321 Studios FLR085D36E, FLF110D60E, FH085D36E, FC085D36E, FLR140D60E User Manual
...
OIL FURNACE
INSTALLATION INSTRUCTIONS
MODELS
FH085D36E FH110D48E FH110D60E
FLF085D36E FLF110D48E FLF110D60E
FLR085D36E FLR110D48E FLR110D60E
FLR140D60E FC085D36E
WARNING
READ ALL INSTRUCTIONS CAREFULL Y BEFORE BEGINNING THE
INSTALLATION.
THIS INST ALLATION MUST COMPL Y WITH THESE INSTRUCTIONS AND
THE REQUIREMENTS OF ALL GOVERNING CODES AND ORDINANCES FOR
THE INST ALLATION LOCA TION.
IT IS THE RESPONSIBILITY OF INSTALLER TO KNOW AND UNDERSTAND
ALL OF THESE REQUIREMENTS.
F AILURE TO DO SO COULD CREATE A HAZARD RESUL TING IN PROPER TY
DAMAGE, BODIL Y INJURY OR DEATH.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE V APORS OR
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
IMPORTANT NOTICE
THIS FURNACE IS NOT INTENDED FOR USE AS A CONSTRUCTION
HEA TER. USE OF THIS FURNACE DURING CONSTRUCTION AND FINISHING
PHASES OF A STRUCTURE IS CONSIDERED AS "OPERA TION IN A
CORROSIVE A TMOSPHERE" AND "UNUSUAL, NEGLIGENT OR IMPROPER
USE" AND AS SUCH ARE CONSIDERED EXCLUSIONS BY THE BARD
MANUFACTURING COMPANY LIMITED WARRANTY.
Bard Manufacturing Company
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Manual: 2100-422B
Supersedes: 2100-422A
File: VOL. I, TAB 3
Date: 09-23-03
Copyright 2003
CONTENTS
Getting Other Information and Publications .........1
Installation and Operating Instructions
Equipment Selection...............................................2
Locating the Furnace..............................................2
Installing the Furnace .............................................6
Duct Work...............................................................6
Installing a Cooling Unit..........................................6
Wiring ...............................................................7
Oil Line Piping ......................................................10
Beckett AFG Oil Burner ........................................10
Beckett “CleanCut” Oil Pump ............................... 11
Beckett Solid State Igniter ....................................11
Beckett R7184B Primary Control.......................... 11
Beckett R7184B Primary Operational Guide ........12
Burner Set up and Adjustments ........................... 14
Short Form Adjustment Procedure .......................16
Combustion Air Requirements..............................20
Louvers and Grilles...............................................25
Venting Options ....................................................25
Thermostat ...........................................................25
T ABLES
Table 1 Minimum Clearances ............................. 2
Table 2 Dimensions FLF/R Models.................... 3
Table 3 Electrical Data ........................................ 7
Table 4 Furnace Data ....................................... 14
Table 5 Correlation of % of CO
Reserve Air .......................................... 19
Table 6 No. 2 Fuel Oil Efficiency Chart ............. 19
T able 7 Recommended Start-Up Settings ........ 19
Table 8 Sq.Ft. Required as
Unconfined Space................................ 22
Table 9 Minimum Ventilation Openings............. 23
Table 10 Temperature Rise Ranges, Limit
Control Settings, and
Heating Blower Speeds........................ 26
Table 11 Filter Sizes for Gas Furnaces............... 27
CHARTS
Chart 1 FH085D36E Data................................. 33
Chart 2 FH1 10D48E Data ................................. 33
Chart 3 FH1 10D60E Data ................................. 33
Chart 4 FLF/FLR085D36E Data ....................... 33
Chart 5 FLF/FLR1 10D48E Data ........................ 33
Chart 6 FLF/FLR1 10D60E Data ........................ 33
Chart 7 FLR140D60E Data............................... 34
Chart 8 FC085D36E Data................................. 34
, O2 and
2
Filters
Upflow & Counterflow Filter Information .............237
Lo-Boy Models – Filter Locations .......................28
Maintenance
Lubrication ............................................................29
Inspect Air Filter....................................................29
Final Inspection and Test......................................29
Service Hints ........................................................29
Combination Combustion Chamber/Burner
Mounting System..................................................30
To Remove Burner Only .......................................31
To Remove Entire Combustion Chamber
Mounting System..................................................31
Common Causes of Trouble.................................32
Care of Finish .......................................................32
Cleaning of the Heat Exchanger...........................32
Blower System Resistance Charts ................. 33-34
Wiring Diagrams............................................. 35-37
FIGURES
Figure 1 FL/R Models Dimensions................... 3
Figure 2 FH Models Dimensions...................... 4
Figure 3 FC Models Dimensions...................... 5
Figure 4 T ypical Unit Setup - FLF .................... 8
Figure 5 T ypical Flue Installation
Requirements - FLF........................... 9
Figure 6 T ypical Single Inside
Tank Installation ............................... 10
Figure 7 Electronic Blower Control ................ 13
Figure 8 T ypical Smoke-CO
Figure 9 Pressure Gauge Connection to
Pressure Gauge Port....................... 18
Figure 10 Electrode Adjustments..................... 20
Figure 1 1 Combination Air Boot Assembly ...... 21
Figure 12 All Air From Inside Building.............. 22
Figure 13 All Air From Outdoors ...................... 23
Figure 14 All Air From Outdoors Through
Ventilated Attic................................. 24
Figure 15 All Air From Outdoors - Inlet Air
From Ventilated Crawl Space and
Outlet Air to Ventilated Attic............. 24
Figure 16 T ypical Installation of 16x25x1
Filter Rack........................................ 27
Figure 17 T ypical Installation of 20x25x1
Filter Rack........................................ 27
Figure 18 Filter Installation - Lo-Boy Models ... 28
Figure 19 Removal of Burner Only .................. 30
Figure 20 Removal of Entire Combustion
Chamber Mounting System ............. 31
Characteristic... 17
2
i
GETTING OTHER INFORMA TION 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
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACC A 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
Duct Design for Residential .............. ACCA Manual D
Winter and Summer Air Conditioning
and Equipment Selection
NFPA National Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: (800) 344-3555
Fax: (617) 984-7057
Manual 2100-422
Page 1
INST ALLATION and OPERA TING 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
sehcnI—secanraelCnoitallatsnImuminiM
1
ledoM
E63D580HF
E84D011HF
E06D011HF
E63D580CF
j
For the first three (3) feet from plenum. After three (3) feet, no clearance required.
C
Combustible flooring
NC
Noncombustible floor
*
Maintained on one side or the other to achieve filter access and/or blower service.
**
Floor must be noncombustible. For furnace only installation can be installed on combustible
flooring only when installed on special base part no. CFB7 available from factory. When air
conditioning coil cabinet DCB23-22 is used then use special base part no. CFB23.
4
4
4
6
E63D580FLF
6
E63D580RLF
6
E84D011FLF
6
E06D011FLF
6
E84D011RLF
6
E06D011RLF
6
E06D041RLF
6
1
1
1
0
81
0
0
81
81
81
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
tcuD
2
2
2
2
2
2
2
2
2
2
2
eulF
epiProolFtnorFkcaBsediSpoTsediStnorFkcaBsediS
9
9
9
9
9
9
9
9
9
9
9
C
C
C
CN
CN
CN
CN
CN
CN
CN
CN **
ecivreSmuminiM
secnaraelCecanruFmunelP
—
42
—
42
—
42
42
42
42
42
42
42
42
—
42
—
—
—
42
42
42
42
42
42
42
*81
*81
*81
*81
*81
*81
*81
—
Manual 2100-422
Page 2
FLF/FLR 085, 110 AND 140
ledoM
rebmuN
tenibaC
munelP
sgninepOnoitcenoCeulFsretliFriA 1
A
htdiW
B
htpeD
C
thgieH
ExD
ylppuS
FxD
nruteRnoitacoL
G
.aiDHJ eziS
.oN
desU
E63D580FLF
E63D580RLF
32
32
521.84
521.84
526.63
526.63
02x22
02x22
41x22
41x22
tnorF
raeR
6
6
526.13
526.13
521.5
521.5
1x02x61
1x02x61
1
1
E84D011FLF
E06D011FLF
E84D011RLF
E06D011RLF
32
32
32
32
521.84
521.84
521.84
521.84
526.04
526.04
526.04
526.04
02x22
02x22
02x22
02x22
41x22
41x22
41x22
41x22
tnorF
tnorF
raeR
raeR
6
6
6
6
526.53
526.53
526.53
526.53
521.5
521.5
521.5
521.5
1x02x02
1x02x02
1x02x02
1x02x02
1
1
1
1
E06D041RLF62052.05526.7402x5261x52raeR6521.24---1x52x021
SPECIFICATION SHEET
FIGURE 1
FLF/R MODELS DIMENSIONS
TABLE 2
FLF/R MODELS DIMENSIONS (INCHES)
J
"FLF" FLUE
KNOCKOUT
A
TOP VIEW
HIGH VOLTAGE
LOW VOLTAGE
KNOCKOUT
"FLF" FLUE
KNOCKOUT
OPTIONAL
ENTRANCE
OPTIONAL
ENTRANCE
OIL
ENTRANCE
OPTIONAL
OIL
ENTRANCE
FRESH AIR
SUPPLY
DUCT
EF
RETURN
DUCT
D
G
REAR FLUE
ON "FLR" MODELS
H
Manual 2100-422
Page 3
FILTER
DOOR
j
Washable type filter 1” nom. thickness
"FLF" FLUE
KNOCKOUT
LOW VOLTAGE
ENTRANCE
C
HIGH VOLTAGE
ENTRANCE
OPTIONAL
OIL ENTRANCE
B
RIGHT SIDE VIEWFRONT VIEWLEFT SIDE VIEW
MIS-1815 A
Manual 2100-422
Page 4
FIGURE 2
FH MODELS DIMENSIONS
16"
19 1/4"
RETURN
OPENING
(CUT OUT)
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"
SUPPLY
OPENING
30 1/2"
REAR CLEANOUT
53" (FH085)
59" (FH110)
LOW VOLTAGE
FLUE
KNOCKOUT
DOOR
HIGH
VOLTAGE
ENTRANCE
ENTRANCE
OPTIONAL
OIL
ENTRANCE
FH085 AND FH110
SPECIFICATION SHEET
RETURN
OPENING
(CUT OUT)
LEFT SIDE VIEW
FRONT VIEW
RIGHT SIDE VIEW
MIS-1814 A
FC085
FIGURE 3
FC085 MODEL DIMENSIONS
21 7/8"
19 7/8"
SUPPLY
OPENING
SPECIFICATION
SHEET
FLUE
KNOCKOUT
OPTIONAL
HIGH VOLTAGE
ENTRANCE
OPTIONAL
LOW VOLTAGE
ENTRANCE
OIL ENTRANCE
OPTIONAL
OIL ENTRANCE
23"
30 1/2"
TOP VIEW
FLUE
KNOCKOUT
54 1/4"
FLUE
KNOCKOUT
REAR
CLEANOUT
DOOR
LOW VOLTAGE
ENTRANCE
HIGH VOLTAGE
ENTRANCE
FRESH AIR
KNOCKOUT
LEFT SIDE VIEW
BOTTOM VIEW
RETURN
OPENING
FRONT VIEW
19 1/8"
OPTIONAL
OIL ENTRANCE
RIGHT SIDE VIEW
18 1/8"
MIS-1826
Manual 2100-422
Page 5
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.
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.
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 2.)
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.
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 two (2) 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 33-36
for additional information.
Manual 2100-422
Page 6
WIRING
FIELD 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.
ELECTRICAL DATA
latoT
ledoMHP-ZH-stloV
E63D580HF1-06-5112.93/15.77/17.15151
E84D011HF1-06-5112.212/15.017/17.16102
E06D011HF1-06-5112.414/35.217/17.19102
E63D580FLF1-06-5113.713/16.57/17.15151
E63D580RLF1-06-5113.713/16.57/17.15151
E84D011FLF1-06-5112.212/15.017/17.16102
E84D011RLF1-06-5112.212/15.017/17.16102
E06D001FLF1-06-5112.414/35.217/17.19102
E06D001RLF1-06-5112.414/35.217/17.19102
E06D041RLF1-06-5112.414/35.217/17.19102
E63D580CF1-06-5113.73/16.57/17.15151
spmA
PHALFPHALF
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
rotoMrewolBrotoMrenruB
emiT.xaM
muminiM
tiucriC
yticapmA
esuFyaleD
RCAHro
rekaerBtiucriC
Manual 2100-422
Page 7
FIGURE 4
TYPICAL UNIT SETUP
FLF UNIT SHOWN
WARNING
ALL WIRING MUST
CONFORM TO THE
NATIONAL ELECTRIC
!
CODE AND ALL LOCAL
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
CODES.
TYPICAL UNIT
SETUP
(FLF UNIT SHOWN)
Inspection
door
Right side
low voltage
(thermostat)
entrance
To thermostat
and optional
A/C unit
Oil line
(see burner
pump inst. for
hookup info.)
Air Boot
knockout
(optional)
Control panel
(junction box
in FH units)
Manual 2100-422
Page 8
Right side
high voltage
(unit power)
entrance
Right side
oil line
entrance
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)
MIS-1836
FIGURE 5
TYPICAL FLUE INSTALLATION REQUIREMENTS
FRONT FLUE LOWBOY MODEL SHOWN
(REPRESENTS ALL MODELS)
L
n
e
d
C
h
Thimble
INSTALLER NOTE:
Follow all appropriate
standards for installing
needed venting system.
Draft Regulator
(Be sure to follow
installation inst.
1/4 inch per
1 foot rise
i
supplied with
regulator).
90° Rotatable
Flue Box on front
flue models
(remove appropriate
cabinet knockout).
Mounting screws
located under flue
box cover.
Flue Box
Cover
Clean-out Door
(keep closed)
i
m
n
e
y
Optional Fresh
Air Boot (remove
rect. knockout).
Optional
Flue
Locations
Oil Burner
MIS-1825
Manual 2100-422
Page 9
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.
TYPICAL SINGLE INSIDE TANK INSTALLATION
Vent Cap
BECKETT AFG OIL BURNER
This furnace is equipped with a high static Beckett AFG
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 Beckett R7184B
primary control.
FIGURE 6
2" Cap
1-1/4"
Vent Pipe
Oil
Tank
2" Fill Pipe
Return Line
Guage
Bushing,
2" x 1-1/2" or
1-1/4"
Gate Valve
3/8" x 4"
nipple
6"
3/8" x 3/8"
Adapter
Legs (either 1-1/4"x10"
or 1-1/2"x10" nipples)
Manual 2100-422
Page 10
Bushing
Oil Filter
3/8" O.D. Copper
Fuel Tubing
MIS-1823
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