Bard FH085D36E, FH110D48E, FH110D60E, FLF085D36E, FLF110D48E Installation Instructions 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

, O2 and

2

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

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

Characteristic... 17

2

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

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: [phone]
Fax: [phone]

ANSI American National Standards Institute

11 West Street, 13th Floor
New York, NY 10036
Telephone: [phone]
Fax: [phone]

ASHRAE American Society of Heating Refrigerating,

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.
Atlanta, GA 30329-2305
Telephone: [phone]
Fax: [phone]

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: [phone]
Fax: [phone]

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

Manual 2100-422

Page 3

FIGURE 1

FLF/R MODELS DIMENSIONS

C

A

H

OIL

ENTRANCE
OPTIONAL

OIL

ENTRANCE

OPTIONAL

LOW VOLTAGE

ENTRANCE

OPTIONAL

HIGH VOLTAGE

ENTRANCE

"FLF" FLUE

KNOCKOUT

REAR FLUE

ON "FLR" MODELS

FILTER

DOOR

FRESH AIR

KNOCKOUT

B

"FLF" FLUE

KNOCKOUT

LOW VOLTAGE

ENTRANCE

HIGH VOLTAGE

ENTRANCE

OPTIONAL

OIL ENTRANCE

FLF/FLR 085, 110 AND 140

SPECIFICATION SHEET

MIS-1815 A

EF

G

D

J

"FLF" FLUE
KNOCKOUT

RETURN

DUCT

SUPPLY

DUCT

RIGHT SIDE VIEWFRONT VIEWLEFT SIDE VIEW

TOP VIEW

j

Washable type filter 1” nom. thickness

TABLE 2

FLF/R MODELS DIMENSIONS (INCHES)

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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

Manual 2100-422

Page 4

FIGURE 2

FH MODELS DIMENSIONS

53" (FH085)

59" (FH110)

23"

VESTIBULE

DOOR

FRONT VIEW

30 1/2"

21 7/8"

19 7/8"

FLUE

KNOCKOUT

SUPPLY

OPENING

FH085 AND FH110

SPECIFICATION SHEET

19 1/4"

16"

RETURN

OPENING

(CUT OUT)

OPTIONAL

OIL

ENTRANCE

OIL

ENTRANCE

FRESH AIR
KNOCKOUT

OPTIONAL

HIGH VOLTAGE

ENTRANCE

OPTIONAL

LOW VOLTAGE

ENTRANCE

FLUE

KNOCKOUT

RETURN

OPENING

(CUT OUT)

LEFT SIDE VIEW

TOP VIEW

OPTIONAL

OIL

ENTRANCE

LOW VOLTAGE

ENTRANCE

FLUE

KNOCKOUT

HIGH

VOLTAGE

ENTRANCE

RIGHT SIDE VIEW

REAR CLEANOUT

DOOR

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

RETURN
OPENING

BOTTOM VIEW

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)

m

n
e
y

i

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