1.7
9
15
Manual 2100-422M
Page
9 of 42
FIGURE 4
TYPICAL UNIT SETUP
FLF UNIT SHOWN
WARNING
!
TYPICAL UNIT
SETUP
(FLF UNIT SHOWN)
ALL WIRING MUST
CONFORM TO THE
NATIONAL ELECTRIC
CODE AND ALL LOCAL
CODES.
Left side
high voltage
(unit power)
entrance
Inspection
door
Left side
low voltage
(thermostat)
entrance
Right side
low voltage
(thermostat)
entrance
Left side oil
line entrance
for opt. air boot
To thermostat
and optional
A/C unit
Left side
oil line
entrance
To power
source
Oil line
(see burner
pump inst. for
hookup info.)
Shut off switch
(if not fused,
power line must
include fuse or
circuit breaker)
Air Boot
knockout
(optional)
Control panel
(junction box
in FH units)
Right side
high voltage
(unit power)
entrance
Manual 2100-422M
Page
10 of 42
Right side
oil line
entrance
Power Wires:
Black (HOT)
White (NEUTRAL)
Green (GROUND)
MIS-1836
FIGURE 5
TYPICAL FLUE INSTALLATION REQUIREMENTS
FRONT FLUE LO-BOY MODEL SHOWN
(REPRESENTS ALL MODELS)
INSTALLER NOTE:
Follow all appropriate
standards for installing
needed venting system.
Thimble
Draft Regulator
(Be sure to follow
installation inst.
supplied with
regulator).
1/4 inch per
1 foot rise
L
i
n
e
d
90° Rotatable
Flue Box on front
flue models
(remove appropriate
cabinet knockout).
Mounting screws
located under flue
box cover.
C
h
i
m
n
e
y
Flue Box
Cover
Optional
Flue
Locations
Oil Burner
Clean-out Door
(keep closed)
Optional Fresh
Air Boot (remove
rect. knockout).
MIS-1825
∨
Note: This accessory is not currently available for Bard Models:
FH110D48F, FH110D60F, FLF110D48F, FLF110D60F with NX Burners
Manual 2100-422M
Page
11 of 42
OIL LINE PIPING
BECKETT AFG OR NX OIL BURNER
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.
This furnace is equipped with a high static Beckett AFG
or Beckett NX 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 Genisys 7505 primary control.
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.
FIGURE 6
TYPICAL SINGLE INSIDE TANK INSTALLATION
Vent Cap
2" Cap
2" Fill Pipe
1-1/4"
Vent Pipe
Return Line
Guage
Bushing,
2" x 1-1/2" or
1-1/4"
Oil
Tank
Gate Valve
3/8" x 4"
nipple
6"
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
12 of 42
Bushing
Oil Filter
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.
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
WARNING
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 should they occur.
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 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 Genisys 7505
primary control is provided following on Page 14.
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.
Manual 2100-422M
Page
13 of 42
BECKETT GENISYS
MODEL 7505
MIS-2491
PRIMARY OPERATIONAL GUIDE
BECKETT GENISYS 7505
Sequence of Operation
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 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.
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
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14 of 42
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.
TABLE A
RESET BUTTON OPERATION
Pus hing the Re s e t button will:
If the burne r is in the
be low s tate :
Button Click
(pre s s < 1 s e cond)
Button Hold
(pre s s > 1 s e cond)
Lockout
Reset from Soft Lockout
Valve- on Delay,
Trial for Ignition,
Ignition Carryover
Go to Pump Prime
(see Below)
Run (igniter is shut off)
Yellow LED flashes to
indicate cad cell resistance.
See "Cad Cell Resistance
Indicator" for table of
resistance values.
Button Hold
(pre s s 15+ s e conds )
Reset from Restricted (Hard) Lockout
Disable the Burner:
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.
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.
Motor- Off Delay, Standby No action
Pump Prime
No action
Exit Pump Prime mode and return to Standby
TABLE B
STATUS LIGHTS
LED
Color
On Continuous ly
Flas hing
Red
Restricted (hard) Lockout
Soft Lockout
Green
Flame Detected (Could be flame or stray light)
Recycle
Yellow
Control is in Pump Prime mode or
Reset button currently held for 15+ seconds
Cad Cell resistance. See "Cad Cell Resistance Indicator"
section for table of resistance values.
Manual 2100-422M
Page
15 of 42
PRIMING THE PUMP
WARNING
Hot Gas Puff-Back & Heavy Smoke Hazard
Failure to bleed the pump properly could
result in unstable combustion, hot gas puffback 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 valve 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.
1. 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.
2. Initiate a call for heat.
3. 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.
4. Release the reset button. The yellow LED will
turn off and the burner will start up again.
Manual 2100-422M
Page
16 of 42
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. At the 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 is 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:
Yellow LED Flashes
Flame Detection Range
1
Normal (0 - 400 ohms)
2
Normal (400 - 800 ohms)
3
Normal (800 - 1600 ohms)
4
Limited (1600 ohms - Lockout)
RESETTING FROM RESTRICTED LOCKOUT
• If 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 FUNCTION
• 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 for cooling speed, and one which
isolates the T–T signal from the oil primary control.
NOTE: If a jumper wire is placed across “R” 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
CONNECTIONS
TRANSFORMER 24V
SECONDARY
CONNECTIONS
3 AMP FUSE
HEATING BLOWER
OFF DELAY
ADJUSTMENT
IN SECONDS.
OIL PRIMARY T-T
CONNECTIONS
LINE VOLTAGE
CONNECTION (HOT)
HUMIDIFIER
CONNECTION
HEATING BLOWER
SPEED CONNECTION
COOLING BLOWER
SPEED CONNECTION
Manual 2100-422M
Page
18 of 42
UNUSED BLOWER MOTOR
SPEED CONNECTIONS
LINE VOLTAGE
CONNECTION (COM, L2)
ELECTRIC AIR
CLEANER CONNECTION
MIS-1819
TABLE 4
FURNACE DATA
Mo del
N umber
B urner
Type
Furnace
Type
N o z z le
Siz e
Type
P ump P ressure
0.75 *
FC 085D 36F
A FG
C ounterflow
0.65
70° Hollow
100 PSIG
0.55
0.75 *
FH 085D 36F
A FG
Hi -Boy
0.65
70° Hollow
100 PSIG
0.55
0.85 *
FH 110D 48F
FH 110D 60F
FLF085D 36F
NX
NX
A FG
Hi -Boy
60° Soli d
FLR 110D 60F
A FG
64,000
140,000
116,000
0.75 *
105,000
87,000
91,000
76,000
77,000
64,000
140,000
116,000
119,000
99,000
140,000
116,000
119,000
99,000
0.65
70° Hollow
100 PSIG
60° Soli d
150 PSIG
Lo-Boy
60° Soli d
150 PSIG
0.65
70° Hollow
100 PSIG
Lo-Boy
70° Hollow
105,000
87,000
91,000
76,000
77,000
64,000
140,000
116,000
100 PSIG
0.85
119,000
99,000
1.00 *
140,000
116,000
119,000
99,000
175,000
145,000
154,000
127,000
Lo-Boy
70° Hollow
100 PSIG
1.25 *
A FG
77,000
99,000
0.85
FLR 140D 60F
76,000
150 PSIG
1.00 *
A FG
87,000
91,000
119,000
60° Soli d
0.55
FLR 110D 48F
105,000
0.75
Lo-Boy
Lo-Boy
64,000
99,000
0.75 *
A FG
77,000
116,000
0.75
FLR 085D 36F
76,000
119,000
0.85 *
NX
91,000
140,000
0.75
FLF110D 60F
87,000
0.85 *
0.85 *
NX
105,000
150 PSIG
0.55
FLF110D 48F
H eating
Output
B TU H
0.75
Hi -Boy
Lo-Boy
H eating
Input
B TU H
Lo-Boy
70° Hollow
1.10
100 PSIG
* 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
1. PREPARATION STEPS
A. Calibrate and Check Operation of
Measuring Equipment Follow
manufacturer’s recommended procedures for
calibration and equipment check out.
B. 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.
C. 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.
D. 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. 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.
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 flare fittings.
E. Adjustment of Electrodes Adjust ignition
electrodes as specified in Figure 10.
F. 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.
G. 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.
I. 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.
J. Develop Smoke - CO2 Curve Record
measurements of smoke and CO2 from the flue.
Then establish the smoke - CO2 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 open and then take smoke and CO2
readings at progressively lower air settings, as
necessary to visualize the general shape of the
curve. (The CO2 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.
K. Adjust Air Setting Examine the smoke - CO2
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
CO2 level 1/2 to 1 percent lower than the CO2
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,
CO2 and smoke measurements to make sure
the setting has not shifted.
3. COMBUSTION DIAGNOSIS
L. Check Performance A well-matched and
well-tuned burner should be capable of
operation with smoke not greater than No. 2
and at a CO2 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 CO2 readings.
Such leaks should be sealed with furnace
cement or other high-temperature sealant.
To check for dilution by leakage, measure
the CO2 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
CO2 measured in the flue. A difference of
more than 1 percent CO2 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. If the CO2 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.
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 exchanger surfaces and
excessive draft. The temperature of the flue gas
provides an indication of these heat losses.
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. 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. CO2 TEST
Check CO2 levels. This level should be between
10% and 12%.
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 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
shutdown. If poor cutoff persists, repair or
replace pump. Also make sure the pump
solenoid is working - if not replace.
Manual 2100-422M
Page
21 of 42
FIGURE 8
TYPICAL SMOKE – CO2 CHART WITH ADJUSTMENT RANGE
High
Air Settings
Low
Bacharach Smoke Number
8
CO2 Curve
from plotted
points
6
Plotted point
Normal
adjustment
range
4
Tolerance
to "knee"
"Best" air
setting
2
Plotted point
Plotted point
"Knee"
0
6
8
12
10
Percent CO2 in Flue Gas
Technician's
plotting area
8
Bacharach Smoke Number
14
6
4
2
0
6
Manual 2100-422M
Page
22 of 42
8
12
10
Percent CO2 in Flue Gas
14
MIS-1827
FIGURE 9
PRESSURE GAUGE CONNECTION TO BLEED PORT
Remove Bleed
Port to attach
pressure guage.
Pressure Gauge
MIS-1660
Manual 2100-422M
Page
23 of 42
TABLE 5 — CORRELATION OF PERCENT OF CO2, O2 AND RESERVE AIR
C arbo n D io xide
Oxyge n
R eserve Air (Appro x.)
15.4
15.0
14.5
0.0
0.6
1.2
0.0
3.0
6.0
14.0
13.5
13.0
2.0
2.6
3.3
10.0
15.0
20.0
12.5
12.0
11.5
4.0
4.6
5.3
25.0
30.0
35.0
11.0
10.5
10.0
6.0
6.7
7.4
40.0
45.0
50.0
TABLE 6 — NO. 2 FUEL OIL EFFICIENCY CHART (NET STACK TEMP. DEGREES F)
% O2
200
250
300
350
400
450
500
550
600
650
700
750
800
% O2
1
89.6
88.4
87.3
86.2
85.1
84.0
82.9
81.7
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
83.5
82.0
80.5
79.0
77.5
76.0
74.5
73.0
71.5
70.0
10.3
TABLE 7 — RECOMMENDED START-UP SETTINGS
Mo del
N umber
N o z z le
B urner Style
P art N o .
Siz e
Type
P ump P ressure
70° Hollow
100 PSIG
0.75 *
FC 085D 36F
FH 085D 36F
FH 110D 48F
FH 110D 60F
FLF085D 36F
FLF110D 48F
FLF110D 60F
AFG/9020-034
AFG/9020-034
0.65
—
—
0.75 *
0
6
—
0
5
—
0.65
70° Hollow
100 PSIG
0.55
0
5
—
0.85 *
—
—
3.75
0.75
—
—
3
0.85 *
—
—
3.75
0.75
—
—
3
0.75 *
0
6
—
—
60° Soli d
60° Soli d
0.65
70° Hollow
150 PSIG
150 PSIG
100 PSIG
0
5
0.55
0
5
—
0.85 *
—
—
3.75
0.75
—
—
3
0.85 *
—
—
3.75
—
—
3
60° Soli d
NX/9020-039
60° Soli d
NX/9020-039
150 PSIG
150 PSIG
0.65
70° Hollow
100 PSIG
6
—
0
5
—
—
0
5
1.00 *
2
10
—
0
8
—
2
10
—
0
8
—
70° Hollow
AFG/9020-037
100 PSIG
1.00 *
70° Hollow
AFG/9020-037
100 PSIG
1.25 *
70° Hollow
AFG/9020-038
1.10
Manual 2100-422M
Page
24 of 42
0
0.55
0.85
FLR 140D 60F
—
5
0.85
FLR 110D 60F
6
5
0.75 *
FLR 110D 48F
0
0
NX/9020-039
AFG/9020-036
Air
Adjustment
P late
Setting
0
0.75
FLR 085D 36F
Air
Shutter
Setting
0.55
NX/9020-039
AFG/9020-034
Air B and
Setting
0
8
—
0
6
—
100 PSIG
* Factory Installed Nozzle. Also shown are optional approved nozzle size/type.
SPACING OF ELECTRODES
COMBUSTION AIR REQUIREMENTS
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 & 10B.
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 combustion of the fuel oil.
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.
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.
NOTE - This accessory is not currently available for
Bard Models: FH110D48F, FH110D60F,
FLF110D48F and FLF110D60F with NX burners.
FIGURE 10A
ELECTRODE ADJUSTMENTS — AFG BURNERS
FIGURE 10B
ELECTRODE ADJUSTMENTS — NX BURNERS
Manual 2100-422M
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FIGURE 11
COMBUSTION AIR BOOT ASSEMBLY
AFG BURNER
COMBUSTION
AIR BOOT
ASSEMBLY
USE THIS
KNOCKOUT
FOR OIL LINE
INTAKE
AIR
TUBE
AFG
BURNER
ASSEMBLY
REMOVE PUMP TO
ASSEMBLE INNER
AIR BOOT
REMOVE KNOCKOUT
IN LEFT SIDE
INSERT OUTER AIR
BOOT AND SECURE
FLANGE TO UNIT
MAKE ALL SETTINGS
ACCORDING TO MANUAL
FOR AIR BOOT.
MIS-1833
Note: This accessory is not currently available for Bard Models:
FH110D48F, FH110D60F, FLF110D48F, FLF110D60F with NX Burners
Manual 2100-422M
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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 “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 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 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
TABLE 8
SQUARE FEET REQUIRED TO
QUALIFY AS UNCONFINED SPACE
Total
B TU H
Input
Unconfined Space
Minimum Area In
Square Feet
8' Ceiling Height
60,000
80,000
375
500
85,000
105,000
531
656
115,000
120,000
719
750
140,000
145,000
875
906
160,000
200,000
1000
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 square inches per
gallon per hour) of the total input rating
of all appliances in the enclosure.
Manual 2100-422M
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TABLE 9
MINIMUM VENTILATION OPENINGS
Mo del
Min. Ventilatio n
Opening
Square Inch
FH085D 36F
ALL VENTILATION AIR FROM OUTDOORS
R eco mmended
Opening
(2 R equired)
Siz e
Sq. In.
240
8 x 16
128
FH110D 48F
280
9 x 18
162
FH110D 60F
280
9 x 18
162
F LF 085D 36F
290
8 x 19
152
FLR085D 36F
290
8 x 19
152
FLF110D 48F
FLF110D 60F
340
9 x 19
171
FLR110D 48F
FLR110D 60F
340
9 x 19
171
FLR140D 60F
360
9.5 x 19
180
F C 085D 36F
240
8 x 16
128
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, & 15.)
B. 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.
FIGURE 13
APPLIANCES LOCATED IN CONFINED SPACES
ALL AIR FROM OUTDOORS
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.
Manual 2100-422M
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FIGURE 14
APPLIANCES LOCATED IN CONFINED SPACES
ALL AIR FROM OUTDOORS THROUGH VENTILATED 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 all
appliances in the enclosure.
FIGURE 15
APPLIANCES LOCATED IN CONFINED SPACES
ALL AIR FROM OUTDOORS
INLET AIR FROM VENTILATED CRAWL SPACE AND OUTLET AIR TO VENTILATED 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.
Manual 2100-422M
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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
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.
Manual 2100-422M
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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 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.
TABLE 10
TEMPERATURE RISE RANGES, LIMIT CONTROL SETTINGS,
AND HEATING BLOWER SPEEDS
Mo del
N umber
N o z z le
B urner
Type
R ise R anges
Siz e
Type
P ump P ressure
0.75 *
FC 085D 36F
FH 085D 36F
A FG
A FG
0.65
60 - 90
70° Hollow
100 PSIG
60 - 90
Medi um Low
0.65
70° Hollow
100 PSIG
150 PSIG
150 PSIG
Low
0.75 *
60 - 90
Medi um
0.65
70° Hollow
100 PSIG
150 PSIG
150 PSIG
Medi um Low
Medi um Hi gh
200
0.75
60 - 90
Medi um Low
0.75 *
60 - 90
Medi um
0.65
70° Hollow
100 PSIG
0.55
A FG
100 PSIG
0.85
100 PSIG
0.85
Medi um Low
Medi um Hi gh
200
60 - 90
1.25 *
Medi um Low
60 - 90
70° Hollow
1.10
Medi um Hi gh
200
60 - 90
70° Hollow
Low
Low
60 - 90
1.00 *
A FG
200
60 - 90
70° Hollow
A FG
60 - 90
60 - 90
1.00 *
FLR 140D 60F
Medi um Hi gh
200
60 - 90
60° Soli d
Low
Low
60 - 90
0.85 *
FLR 110D 60F
200
60 - 90
60° Soli d
NX
60 - 90
60 - 90
0.75
FLR 110D 48F
Medi um
200
60 - 90
NX
A FG
Low
0.75
0.85 *
FLR 085D 36F
Medi um Low
200
60 - 90
60° Soli d
Low
Low
70 - 100
0.55
FLF110D 60F
200
60 - 90
60° Soli d
NX
70 - 100
70 - 100
0.85 *
FLF110D 48F
Low
0.75 *
NX
A FG
200
Low
0.75
FLF085D 36F
Medi um
70 - 100
0.85 *
FH 110D 60F
70 - 100
H eating
B lo wer
Speed
0.55
0.55
FH 110D 48F
Maximum
Outlet Air
Temp (°F)
100 PSIG
Medi um Hi gh
200
60 - 90
Medi um Low
* Factory Set Point.
Manual 2100-422M
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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 cutting of the return openings.
TABLE 11
FILTER SIZES FOR OIL FURNACES
Model
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.
Siz e
FH085D36F
Hi-Boy
(1)
16 x 25 x 1
FH110D48F
Hi-Boy
(1)
16 x 25 x 1
FH110D60F
Hi-Boy
(1)
20 x 25 x 1
F LF 085D 36F
FLR085D36F
Lo-Boys
(1)
16 x 20 x 2
FLF110D48F
FLR110D48F
FLF110D60F
FLR110D60F
Lo-Boys
(1)
20 x 20 x 2
FLR140D60F
Lo-Boy
(1)
20 x 25 x 2
F C 085D 36F
Counterflow
(2)
16 x 20 x 1
See Table 11 for filter sizes and quantities.
FIGURE 16
TYPICAL INSTALLATION OF FR26 AND
FR27 FILTER RACKS
FIGURE 17
TYPICAL INSTALLATION OF FR25
FILTER KIT
Optional
Filter
Box
"FC"
Unit
19 1/4"
16"
70 5/16"
Filter
Frame
(2) screws
Filter
Filter
Door
Manual 2100-422M
Page
32 of 42
MIS-1839 A
MIS-1841
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/FLR085 16 x 20 x 2
FLF/FLR110 20 x 20 x 2
FLR140
20 x 25 x 2
STEP 3:
SLIDE FILTER OUT
TOWARDS BLOWER
DOOR
STEP 2:
REMOVE BLOWER DOOR
BY PULLING OUT ON
SWELL LATCHES AND
TILTING OUTWARDS
STEP 1:
UNFASTEN SWELL
LATCHES BY PULLING
HANDLES OUTWARD
MIS-1835 A
Manual 2100-422M
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MAINTENANCE
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:
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’s 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 on / 1/2 second off. Ignition and
motor stop and oil valve closes.
Manual 2100-422M
Page
34 of 42
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.
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.
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.
WARNING
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
!
DANGER
BURNER REMOVAL
INSTRUCTIONS
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
STEP 2:
LOOSEN (3) BOLTS
ENOUGH TO ROTATE
BURNER ASSEMBLY.
STEP 3:
ROTATE BURNER
COUNTER-CLOCKWISE
STEP 4:
PULL BURNER STRAIGHT
OUT TO PREVENT DAMAGE
TO CHAMBER DURING
REMOVAL.
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
Disconnect fuel line, power cord and wires from T, T
on primary control. Loosen (3) 1/4 inch bolts securing
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
BURNER AND COMB. CHAMBER
MOUNTING SYSTEM
REMOVAL INSTRUCTIONS
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
STEP 3:
REMOVE (2) NUTS
IN THE TOP LEFT
AND RIGHT CORNERS
OF BURNER PLATE.
CHAMBER
BURNER
PLATE
STEP 4:
PULL BURNER ASSEMBLY
STRAIGHT OUT TO PREVENT
DAMAGE TO CHAMBER
DURING REMOVAL.
Manual 2100-422M
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36 of 42
STEP 2:
REMOVE (6) BOLTS
AROUND PERIMETER
OF BURNER PLATE
STEP 1:
DISCONNECT "T-T" WIRES,
POWER CONNECTIONS, AIR
BOOT (OPTIONAL) AND OIL
LINES TO BURNER.
MIS-1837 A
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.
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 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.
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 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.
WARNING
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.
Manual 2100-422M
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BLOWER SYSTEM RESISTANCE CHARTS
CHART 1
FH085D36F DATA
Blow er Speed
CHART 4
FLF/FLR085D36F DATA
Blow er Speed
Blow er Static
Blow er Static
Low
.10
.15
.23
.30
Low
.07
.13
.19
.25
Medium
.16
.24
.34
.43
Medium
.15
.24
.33
.41
High
.20
.30
.40
.50
High
.20
.30
.40
.50
CHART 5
FLF/FLR110D48F DATA
CHART 2
FH110D48F DATA
Blow er Speed
Blow er Static
Blow er Speed
Blow er Static
Low
.03
.08
.13
.18
Low
.05
.09
.15
.20
Medium Low
.09
.16
.23
.32
Medium Low
.09
.16
.23
.31
Medium High
.16
.25
.34
.44
Medium High
.15
.24
.34
.42
High
.20
.30
.40
.50
High
.20
.30
.40
.50
CHART 3
FH110D60F DATA
Blow er Speed
CHART 6
FLF/FLR110D60F DATA
Blow er Static
Blow er Speed
Blow er Static
Low
.06
.12
.17
.21
Low
.08
.12
.17
.21
Medium Low
.10
.17
.23
.30
Medium Low
.10
.16
.22
.28
Medium High
.14
.21
.31
.38
Medium High
.13
.21
.29
.36
High
.20
.30
.40
.50
High
.20
.30
.40
.50
Manual 2100-422M
Page
38 of 42
CHART 8
FC085D36F DATA
CHART 7
FLR140D60F DATA
Blow er Speed
Blow er Speed
Blow er Static
Blow er Static
Low
.05
.14
.17
.24
Low
.08
.14
.20
.26
Medium Low
.08
.17
.22
.30
Medium
.16
.24
.36
.42
Medium High
.11
.20
.27
.35
High
.20
.30
.40
.50
High
.20
.30
.40
.50
Manual 2100-422M
Page
39 of 42
FH SERIES
WIRING DIAGRAM
UNIT
BACKUP
LIMIT
BURNER ASS'Y
IGNITOR
CAD CELL
CAD CELL
BLACK
IGNITOR
BLACK
BURNER
MOTOR
BLACK
BURNER
MOTOR
BLACK
OIL VALVE
BLACK
WHITE
TT
L1
L2
VALVE
PRIMARY
LIMIT
CONTROL
HEAT EXCHANGER AREA
PURPLE
PURPLE
PURPLE
PURPLE
BLACK
BLACK
BLACK
DOOR
SWITCH
HIGH
VOLTAGE
SEE CHART FOR
HEATING AND COOLING
WIRE COLORS
BLUE
ORANGE
RED
WHITE
BLACK
1 2 3 4 5
BROWN
BLOWER
CAPACITOR
FIELD
WIRING
BLOWER ASSEMBLY
Manual 2100-422M
Page
40 of 42
UNIT
FH085D36F
FH110D48F
FH110D60F
CONTROL PANEL
120V COM
BLACK
WHITE
PLUG #3
BROWN
LOW
VOLTAGE
SEC1
SEC2
SPR3
WHITE
WHITE
TRANSFORMER
L1
4
WARNING
C Y
24V
RETURN AREA
2
4
ONLY ONE HEATING
AND COOLING SPEED
CAN BE CONNECTED.
ALL OTHER TAPS
CONNECT TO "SPARE"
TERMINALS.
DASHED LINES
REPRESENT FIELD WIRING.
IF ANY OF THE ORIGINAL WIRE AS
SUPPLIED WITH THIS APPLIANCE
MUST BE REPLACED, IT MUST BE
REPLACED WITH WIRING MATERIAL
HAVING A TEMP. RATING OF AT
LEAST 105°C EXCEPT PRIMARY
LIMIT WIRES. SEE NOTE "1".
BLUE
T
T
SPR1
SPR2
L2
COM
COOL
EAC
HEAT
HUM
3
COOLING SPEED
CONNECTION POINT.
!
BLACK
BLOWER CONTROL
3
PLUG #2
YELLOW
150
180
210
240
HEATING SPEED
CONNECTION POINT.
HOT
NEUTRAL
GROUND
GREEN
WHITE
R W G Y C
2
! DANGER
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
BLACK
WHITE
GREEN
1 2
1
5
1
PLUG
#1
1 2 3 4 5 6 7 8 9
NOTES
IF PRIMARY LIMIT WIRES
ARE TO BE REPLACED,
USE WIRE WITH INSUL.
TEMP. RATING OF 200°C.
5
Rc Y G W Rh
COND.
UNIT THERMOSTAT
24V.
CONN.
T87F/Q539A1220
OR EQUIVELANT
OPTIONAL AIR COND. SETTINGS
NOM.
COOLING BLOWER CFM @
A/C
SPEED (COLOR)
.50 WC
TONS
2
LOW (RED)
730
FH085D36F
2 1/2
MED (BLUE)
900
3
HIGH (BLACK)
1160
2 1/2
LOW (RED)
1020
3
MED-LOW (ORANGE) 1280
FH110D48F
3 1/2
MED-HIGH (BLUE)
1495
4
HIGH (BLACK)
1640
3
LOW (RED)
1300
3 1/2 MED-LOW (ORANGE) 1460
FH110D60F
4
MID-HIGH (BLUE)
1660
5
HIGH (BLACK)
1970
UNIT
FACTORY SETTINGS
INPUT
TEMP.
HEATING BLOWER COOLING BLOWER
RATE
RISE
SPEED (COLOR)
SPEED (COLOR)
GPH
RANGE
0.55
LOW (RED)
70°-100°
0.65
LOW (RED)
70°-100°
0.75
MED (BLUE)
60°-90°
HIGH (BLACK)
0.85
LOW (RED)
70°-100°
1
MED-LOW (ORANGE)
60°-90°
0.85
LOW (RED)
60°-90°
1
MED-LOW (ORANGE)
60°-90°
BLOWER CAPACITOR RATING
UNIT
MOTOR CAPACITOR
FH085D36F
1/3
5/370
FH110D48F
1/2
7.5/370
FH110D60F
3/4
15/370
4047-118 F
Manual 2100-422M
Page
41 of 42
IGNITOR
CAD CELL
IGNITOR
CAD CELL
BLACK
BLUE
ORANGE
RED
WHITE
BLOWER ASSEMBLY
BROWN
BROWN
1
2
1
2
3
4
5
BLOWER CAPACITOR
BLACK
BURNER
MOTOR
BURNER
MOTOR
BLACK
OIL VALVE
L1
L2
VALVE
BURNER ASS'Y
BLACK
150
180
210
240
SEE CHART FOR
"HEAT" AND "COOL"
WIRE COLORS.
2
3
BLOWER CONTROL
R W G Y C
PURPLE
PURPLE
BLACK
BLACK
HEAT
BLACK
SPR3
T
T
24V
TRANSFORMER
L1
4
SEC2
COM 120V
CONTROL PANEL
COOL
EAC
1
HUM
PRIMARY LIMIT
SEC1
BACKUP LIMIT
L2
COM
WHITE
WHITE
WHITE
HEAT EX. AREA
FLF/R SERIES
WIRING DIAGRAM
SPR1
SPR2
TT
RETURN AREA
BLACK
WHITE
GREEN
BLACK
BLACK
YELLOW
BLUE
NEUTRAL
GROUND
HOT
T87F/Q539A1220
OR EQUIVELANT
THERMOSTAT
5
COLING BLWR.
SPEED
HIGH (BLACK)
HIGH (BLACK)
HIGH (BLACK)
HIGH (BLACK)
HIGH (BLACK)
HIGH (BLACK)
HIGH (BLACK)
! DANGER
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
5
4
4047-119 E
ONLY ONE HEATING
AND COOLING SPEED
CAN BE CONNECTED.
ALL OTHER TAPS
CONNECT TO "SPARE"
TERMINALS.
DASHED LINES
REPRESENT FIELD WIRING.
IF PRIMARY LIMIT WIRES
ARE TO BE REPLACED,
1 USE WIRE WITH INSUL.
TEMP. RATING OF 200°C.
HEATING SPEED
2 CONNECTION POINT.
COOLING SPEED
3 CONNECTION POINT.
NOTES
COOLING BLOWER SPEEDS
NOM. A/C
CFM@
SPEED (COLOR)
(TONS)
.50" WC
2
LOW (RED)
775
FLF/R085D36F
2.5
MED (BLUE)
1070
3
HIGH (BLACK)
1275
2.5
LOW (RED)
1065
3
MED LOW (ORANGE)
1235
FLF/R110D48F
3.5
MED HIGH (BLUE)
1415
4
HIGH (BLACK)
1525
3
LOW (RED)
1190
FLF/R110D60F
3.5
MED LOW (ORANGE)
1400
FLR140D60F
4
MED HIGH (BLUE)
1640
5
HIGH (BLACK)
2250
UNIT
Rc Y G W Rh
BLOWER CAPACITOR RATING
UNIT
MOTOR CAPACITOR
FLF/R085D36F
1/3
5/370
FLF/R110D48F
1/2
7.5/370
FLF/R110D60F
3/4
15/370
FLR140D60F
24V.
CONN.
COND.
UNIT
C Y
FLR140D60F
FLF/R110D48F
FLF/R110D60F
FLF/R085D36F
UNIT
FACTORY SETTINGS
TEMP.
HTG. BLWR
GPH INPUT
RISE
SPD. (COLOR)
0.55
LOW (RED)
60°-90°
0.65
LOW (RED)
60°-90°
0.75
MED (BLUE)
60°-90°
0.85 MED. HIGH (BLUE)60°-90°
1
MED. HIGH (BLUE)60°-90°
1.1
MED. HIGH (BLUE)60°-90°
1.25 MED. HIGH (BLUE)60°-90°
IGNITOR
CAD CELL
IGNITOR
CAD CELL
BLACK
BLACK
BLACK
BLACK
RED
WHITE
BLACK
BLUE
BLOWER ASSEMBLY (1/3 HP)
BROWN
BROWN
BLOWER CAPACITOR
(5/370)
DOOR
SWITCH
BURNER
MOTOR
BURNER
MOTOR
BACKUP LIMIT
OIL VALVE
L1
L2
VALVE
BURNER ASS'Y
1
2
3
4
5
1
2
3
4
1
2
150
180
210
240
3
BLOWER CONTROL
R W G Y C
PURPLE
PURPLE
SEE CHART FOR
"HEAT" AND "COOL"
WIRE COLORS.
2
HEAT
BLACK
COM 120V
SPR3
4
CONTROL PANEL
24V
TRANSFORMER
WHITE
SEC2
L1
T
T
SEC1
BLACK
COOL
EAC
1
HUM
PRIMARY LIMIT
L2
COM
WHITE
WHITE
WHITE
HEAT EX. AREA
FC SERIES
WIRING DIAGRAM
SPR1
SPR2
TT
RETURN AREA
BLACK
YELLOW
WHITE
GREEN
BLACK
BLACK
Manual 2100-422M
Page
42 of 42
Rc Y G W Rh
NEUTRAL
GROUND
HOT
! DANGER
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
5
4
4047-120 D
ONLY ONE HEATING
AND COOLING SPEED
CAN BE CONNECTED.
ALL OTHER TAPS
CONNECT TO "SPARE"
TERMINALS.
DASHED LINES
REPRESENT FIELD WIRING.
IF PRIMARY LIMIT WIRES
ARE TO BE REPLACED,
1 USE WIRE WITH INSUL.
TEMP. RATING OF 200°C.
HEATING SPEED
2 CONNECTION POINT.
COOLING SPEED
3 CONNECTION POINT.
NOTES
CFM@
.50" WC
775
1070
1230
T87F/Q539A1220
OR EQUIVELANT
COLING BLWR.
SPEED
HIGH (BLACK)
HIGH (BLACK)
HIGH (BLACK)
THERMOSTAT
5
COOLING BLOWER SPEEDS
NOM. A/C
UNIT
SPEED (COLOR)
(TONS)
D
LOW (RED)
FC085D36F
2.5
MED (BLUE)
3
HIGH (BLACK)
24V.
CONN.
COND.
UNIT
C Y
FC085D36F
UNIT
FACTORY SETTINGS
TEMP.
HTG. BLWR
GPH INPUT
RISE
SPD. (COLOR)
0.55
LOW (RED)
60°-90°
0.65
LOW (RED)
70°-100°
0.75
MED (BLUE)
60°-90°