Bard FLR110D60F User Manual

Size:
1.11 Mb
Download

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 otherhigh-temperaturesealant.

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 badlysooted heat exchanger surfaces and excessive draft. The temperature of the flue gas provides an indication of these heat losses.

Measure flue temperature by subtracting the room air temperature from the thermometer reading. Excessive stack loss is indicated 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.

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%.

Manual

2100-422M

Page

21 of 42

Bacharach Smoke Number

FIGURE 8

TYPICAL SMOKE – CO2 CHART WITH ADJUSTMENT RANGE

High

Air Settings

Low

8

CO2 Curve6 from plotted

points

 

 

Plotted point

 

 

 

Normal

 

 

 

 

adjustment

 

 

 

4

range

 

 

 

 

Tolerance

 

 

 

 

to "knee"

 

 

 

 

"Best" air

 

 

 

2

setting

 

Plotted point

 

 

Plotted point

 

 

 

 

 

 

"Knee"

 

0

 

 

 

 

6

8

10

12

14

 

 

Percent CO2

in Flue Gas

 

Bacharach Smoke Number

Technician's

plotting area

8

6

4

2

0

6

8

10

12

14

 

 

Percent CO2

in Flue Gas

MIS-1827

Manual

2100-422M

Page

22 of 42

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

Carbon Dioxide

Oxygen

Reserve Air (Approx.)

 

 

 

15.4

0.0

0.0

15.0

0.6

3.0

14.5

1.2

6.0

 

 

 

14.0

2.0

10.0

13.5

2.6

15.0

13.0

3.3

20.0

 

 

 

12.5

4.0

25.0

12.0

4.6

30.0

11.5

5.3

35.0

 

 

 

11.0

6.0

40.0

10.5

6.7

45.0

10.0

7.4

50.0

 

 

 

TABLE 6

NO. 2 FUEL OIL EFFICIENCY CHART

(NET STACK TEMP. DEGREES F)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

% 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-UPSETTINGS

 

 

 

 

 

Nozzle

 

Air

Air

 

 

Model

Burner Style

 

 

Air Band

Adjustment

 

 

 

 

 

 

Shutter

 

 

Number

Part No.

Size

 

Type

Pump Pressure

Setting

Setting

Plate

 

 

 

 

 

 

Setting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.75

*

 

 

0

6

 

 

FC085D36F

AFG/9020-034

 

 

70° Hollow

100 PSIG

 

 

 

 

 

0.65

 

0

5

 

 

 

 

0.55

 

 

 

0

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.75

*

 

 

0

6

 

 

FH085D36F

AFG/9020-034

 

 

70° Hollow

100 PSIG

 

 

 

 

 

0.65

 

0

5

 

 

 

 

0.55

 

 

 

0

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.85

*

 

 

3.75

 

 

FH110D48F

NX/9020-039

 

 

60° Solid

150 PSIG

 

 

 

 

 

0.75

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.85

*

 

 

3.75

 

 

FH110D60F

NX/9020-039

 

 

60° Solid

150 PSIG

 

 

 

 

 

0.75

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.75

*

 

 

0

6

 

 

FLF085D36F

AFG/9020-034

 

 

70° Hollow

100 PSIG

 

 

 

 

 

0.65

 

0

5

 

 

 

 

0.55

 

 

 

0

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.85

*

 

 

3.75

 

 

FLF110D48F

NX/9020-039

 

 

60° Solid

150 PSIG

 

 

 

 

 

0.75

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.85

*

 

 

3.75

 

 

FLF110D60F

NX/9020-039

 

 

60° Solid

150 PSIG

 

 

 

 

 

0.75

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0.75

*

 

 

0

6

 

 

FLR085D36F

AFG/9020-036

 

 

70° Hollow

100 PSIG

 

 

 

 

 

0.65

 

0

5

 

 

 

 

0.55

 

 

 

0

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.00

*

 

 

2

10

 

 

FLR110D48F

AFG/9020-037

 

 

70° Hollow

100 PSIG

 

 

 

 

 

0.85

 

0

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.00

*

 

 

2

10

 

 

FLR110D60F

AFG/9020-037

 

 

70° Hollow

100 PSIG

 

 

 

 

 

0.85

 

0

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.25

*

 

 

0

8

 

 

FLR140D60F

AFG/9020-038

 

 

70° Hollow

100 PSIG

 

 

 

 

 

1.10

 

0

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Manual

2100-422M

*

 

 

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

Page

24 of 42

 

SPACING OF ELECTRODES

The electrodes should be spaced 5/32" apart. They should extend 1/16" beyond the end and 5/16" above the center of the nozzle tip as shown in Figures 10A & 10B.

GUN ASSEMBLY ADJUSTMENT

The gun assembly can be adjusted in the slot inside of fan housing by loosening screw holding slot cover in position. Nozzle tip should ordinarily be located 1-1/8"behind the front face of the cone.

REMOVING GUN ASSEMBLY

Disconnect the oil line at the fan housing and remove lock nuts on copper tube fitting. Loosen igniter hold down clamps, then swing igniter up and backward. Gun assembly can now be removed through this opening.

COMBUSTION AIR REQUIREMENTS

This furnace must be installed in a location where a sufficient supply of combustion air is available for the complete combustion of the fuel oil. Keep in mind that a certain amount of excess air is required as well to ensure complete combustion of the fuel oil.

When structures are constructed too tightly to supply sufficient combustion air, air from outside the structure is required to be brought in directly to the furnace. This furnace has been conveniently designed to accept a combustion air boot which is attached directly to the outdoors by means of a 4" pipe. This pipe can be rigid or flexible, but it is recommended that a metallic material be used. Refer to Figure 11. The air boot used for this design is a Field Controls model number CAS-2B-90Ethat 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

Page

25 of 42

FIGURE 11

COMBUSTION AIR BOOT ASSEMBLY

AFG BURNER

COMBUSTION

AIR BOOT

ASSEMBLY

USE THIS

KNOCKOUT

INTAKE FOR OIL LINE

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

Page

26 of 42

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

APPLIANCESLOCATED

IN CONFINED SPACES

ALL AIR FROM INSIDE THE BUILDING

TABLE 8

SQUARE FEET REQUIRED TO

QUALIFY AS UNCONFINED SPACE

Total

Unconfined Space

Minimum Area In

BTUH

Square Feet

Input

8' Ceiling Height

 

 

 

60,000

375

80,000

500

 

 

85,000

531

105,000

656

 

 

115,000

719

120,000

750

 

 

140,000

875

145,000

906

 

 

160,000

1000

200,000

1250

 

 

ALL AIR FROM INSIDE BUILDING

The confined space shall be provided with two permanent openings, one near the top of the enclosure and one near the bottom. Each opening shall have a free area of not less than one square inch per 1,000 BTU per hour (140 square inches per gallon per hour) of the total input rating of all appliances in the enclosure freely communicating with interior areas having in turn adequate infiltration from the outside. (See Figure 12.) Also see Table 9 on the following page for specific ventilation opening requirements for the furnace only.

The flow of combustion and ventilating air must not be 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

Page

27 of 42

TABLE 9

MINIMUM VENTILATION OPENINGS

 

 

Recommended

 

Min. Ventilation

Opening

 

(2 Required)

 

Opening

 

 

 

Model

Square Inch

Size

Sq. In.

 

 

 

 

FH085D36F

240

8 x 16

128

 

 

 

 

FH110D48F

280

9 x 18

162

 

 

 

 

FH110D60F

280

9 x 18

162

 

 

 

 

FLF085D36F

290

8 x 19

152

 

 

 

 

FLR085D36F

290

8 x 19

152

 

 

 

 

FLF110D48F

340

9 x 19

171

FLF110D60F

 

 

 

 

 

 

 

FLR110D48F

340

9 x 19

171

FLR110D60F

 

 

 

 

 

 

 

FLR140D60F

360

9.5 x 19

180

 

 

 

 

FC085D36F

240

8 x 16

128

 

 

 

 

ALL VENTILATION AIR FROM OUTDOORS

A.The confined space shall be provided with two permanent openings, one in or near the top of the enclosure and one in or near the bottom. The openings shall communicate directly, or by means of ducts with outdoors or to such spaces (crawl or attic) that freely communicate with outdoors. (See Figures 13, 14, & 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

Page

28 of 42

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

Page

29 of 42

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 30-35percent free area and metal louvers and grilles will have60-75percent 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-resistantmaterial having an upward pitch of 1/4" for every foot of horizontal run, and be made of material capable of handling temperatures up to 1800° F.

A barometric damper is supplied with the furnace and must be installed in the flue pipe observing the instructions packaged with the damper control. The barometric damper opening must be located in the same atmospheric pressure zone as the combustion air inlet to the furnace. The furnace must not be vented into the same chimney with any solid fuel burning appliance such as a wood burner or pellet burner. Masonry chimneys must be lined with a listed system or other approved material that will resist corrosion, softening or cracking from flue gas temperatures up to 1800° F. See Standard for Installation of Oil Burning Equipment NFPA31 latest edition and Standard for Chimneys NFPA211 latest edition for additional information.

HORIZONTALVENTING

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-4HDSfor 085 and 110 models, andSWG-5Sfor 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.

Manual

2100-422M

Page

30 of 42