Bard FLR110D60F User Manual

Size:
1.11 Mb
Download

L i n e d

C h i m n e y

FIGURE 5

TYPICAL FLUE INSTALLATION REQUIREMENTS FRONT FLUE LO-BOYMODEL SHOWN

(REPRESENTS ALL MODELS)

Thimble

INSTALLER NOTE:

 

 

Follow all appropriate

 

standards for installing

 

needed venting system.

 

Draft Regulator

 

(Be sure to follow

 

installation inst.

1/4 inch per

supplied with

regulator).

1 foot rise

 

 

90° Rotatable

 

Flue Box on front

 

flue models

 

(remove appropriate

 

cabinet knockout).

 

Mounting screws

 

located under flue

 

box cover.

 

Flue Box

 

Cover

Optional

Flue

Locations

Oil Burner

Clean-outDoor

Optional Fresh

 

(keep closed)

Air Boot (remove

MIS-1825

 

rect. knockout).

 

 

 

 

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

First determine whether the pipe system is to be a single line system or a two line system. All connections must be absolutely air tight or you will have a malfunction of the burner. When installing the piping, a good oil filter should be installed close to the burner. A single line system is recommended for gravity feed.

A typical single inside tank installations shown in Figure 6. For installation details for this and other tank configurations, refer to NFPA31 --latest edition. All tank and pipe setups must comply with NFPA31.

BECKETT AFG OR NX OIL BURNER

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.

FIGURE 6

TYPICAL SINGLE INSIDE TANK INSTALLATION

Vent Cap

2" Cap

2" Fill Pipe

1-1/4"

 

 

Return Line

Vent Pipe

 

 

 

 

 

 

 

 

Guage

Oil

 

 

Bushing,

 

 

2" x 1-1/2"or

Tank

 

 

 

 

1-1/4"

 

 

 

 

 

 

Gate Valve

 

 

 

3/8" x 4"

 

6"

 

nipple

 

 

 

 

 

 

3/8" x 3/8"

 

 

 

Adapter

 

 

 

3/8" O.D. Copper

 

 

 

Fuel Tubing

Legs (either 1-1/4"x10"

 

 

MIS-1823

or 1-1/2"x10"nipples)

Bushing

Oil Filter

Manual

2100-422M

Page

12 of 42

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.

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.

BECKETT “CLEANCUT” OIL PUMP

This oil pump is equipped with an oil solenoid valve installed in the pump housing. This feature provides quick cutoffs resulting in reduction in smoke after the burner shuts down. This is a time proven pump design and is capable of both one and two pipe systems. All installation and set up instructions are outlined in the “Oil Pump Specification” section of the installation instructions manual.

BECKETT SOLID STATE IGNITER

This igniter differs from the traditional iron core transformer in that it produces a 14,000 volt spark instead of a 10,000 volt spark of the iron core transformer. This hotter spark provides for cleaner, faster ignitions. Being solid state technology this igniter is less susceptible to problems caused by voltage variations. It also has a greater ability to ignite cold and/or inconsistent oil. The solid state igniter is wired to the primary control the same as an iron core transformer.

GENISYS 7505 PRIMARY CONTROL

The Genisys 7505 Interrupted Electronic Oil Primary is a line voltage, safety rated, interrupted ignition oil primary control for residential oil burners. The Genisys 7505 used with a cad cell flame sensor, operates the oil burner and oil valve. The primary controls fuel oil, senses flame, controls ignition spark and is designed to notify a remote alarm circuit before going into lockout when equipped with a flame monitoring system.

This primary 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.

Manual

2100-422M

Page

13 of 42

BECKETT GENISYS

MODEL 7505

MIS-2491

PRIMARY OPERATIONAL GUIDE

BECKETT GENISYS 7505

Sequence of Operation

BURNER STATES

1.Standby: The burner is idle, waiting for a call for heat.

2.Valve-OnDelay (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-OnDelay.

The Recycle mode 30-secondtime budget expires (see “Recycle” section for complete explanation of recycle time budget).

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-OffDelay (Postpurge), if applicable, or it is shut down and sent to Standby.

7.Recycle: If the flame is lost while the burner is firing, the control shuts down the burner, enters a 60-secondrecycle delay and then repeats the ignition sequence. The control will continue to Recycle each time the flame is lost until the accumulatedoil-flow-without-flametime 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-OffDelay: If applicable, the fuel valve is closed and the control delays turning the motor off for the setmotor-offdelay 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.

Manual

2100-422M

Page

14 of 42

TABLE A

RESET BUTTON OPERATION

If the burner is in the

 

Pushing the Reset button will:

 

 

 

Button Click

Button Hold

Button Hold

below state:

 

(press < 1 second)

(press > 1 second)

(press 15+ seconds)

Lockout

Reset from Soft Lockout

 

Reset from Restricted (Hard) Lockout

 

 

 

 

Valve-onDelay,

Go to Pump Prime

 

 

Trial for Ignition,

Disable the Burner:

 

(see Below)

Enables Pump Priming:

Ignition Carryover

 

Any time the burner is running,

 

 

After the reset button has been held for

 

Yellow LED flashes to

press and hold the reset button

 

15 seconds, the button can then be

 

indicate cad cell resistance.

to disable the burner.

tapped during the next ignition sequence

 

The burner will remain off as

Run (igniter is shut off)

See "Cad Cell Resistance

to enter Pump Prime mode.

long as the button is held.

 

Indicator" for table of

 

 

 

 

 

resistance values.

 

 

 

 

 

 

Motor-OffDelay, Standby

No action

 

 

 

 

 

 

Pump Prime

No action

Exit Pump Prime mode and return to Standby

 

 

 

 

TABLE B

STATUS LIGHTS

LED

On Continuously

Flashing

Color

 

 

 

 

 

Red

Restricted (hard) Lockout

Soft Lockout

Green

Flame Detected (Could be flame or stray light)

Recycle

Yellow

Control is in Pump Prime mode or

Cad Cell resistance. See "Cad Cell Resistance Indicator"

Reset button currently held for 15+ seconds

section for table of resistance values.

 

 

 

 

Manual

2100-422M

Page

15 of 42

PRIMING THE PUMP

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.

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-enterPump 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)

 

 

 

 

Manual 2100-422M

Page 16 of 42

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–Tsignal 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

HEATING BLOWER

OFF DELAY

ADJUSTMENT

IN SECONDS.

HUMIDIFIER

CONNECTION

HEATING BLOWER

SPEED CONNECTION

COOLING BLOWER

SPEED CONNECTION

TRANSFORMER 24V

SECONDARY

CONNECTIONS

3 AMP FUSE

OIL PRIMARYT-T

CONNECTIONS

LINE VOLTAGE

CONNECTION (HOT)

UNUSED BLOWER MOTOR

SPEED CONNECTIONS

LINE VOLTAGE

CONNECTION (COM, L2)

ELECTRIC AIR

MIS-1819

CLEANER CONNECTION

 

Manual

2100-422M

Page

18 of 42

TABLE 4

FURNACE DATA

Model

Burner

Furnace

 

 

Nozzle

 

Heating

Heating

 

 

 

 

 

 

 

 

 

 

Input

Output

Number

Type

Type

 

 

 

 

 

Size

 

Type

 

Pump Pressure

BTUH

BTUH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.75

*

 

 

 

105,000

87,000

FC085D36F

AFG

Counterflow

 

 

70° Hollow

 

100 PSIG

 

 

0.65

 

 

91,000

76,000

 

 

 

0.55

 

 

 

 

77,000

64,000

 

 

 

 

 

 

 

 

 

 

 

 

 

0.75

*

 

 

 

105,000

87,000

FH085D36F

AFG

Hi-Boy

 

 

70° Hollow

 

100 PSIG

 

 

0.65

 

 

91,000

76,000

 

 

 

0.55

 

 

 

 

77,000

64,000

 

 

 

 

 

 

 

 

 

 

 

 

 

0.85

*

 

 

 

140,000

116,000

FH110D48F

NX

Hi-Boy

 

 

60° Solid

 

150 PSIG

 

 

0.75

 

119,000

99,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.85

*

 

 

 

140,000

116,000

FH110D60F

NX

Hi-Boy

 

 

60° Solid

 

150 PSIG

 

 

0.75

 

119,000

99,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.75

*

 

 

 

105,000

87,000

FLF085D36F

AFG

Lo-Boy

 

 

70° Hollow

 

100 PSIG

 

 

0.65

 

 

91,000

76,000

 

 

 

0.55

 

 

 

 

77,000

64,000

 

 

 

 

 

 

 

 

 

 

 

 

 

0.85

*

 

 

 

140,000

116,000

FLF110D48F

NX

Lo-Boy

 

 

60° Solid

 

150 PSIG

 

 

0.75

 

119,000

99,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.85

*

 

 

 

140,000

116,000

FLF110D60F

NX

Lo-Boy

 

 

60° Solid

 

150 PSIG

 

 

0.75

 

119,000

99,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.75

*

 

 

 

105,000

87,000

FLR085D36F

AFG

Lo-Boy

 

 

70° Hollow

 

100 PSIG

 

 

0.65

 

 

91,000

76,000

 

 

 

0.55

 

 

 

 

77,000

64,000

 

 

 

 

 

 

 

 

 

 

 

 

 

1.00

*

 

 

 

140,000

116,000

FLR110D48F

AFG

Lo-Boy

 

 

70° Hollow

 

100 PSIG

 

 

0.85

 

119,000

99,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.00

*

 

 

 

140,000

116,000

FLR110D60F

AFG

Lo-Boy

 

 

70° Hollow

 

100 PSIG

 

 

0.85

 

119,000

99,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.25

*

 

 

 

175,000

145,000

FLR140D60F

AFG

Lo-Boy

 

 

70° Hollow

 

100 PSIG

 

 

1.10

 

154,000

127,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

* Factory Installed Nozzle. Also shown are optional approved nozzle size/type.

BURNER SETUP AND ADJUSTMENT PROCEDURES

All oil burner installations should be performed by a qualified installer in accordance with regulations of the National Fire Protection Standard for Oil-BurningEquipment, 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 installoil-burningequipment 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.PREPARATIONSTEPS

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-lineoil 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

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.COMBUSTIONDIAGNOSIS

L.Check Performance A well-matchedandwell-tunedburner 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:

Manual

2100-422M

Page

20 of 42