Bard FC085D36F User Manual

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OIL FURNACE

INSTALLATION INSTRUCTIONS

 

MODELS

 

FH085D36F

FH110D48F

FH110D60F

FLF085D36F

FLF110D48F

FLF110D60F

FLR085D36F

FLR110D48F

FLR110D60F

FLR140D60F

FC085D36F

 

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.

Manual:

2100-422M

Bryan, Ohio 43506

Supersedes:

2100-422L

Since 1914...Moving ahead just as planned.

File:

VOL. I, TAB 3

Date:

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

 

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 .............................

Minimum Clearances

 

4

Table 2 ...................

Dimensions FLF/R Models

 

5

Table 3 ........................................

Electrical Data

 

9

Table A .......................

Reset Button Operation

 

15

Table B ........................................

Status Lights

 

15

Table 4 .......................................

Furnace Data

 

19

Table 5

Correlation of % of CO 2 , 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

CHARTS

 

 

 

Chart 1 .................................

FH085D36F Data

 

38

Chart 2 .................................

FH110D48F Data

 

38

Chart 3 .................................

FH110D60F Data

 

38

Chart 4 .......................

FLF/FLR085D36F Data

 

38

Chart 5 .......................

FLF/FLR110D48F Data

 

38

Chart 6 .......................

FLF/FLR110D60F Data

 

38

Chart 7 ...............................

FLR140D60F Data

 

39

Chart 8 .................................

FC085D36F Data

 

39

Filters

 

Lo-BoyModels – 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

FIGURES

 

 

Figure 1

FLF/R Models Dimensions ................

5

Figure 2

FH Models Dimensions .....................

6

Figure 3

FC Models Dimensions .....................

7

Figure 4

Typical Unit Setup - FLF ..................

10

Figure 5

Typical Flue Installation

 

 

Requirements - FLF ........................

11

Figure 6

Typical Single Inside

 

 

Tank Installation...............................

12

Figure 7

Electronic Blower Control ................

18

Figure 8

Typical Smoke-CO2 Characteristic ..

22

Figure 9

Pressure Gauge Connection to

 

 

Bleed Port .......................................

23

Figure 10

Electrode Adjustments .....................

25

Figure 11

Combustion Air Boot Assembly .......

26

Figure 12

All Air From Inside Building .............

27

Figure 13

All Air From Outdoors ......................

28

Figure 14

All Air From Outdoors Through

 

 

Ventilated Attic .................................

29

Figure 15

All Air From Outdoors - Inlet Air

 

 

From Ventilated Crawl Space and

 

 

Outlet Air to Ventilated Attic .............

29

Figure 16

Typical Installation of FR26 and FR27.

 

Filter Rack .......................................

32

Figure 17

Typical Installation of FR25 Filter

 

 

Kit ....................................................

32

Figure 18

Filter Installation - Lo-BoyModels ...

33

Figure 19

Removal of Burner Only ..................

35

Figure 20

Removal of Entire Combustion

 

 

Chamber Mounting System .............

36

Manual

2100-422M

Page

2 of 42

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

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

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

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.

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 Installation Clearnaces — Inches

 

Minimum Service

 

 

 

 

 

 

 

 

 

 

 

 

Furnace

 

Plenum

1

Flue

 

Clearances

 

 

 

 

 

 

 

 

 

 

 

Model

Front

Back

 

Sides

Top

Sides

Duct

Pipe

Floor

Front

Back

Sides

 

 

 

 

 

 

 

 

 

 

 

 

 

FH085D36F

4

1

 

2

2

2

2

9

C

24

FH110D48F

4

1

 

2

2

2

2

9

C

24

FH110D60F

4

1

 

2

2

2

2

9

C

24

 

 

 

 

 

 

 

 

 

 

 

 

 

FLF085D36F

6

0

 

2

2

2

2

9

NC

24

24

18 *

FLR085D36F

6

18

 

2

2

2

2

9

NC

24

24

18 *

FLF110D48F

6

0

 

2

2

2

2

9

NC

24

24

18 *

FLF110D60F

6

0

 

2

2

2

2

9

NC

24

24

18 *

 

 

 

 

 

 

 

 

 

 

 

 

 

FLR110D48F

6

18

 

2

2

2

2

9

NC

24

24

18 *

FLR110D60F

6

18

 

2

2

2

2

9

NC

24

24

18 *

FLR140D60F

6

18

 

2

2

2

2

9

NC

24

24

18 *

FC085D36F

6

1

 

2

2

2

2

9

NC **

24

 

 

 

 

 

 

 

 

 

 

 

 

 

1 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 DCB23-22is used then use special base part no. CFB23.

Manual

2100-422M

Page

4 of 42

Page

Manual

42 of 5

422M-2100

FLF/FLR 085, 110 AND 140 SPECIFICATION SHEET

 

TOP VIEW

J

RETURN

SUPPLY

 

DUCT

 

DUCT

D

G

 

F

E

 

"FLF" FLUE

REAR FLUE

KNOCKOUT

 

ON "FLR" MODELS

OPTIONAL

 

 

HIGH VOLTAGE

 

ENTRANCE

OPTIONAL

LOW VOLTAGE

ENTRANCE

H

OIL

ENTRANCE

OPTIONAL

FILTER OIL

DOOR ENTRANCE

FRESH AIR

KNOCKOUT

LEFT SIDE VIEW

FIGURE 1

FLF/R MODELS DIMENSIONS

TABLE 2

FLF/R MODELS DIMENSIONS (INCHES)

 

 

 

 

 

Plenum

 

 

 

 

 

 

 

 

 

Cabinet

 

Openings

Flue Conection

 

Air Filters

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

A

B

 

C

D x E

D x F

 

G

 

 

 

 

No.

Number

Width

Depth

 

Height

Supply

Return

Location

Dia.

H

J

Size

 

Used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FLF085D36F

23

48.125

 

36.625

22x20

22x14

Front

6

31.625

5.125

16 x 20 x 1

 

1

FLR085D36F

23

48.125

 

36.625

22x20

22x14

Rear

6

31.625

5.125

16 x 20 x 1

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FLF110D48F

23

48.125

 

40.625

22x20

22x14

Front

6

35.625

5.125

20 x 20 x 1

 

1

FLF110D60F

23

48.125

 

40.625

22x20

22x14

Front

6

35.625

5.125

20 x 20 x 1

 

1

FLR110D48F

23

48.125

 

40.625

22x20

22x14

Rear

6

35.625

5.125

20 x 20 x 1

 

1

FLR110D60F

23

48.125

 

40.625

22x20

22x14

Rear

6

35.625

5.125

20 x 20 x 1

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FLR140D60F

26

50.250

 

47.625

25x20

25x16

Rear

6

42.125

- - -

20 x 25 x 1

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 Washable type filter 1” nom. thickness

"FLF" FLUE KNOCKOUT

A

B

 

"FLF" FLUE

 

KNOCKOUT

 

LOW VOLTAGE

 

ENTRANCE

C

HIGH VOLTAGE

 

ENTRANCE

 

OPTIONAL

 

OIL ENTRANCE

FRONT VIEW

RIGHT SIDE VIEW

MIS-1815A

Page

Manual

42 of 6

422M-2100

 

19 1/4"

 

RETURN

16"

OPENING

(CUT OUT)

 

LEFT SIDE VIEW

FIGURE 2

FH MODELS DIMENSIONS

TOP VIEW

19 7/8"

FLUE

KNOCKOUT

FLUE

KNOCKOUT

OPTIONAL

HIGH VOLTAGE

ENTRANCE

OPTIONAL

LOW VOLTAGE

ENTRANCE

OPTIONAL

OIL

ENTRANCE

OIL

ENTRANCE

FRESH AIR

KNOCKOUT

VESTIBULE

DOOR

21 7/8"

23"

FH085 AND FH110

SUPPLY SPECIFICATION SHEET

OPENING

30 1/2"

FLUE

KNOCKOUT

REAR CLEANOUT

DOOR

HIGH

VOLTAGE

ENTRANCE

53" (FH085) 59" (FH110)

LOW VOLTAGE

ENTRANCE

OPTIONAL

OIL

ENTRANCE RETURN OPENING (CUT OUT)

FRONT VIEW

RIGHT SIDE VIEW MIS-1814 A

FIGURE 3

FC085 MODEL DIMENSIONS

22"

COUNTERFLOW 20"

SPECIFICATION

SHEET

FLUE

KNOCKOUT

OPTIONAL

HIGH VOLTAGE

ENTRANCE

OPTIONAL

LOW VOLTAGE

ENTRANCE

OIL ENTRANCE

OPTIONAL

OIL ENTRANCE

FRESH AIR

KNOCKOUT

LEFT SIDE VIEW

SUPPLY

OPENING

RETURN

OPENING

30 5/8"

TOP VIEW

FLUE

23" KNOCKOUT

 

FLUE

 

KNOCKOUT

54 1/4"

REAR

 

CLEANOUT

 

DOOR

 

LOW VOLTAGE

 

ENTRANCE

 

HIGH VOLTAGE

 

ENTRANCE

FRONT VIEW

OPTIONAL

 

OIL ENTRANCE

 

RIGHT SIDE VIEW

18 1/8"

BOTTOM VIEW

 

19 1/8"

MIS-1826A

 

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.

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.

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.

DUCT WORK

The air distribution system should be designed and installed in conformance with manuals published by Air Conditioning Contractors of America (ACCA) as set forth in Manual D, or ASHRAE publications.

IMPORTANT

When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside 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. 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 38-39for additional information.

Manual

2100-422M

Page

8 of 42

WIRING

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.

FIELD 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.

TABLE 3

ELECTRICALDATA

 

 

 

 

 

 

 

 

Max. Time

 

 

 

Blower Motor

Burner Motor

Minimum

Delay Fuse

 

 

 

 

 

 

 

 

 

Total

HP

FLA

HP

FLA

Circuit

or HACR

Model

Volts-HZ-PH

Amps

Ampacity

Circuit Breaker

 

 

 

 

 

 

 

 

 

 

 

 

 

FH085D36F

115-60-1

7.3

1/3

5.6

1/7

1.7

9

15

 

 

 

 

 

 

 

 

 

FH110D48F

115-60-1

12.2

1/2

10.5

1/7

1.7

15

20

 

 

 

 

 

 

 

 

 

FH110D60F

115-60-1

14.2

3/4

12.5

1/7

1.7

18

20

 

 

 

 

 

 

 

 

 

FLF085D36F

115-60-1

7.3

1/3

5.6

1/7

1.7

9

15

 

 

 

 

 

 

 

 

 

FLR085D36F

115-60-1

7.3

1/3

5.6

1/7

1.7

9

15

 

 

 

 

 

 

 

 

 

FLF110D48F

115-60-1

12.2

1/2

10.5

1/7

1.7

15

20

 

 

 

 

 

 

 

 

 

FLR110D48F

115-60-1

12.2

1/2

10.5

1/7

1.7

15

20

 

 

 

 

 

 

 

 

 

FLF110D60F

115-60-1

14.2

3/4

12.5

1/7

1.7

18

20

 

 

 

 

 

 

 

 

 

FLR110D60F

115-60-1

14.2

3/4

12.5

1/7

1.7

18

20

 

 

 

 

 

 

 

 

 

FLR140D60F

115-60-1

14.2

3/4

12.5

1/7

1.7

18

20

 

 

 

 

 

 

 

 

 

FC085D36F

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

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)

Right side high voltage (unit power) entrance

TYPICAL UNIT

SETUP

(FLF UNIT SHOWN)

Inspection door

Right side low voltage (thermostat) entrance

To thermostat and optional A/C unit

To power source

Shut off switch (if not fused, power line must include fuse or circuit breaker)

Power Wires:

Black (HOT) White (NEUTRAL)

Green (GROUND)

Right side

oil line MIS-1836

entrance

Manual

2100-422M

Page

10 of 42