Bard FC085V42A, FH110V60A, FH085V42A, FH110V48A, FLF085V42A Installation Instructions Manual

OIL FURNACE

INSTALLATION INSTRUCTIONS

MODELS

FC085V42A FH085V42A FH110V48A
FH110V60A FLF085V42A FLF110V48A
FLF110V60A FLR085V42A FLR110V48A
FLR110V60A FLR140V60A

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.
Bryan, Ohio 43506

Since 1914...Moving ahead just as planned.

Manual: 2100-540D
Supersedes: 2100-540C
File: VOL. I, TAB 3
Date: 04-24-13

Manual 2100-540D
Page 1 of 45

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 GeniSys 7505 ...........................14 & 16-17

Burner States, Reset Button Op., Priming the Pump, Cad
Cell Resistance Indicator, Reset Restricted Lockout

Troubleshooting GE ECM2.3......................... 21-23

Burner Setup and Adjustments ...................... 24-26

Short Form Adjustment Procedure ..................... 26

Combustion Air Requirements ............................ 30

Louvers and Grilles............................................. 35

Venting Options .................................................. 35

Thermostat.......................................................... 35

T ABLES

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 C Heating Tap Select Settings................. 19

Table D Cooling Tap Select Settings .................19

Table E Adjustment Tap Selects ....................... 20

Table F Heating Delay Profile Taps .................. 20

Troubleshooting GE ECM2.3............... 21

Table 4 Furnace Data.......................................24

Table 5 Correlation of % of CO

Reserve Air .......................................... 29

, O2 and

2

Table 6 No. 2 Fuel Oil Efficiency Chart.............29

Table 7 Recommended Start-Up Settings ........29

Table 8 Sq.Ft. Required as

Unconfined Sp ace ............................... 32

Table 9 Minimum Ventilation Openings ............33

Table 10 Temperature Rise Ranges, Limit

Control Settings, and

Heating Blower Speeds ....................... 36

Table 11 Filter Sizes for Oil Furnaces ................ 37

Manual 2100-540D
Page 2 of 45

Filters

Lo-Boy Models – Filter Locations.................37-38

Maintenance

Lubrication .......................................................... 39

Inspect Air Filter .................................................. 39

Final Inspection and Test .................................... 39

Service Hints....................................................... 39

Combination Combustion Chamber/Burner

Mounting System ................................................ 40

To Remove Burner Only ..................................... 41

To Remove Entire Combustion Chamber

Mounting System ................................................ 41

Common Causes of Trouble............................... 42

Care of Finish ..................................................... 42

Cleaning of the Heat Exchanger......................... 42

Wiring Diagrams ............................................43-45

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 Inst allation

Requirements - FLF ........................ 11

Figure 6 Typical Single Inside

Tank Installation............................... 12

Figure 7 Electronic Blower Control ................18

Figure 8 Control Disassembly .......................23

Figure 9 Winding Test....................................23

Figure 10 Drip Loop......................................... 23

Figure 11 Typical Smoke-CO

Characteristic .. 27

2

Figure 12 Pressure Gauge Connection to

Bleed Port ....................................... 28

Figure 13A Electrode Adjustments-AFG............30

Figure 13B Electrode Adjustments-NX .............. 30

Figure 14 Combustion Air Boot Assembly .......31

Figure 15 All Air From Inside Building ............. 32

Figure 16 All Air From Outdoors ...................... 33

Figure 17 All Air From Outdoors Through

Ventilated Attic.................................34

Figure 18 All Air From Out doors - Inlet Air

From Ventilated Crawl Space and

Outlet Air to Ventilated Attic .............34

Figure 19 Typical Installation of FR26 and FR27.

Filter Rack ....................................... 37

Figure 20 Typical Inst allation of FR25 Filter

Kit ....................................................37

Figure 21 Filter Installation - Lo-Boy Models ... 38

Figure 22 Removal of Burner Only ..................40

Figure 23 Removal of Entire Combustion

Chamber Mounting System.............41

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

FOR MORE INFORMATION, CONTACT THESE
PUBLISHERS:

ACCA 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 2100-540D
Page 3 of 45

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

sehcnI—secanraelCnoitallatsnImuminiM

1

ledoM

A24V580CF 6 122229CN ** 42——

A24V580HF
A84V011HF
A06V011HF

4V011FLF

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

4
4
4

A24V580FLF

6

A8

6
6

A06V011FLF

6

A24V580RLF

6

A84V011RLF
A06V011RLF

6

A06V041RLF

6

1
1
1

0
0
0

81
81
81
81

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

eulF
epiProolFtnorFkcaBsediSpoTsediStnorFkcaBsediS

—

9
9
9

9
9
9

9
9
9
9

C
C
C

CN
CN
CN

CN
CN
CN
CN

42

—

42

—

42

42
42
42

42
42
42
42

42
42
42

42
42
42
42

ecivreSmuminiM

secnaraelCecanruFmunelP

—
—
—

*81
*81
*81

*81
*81
*81
*81

Manual 2100-540D
Page 4 of 45

Washable type filter 1” nom. thickness

ledoM

rebmuN

tenibaC

munelP

sgninepOnoitcennoCeulFsretliFriA 1

A

htdiW

B

htpeD

C

thgieH

ExD

ylppuS

FxD

nruteRnoitacoL

G

.aiDH

J eziS

.oN

desU

A24V580FLF

A24V580RLF

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

A84V011FLF

A06V011FLF

A84V011RLF

A06V011RLF

323232

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

666

6

526.53

526.53

526.53

526.53

521.5

521.5

521.5

521.5

1x02x02

1x02x02

1x02x02

1x02x02

111

1

A06V041RLF62052.05526.7402x5261x52raeR6

521.24— 1x52x021

1

B

MIS-1815 A

RIGHT SIDE VIEWFRONT VIEWLEFT SIDE VIEW

TABLE 2

FLF/R MODELS DIMENSIONS (INCHES)

"FLF" FLUE

KNOCKOUT

LOW VOLTAGE

ENTRANCE

ENTRANCE

HIGH VOLTAGE

C

OPTIONAL

OIL ENTRANCE

FIGURE 1

A

FLF/R MODELS DIMENSIONS

SPECIFICATION SHEET

FLF/FLR 085, 110 AND 140

J

DUCT

SUPPLY

TOP VIEW

DUCT

RETURN

"FLF" FLUE

KNOCKOUT

EF

OIL

OPTIONAL

"FLF" FLUE

KNOCKOUT

G

D

REAR FLUE

OPTIONAL

ENTRANCE

HIGH VOLTAGE

ON "FLR" MODELS

ENTRANCE

LOW VOLTAGE

H

OIL

OPTIONAL

ENTRANCE

FILTER

ENTRANCE

FRESH AIR

KNOCKOUT

DOOR

Manual 2100-540D
Page 5 of 45

FH085 AND FH110

SPECIFICATION SHEET

RETURN

OPENING

(CUT OUT)

MIS-1814 A

RIGHT SIDE VIEW

SUPPLY

OPENING

FIGURE 2

21 7/8"

FH MODELS DIMENSIONS

19 7/8"

TOP VIEW

30 1/2"

FLUE

KNOCKOUT

23"

FLUE

FLUE

KNOCKOUT

KNOCKOUT

OPTIONAL

HIGH VOLTAGE

HIGH

DOOR

REAR CLEANOUT

ENTRANCE

VOLTAGE

OPTIONAL

ENTRANCE

LOW VOLTAGE

ENTRANCE

53" (FH085)

OIL

OPTIONAL

ENTRANCE

LOW VOLTAGE

59" (FH110)

OIL

ENTRANCE

OPTIONAL

ENTRANCE

FRESH AIR

KNOCKOUT

OIL

ENTRANCE

DOOR

VESTIBULE

FRONT VIEW

Manual 2100-540D
Page 6 of 45

19 1/4"

RETURN

OPENING

(CUT OUT)

16"

LEFT SIDE VIEW

COUNTERFLOW

FIGURE 3

FC085 MODEL DIMENSIONS

22"

20"

RETURN
OPENING

SPECIFICATION

SHEET

FLUE

KNOCKOUT

OPTIONAL

HIGH VOLTAGE

ENTRANCE

OPTIONAL

LOW VOLTAGE

ENTRANCE

OIL ENTRANCE

OPTIONAL

OIL ENTRANCE

23"

30 5/8"

TOP VIEW

FLUE
KNOCKOUT

54 1/4"

FLUE
KNOCKOUT

REAR

CLEANOUT

DOOR

LOW VOLTAGE
ENTRANCE

HIGH VOLTAGE
ENTRANCE

FRESH AIR

KNOCKOUT

LEFT SIDE VIEW

SUPPLY
OPENING

BOTTOM VIEW

FRONT VIEW

19 1/8"

OPTIONAL
OIL ENTRANCE

RIGHT SIDE VIEW

18 1/8"

MIS-1826 A

Manual 2100-540D
Page 7 of 45

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 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 ensure 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 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 Cooling Tap Select Table D (Page 19) for CFM at
static pressures for additional information.

Manual 2100-540D
Page 8 of 45

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

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

rotoMrewolBrotoMrenruB

latoT

ledoMHP-ZH-stloV

A24V580CF1-06-5116.82/19.67/17.13.0151

A24V580HF1-06-5116.82/19.67/17.13.0151

A84V011HF1-06-5113.014/36.87/17.15.2151

A06V011HF1-06-5112.511

A24V580FLF1-06-5116.82/19.67/17.13.0151

A84V011FLF1-06-5113.014/36.87/17.15.2151

A06V011FLF1-06-5112.511

A24V580RLF1-06-5116.82/19.67/17.13.0151

A84V011RLF1-06-5113.014/36.87/17.15.2151

A06V011RLF1-06-5112.511

A06V041RLF1-06-5115.4118.217/17.17.7102

spmA

PHALFPHALF

5.317/17.16.8102

5.317/17.16.8102

5.317/17.16.8102

muminiM
tiucriC

yticapmA

emiT.xaM

esuFyaleD

RCAHro

rekaerBtiucriC

Manual 2100-540D
Page 9 of 45

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 2100-540D
Page 10 of 45

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 LO-BOY MODEL SHOWN

(REPRESENTS ALL MODELS)

L

i
n
e
d

C

h

i

m

n

Thimble

1/4 inch per

1 foot rise

INSTALLER NOTE:

Follow all appropriate

standards for installing

needed venting system.

Draft Regulator
(Be sure to follow
installation inst.
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

Optional
Flue
Locations

e
y

Clean-out Door
(keep closed)

∨

∨∨

∨∨

Note: This accessory is not currently available for Bard Models:
FH110V48A, FH110V60A, FLF110V48A, FLF110V60A with NX Burners

Optional Fresh
Air Boot (remove
rect. knockout).

Oil Burner

MIS-1825

Manual 2100-540D
Page 11 of 45

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 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

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 2100-540D
Page 12 of 45

Bushing

Oil Filter

3/8" O.D. Copper
Fuel Tubing

MIS-1823

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.

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.

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.

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.

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 2100-540D
Page 13 of 45

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-On Delay (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-On
Delay.

• The Recycle mode 30-second time 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-Off Delay (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-second recycle delay and then repeats the
ignition sequence. The control will continue to
Recycle each time the flame is lost until the
accumulated oil-flow-without-flame time
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-Off Delay: If applicable, the fuel valve is
closed and the control delays turning the motor
off for the set motor-off delay 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 2100-540D
Page 14 of 45

TABLE A

RESET BUTTON OPERATION

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emirPpmuPotoG

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ecnatsiseRlleCdaC"eeS

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TABLE B

STATUS LIGHTS

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DEL

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Manual 2100-540D
Page 15 of 45

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.

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-enter Pump 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.

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.

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:

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1)smho004-0(lamroN

2)smho008-004(lamroN

3)smho0061-008(lamroN

4)tuokcoL-smho0061(detimiL

Manual 2100-540D
Page 16 of 45

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.

Electronic Blower Control Interface

This furnace is equipped with an Electronic Blower
Control Interface, which through its set points
determines what the blower does with the 24 VAC
inputs from the home thermostat.

There are dip switches that control the ECM motor for:

1. Heating Airflow

2. Cooling Airflow

3. Heating On/Off Delay

4. A

+10% adjustment for heating airflows.

(See to Figure 7 for the location of these switches.)

The Electronic Blower Control Interface also
performs the additional functions of having a
diagnostic light, which indicates a safety limit is
open, and also has a relay which isolates the T-T
signal from the oil primary control.

Required 24 VAC inputs for various functions:

Continuous Blower: “R” to “G”
Heating with Oil Furnace: “R” to “W”
Cooling Single Stage: “R” to “G”, “Y1” & “Y2”
Cooling Two-Stage, Part Load: “R” to “G” & “Y1”
Cooling Two-Stage, Full Load: “R” to “G”, “Y1” & “Y2”
Heat Pump Single Stage: “R” to “G”, “Y1”, “Y2” & “O”
Heat Pump Two-Stage, Part Load: “R” to “G”, “Y1” & “O”
Heat Pump Two-Stage, Full Load: “R” to “G”, “Y1”, “Y2” & “O”

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.

Manual 2100-540D
Page 17 of 45

FIGURE 7

ELECTRONIC BLOWER CONTROL

COOLING SPEED
TAP SELECT
SWITCHES

HEATING SPEED
TAP SELECT
SWITCHES

HEATING BLOWER
DELAY SELECT
SWITCHES

+/- ADJUSTMENT
TAP SELECT
SWITCHES

CFM BLINK LIGHT
(100 CFM/BLINK)

LINE VOLTAGE

"HOT"

LINE VOLTAGE

"NEUTRAL"

CONNECTION

HUMIDIFIER 120 VAC
LINE VOLTAGE OUTPUT
TERMINAL (ENERGIZES
WITH OIL BURNER MOTOR)

TRANSFORMER
24V SECONDARY
CONNECTIONS

3 AMP FUSE

LIMIT LIGHT

REMOVE FACTORY INSTALLED
JUMPER WIRE FOR 2-STAGE AIR
CONDITIONER OR HEAT PUMP

INPUT SIGNAL
LIGHTS

THERMOSTAT CONNECTIONS

MIS-2869

Manual 2100-540D
Page 18 of 45

TABLE C

HEATING TAP SELECT SETTINGS BY MODEL

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A24V580CF

A24V580HFBNOFFO5301

A24V580FLF56.0CFFONO039

A24V580RLF55.0DNONO097

A84V011HF

A84V011FLF

A84V011RLFDNONO0601

A06V011HF

A06V011FLF

A06V011RLFDNONO0601

A06V041RLF

57.0

00.1

58.0

00.1

58.0

52.1

01.1

A FFO FFO 5701

A FFO FFO 0821

BNOFFO5221

CFFONO0601

A FFO FFO 0821

BNOFFO5221

CFFONO0601

A FFO FFO 0681

BNOFFO0971

CFFONO5461

DNONO5461

TABLE D

COOLING TAP SELECT SETTINGS BY MODEL

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COLUMN A COLUMN B COLUMN C

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A24V580CF

A24V580HFBNOFFO3 0021058006

A24V580FLF56.0C FFONO5.20001527005
A24V580RLF55.0D NONO2 008575004

A84V011HF

A84V011FLF
A84V011RLFDNONO5.20001527005

A06V011HF

A06V011FLF
A06V011RLFDNONO3 0021058006

A06V041RLF

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A FFO FFO 5.3 0041 0001 007

A FFO FFO 4 0061 0511 008
BNOFFO5.300410001007
CFFONO3 0021058006

A FFO FFO 5 0002 0541 0001
BNOFFO4 00610511008
CFFONO5.300410001007

A FFO FFO 5 0002 0541 0001
BNOFFO4 00610511008
CFFONO5.300410001007
DNONO3 0021058006

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Note: Part Load Airflow for 2-stage A/C or HP systems is achieved when removing the factory installed jumper
wire on the Electronic Blower Control Interface Board that is (installed) between the thermostat connection
screws “Y2” and “Y1” dependent upon the tap selected. This allows for 2-stage A/C or HP systems to be installed
with this product. (See Figure 7 or the Wiring Diagrams.)

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For 1-stage compressor systems requiring lower airflow than shown in Column A, remove “Y1-Y2” jumper to
achieve Column B airflow delivery.

Manual 2100-540D
Page 19 of 45

TABLE E

ADJUSTMENT TAP SELECTS

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LLA

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CFFONOwolfriAgnitaeH%01-

DNONOegnahCoN

TABLE F

HEATING DELAY PROFILE TAPS

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AFFOFFO030060500328

BNOFFO0300605042001

CFFONO540 0210500388

DNONO0600 001081001

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Manual 2100-540D
Page 20 of 45

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TROUBLESHOOTING GE ECM 2.3™ MOTORS

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16-PIN BLOWER TAP SELECT CONTROLS - OUTPUTS BASED UPON MODE

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2 .ecafretnIlortnoCrewolBcinortcelEnoeriwrepmuj"2Y"ot"1Y"dellatsnIyrotcaFfolavomerseriuqeR

Manual 2100-540D
Page 21 of 45

TROUBLESHOOTING GE ECM 2.3

™

MOTORS

CAUTION:

Disconnect power from unit before removing or replacing
connectors, or servicing motor. To avoid electric shock
from the motor’s capacitors, disconnect power and wait at
least 5 minutes before opening motor.

Symptom Cause/Procedure

Motor rocks slightly • This is normal start-up for ECM
when starting

Motor won’t start • Check blower turns by hand

• No movement

• Motor rocks, • Check for loose or compliant motor mount
but won’t start

Motor oscillates up • It is normal for motor to oscillate with no
load & down while being on shaft

tested off of blower

Motor starts, but
runs erratically

• Varies up and down • Check line voltage for variation or “sag”

or intermittent • Check low voltage connections

• “Hunts” or “puffs” at • Does removing panel or filter reduce

high CFM (speed) “puffing”?

• Stays at low CFM • Check low voltage (Thermostat) wires and

despite system call connections
for cool or heat CFM • Verify fan is not in delay mode; wait until

• Stays at high CFM • “R” missing/not connected at motor

• Blower won’t shut off •

Excessive noise • Determine if it’s air noise, cabinet, duct or

• Air noise • High static creating high blower speed?

• Check power at motor

• Check low voltage (24 Vac R to C) at motor

• Check low voltage connections
(G, Y, W, R, C) at motor

• Check for unseated pins in connectors on
motor harness

• Test with a temporary jumper between R - G

• Check motor for tight shaft

• Perform motor/control replacement check

• Perform Moisture Check

• Make sure blower wheel is tight on shaft

• Perform motor/control replacement check

(G, Y, W, R, C) at motor, unseated pins in
motor harness connectors

• Check “Bk” for erratic CFM command (in
variable-speed applications)

• Check out system controls, Thermostat

• Perform Moisture Check

- Reduce restriction

- Reduce max airflow

delay complete

• “R” missing/not connected at motor

• Perform motor/control replacement check

• Is fan in delay mode? - wait until delay time
complete

• Perform motor/control replacement check

Current leakage from controls into G, Y or W?
Check for Triac switched thermostat or solid­ state relay

motor noise; interview customer, if necessary

- Is airflow set properly?

- Does removing filter cause blower to slow
down? Check filter

- Use low-pressure drop filter

- Check/correct duct restrictions

Symptom Cause/Procedure

• Noisy blower or cabinet • Check for loose blower housing, panels, etc.

• “Hunts” or “puffs” at • Does removing panel or filter reduce
high CFM (speed)

Evidence of Moisture

• Motor failure or • Replace motor and
malfunction has occurred
and moisture is present

• Evidence of moisture • Perform Moisture Check

present inside air mover

• High static creating high blower speed?

- Check for air whistling through seams in
ducts, cabinets or panels

- Check for cabinet/duct deformation

“puffing”?

- Reduce restriction

- Reduce max. airflow

Perform Moisture Check

Do Don’t

• Check out motor, controls, • Automatically assume the motor is bad.

wiring and connections
thoroughly before replacing
motor

• Orient connectors down so • Locate connectors above 7 and 4 o’clock

water can’t get in positions

- Install “drip loops”

• Use authorized motor and • Replace one motor or control model # with

model #’s for replacement another (unless an authorized replacement)

• Keep static pressure to a • Use high pressure drop filters some have

minimum: H20 drop!

- Recommend high • Use restricted returns

efficiency, low static filters

- Recommend keeping filters

clean.

- Design ductwork for min.

static, max. comfort

- Look for and recommend

ductwork improvement,
where necessary

• Size the equipment wisely • Oversize system, then compensate with low

• Check orientation before • Plug in power connector backwards

inserting motor connectors • Force plugs

airflow

Moisture Check

• Connectors are oriented “down” (or as recommended by equipment

manufacturer)

• Arrange harness with “drip loop” under motor

• Is condensate drain plugged?

• Check for low airflow (too much latent capacity)

• Check for undercharged condition

• Check and plug leaks in return ducts, cabinet

Comfort Check

• Check proper airflow settings

• Low static pressure for lowest noise

• Set low continuous-fan CFM

• Use humidistat and 2-speed cooling units

• Use zoning controls designed for ECM that regulate CFM

• Thermostat in bad location?

½"

Manual 2100-540D
Page 22 of 45

TROUBLESHOOTING GE ECM

™

MOTORS CONT’D.

Replacing ECM Control Module

To replace the control module for the GE variable-speed indoor blower
motor you need to take the following steps:

1. You MUST have the correct replacement module. The controls are
factory programmed for specific operating modes. Even though they look
alike, different modules may have completely different functionality.

USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT
WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.

2. Begin by removing AC power from the unit being serviced. DO NOT
WORK ON THE MOTOR WITH AC POWER APPLIED. To avoid

electric shock from the motor’s capacitors, disconnect power and wait at
least 5 minutes before opening motor.

3. It is not necessary to remove the motor from the blower assembly, nor
the blower assembly from the unit. Unplug the two cable connectors to the
motor control assembly. There are latches on each connector. DO NOT
PULL ON THE WIRES. The plugs remove easily when properly
released.

4. Locate the screws that retain to t
sheet metal of the unit and remove them. Remove two (2) nuts that
retain the control to the bracket and then remove two (2) nuts that
retain sheet metal motor control end plate. Refer to Figure 8.

5. Disconnect the three (3) wires interior of the motor control by
using your thumb and forefinger squeezing the latch tab and the
opposite side of the connector plug, gently pulling the connector. DO

NOT PULL ON THE WIRES, GRIP THE PLUG ONLY. Refer to
Figure 8.

6. The control module is now completely detached from the motor.
Verify with a standard ohmmeter that the resistance from each motor
lead (in the motor plug just removed) to the motor shell is >100K
ohms. Refer to Figure 9. (Measure to unpainted motor end plate.) If
any motor lead fails this test, do not proceed to install the control
module. THE MOTOR IS DEFECTIVE AND MUST BE
REPLACED. Installing the new control module will cause it to fail
also.

he motor control bracket to the

7. Verify that the replacement control is correct for your

application. Refer to the manufacturer's authorized replacement list.

USING THE WRONG CONTROL WILL RESULT IN
IMPROPER OR NO BLOWER OPERATION. Orient the control

module so that the 3-wire motor plug can be inserted into the socket in
the control. Carefully insert the plug and press it into the socket until
it latches. A SLIGHT CLICK WILL BE HEARD WHEN

PROPERLY INSERTED.

8. Reverse the steps #5, 4, 3 to reconnect the motor control to the
motor wires, securing the motor control cover plate, mounting the
control to the bracket, and mounting the motor control bracket back
into the unit. MAKE SURE THE ORIENTATION YOU SELECT

FOR REPLACING THE CONTROL ASSURES THE
CONTROL'S CABLE CONNECTORS WILL BE LOCATED
DOWNWARD IN THE APPLICATION SO THAT WATER
CANNOT RUN DOWN THE CABLES AND INTO THE
CONTROL. DO NOT OVERTIGHTEN THE BOLTS.

9. Plug the 16-pin control plug into the motor. The plug is keyed.
Make sure the connector is properly seated and latched.

10. Plug the 5-pin power connector into the motor. Even though
the plug is keyed, OBSERVE THE PROPER ORIENTATION. DO
NOT FORCE THE CONNECTOR. It plugs in very easily when
properly oriented. REVERSING THIS PLUG WILL CAUSE

IMMEDIATE FAILURE OF THE CONTROL MODULE.

11.

Final installation check. Make sure the motor is installed as follows:

a. Motor connectors should be oriented between the 4 o’clock

and 8 o’clock positions when the control is positioned in its
final location and orientation.

b. Add a drip loop to the cables so that water cannot enter the

motor by draining down the cables. Refer to Figure 10.

The installation is now complete. Reapply the AC power to the
HVAC equipment and verify that the new motor control module is
working properly. Follow the manufacturer's procedures for
disposition of the old control module.

Only remove

Hex Head Bolts

ECM 2.0

Note:
Use the shorter
bolts and
alignment pin
supplied when
replacing an
ECM 2.0
control.

Figure 8

Figure 3

Control Disassembly

Push until
Latch Seats
Over Ramp

ECM

2.3/2.5

Hex-head Screws

From Motor

Circuit
Board

Motor

Motor Conne c tor
(3-pin)

Control Connector
(16-pin)

Power Connector
(5-pin)

Motor Connector
(3-pin)

Back of
Control

Figure 9

Figure 4

Winding Test

Motor OK when

R > 100k ohm

Figure 10

Figure 5

Drip Loop

Connector Orientation

Between 4 and 8 o'clock

Drip Loop

Manual 2100-540D
Page 23 of 45

TABLE 4

FURNACE DATA

ledoM

rebmuN

A24V580CF

A24V580HF

A84V011HF

A06V011HF

A24V580FLF

A84V011FLF

A06V011FLF

A24V580RLF

A84V011RLF

A06V011RLF

A06V041RLF

renruB

epyT

GFAwolfretnuoC

GFAyoB-iH

XNyoB-iH

XNyoB-iH

GFAyoB-oL

XNyoB-oL

XNyoB-oL

GFAyoB-oL

GFAyoB-oL

GFAyoB-oL

GFAyoB-oL

ecanruF

epyT

eziSepyTerusserPpmuP

57.0 *

56.0000,19000,67

55.0000,77000,46

57.0 *

56.0000,19000,67

55.0000,77000,46

58.0 *

57.0000,911000,99

58.0 *

57.0000,911000,99

57.0 *

56.0000,19000,67

55.0000,77000,46

58.0 *

57.0000,911000,99

58.0 *

57.0000,911000,99

57.0 *

56.0000,19000,67

55.0000,77000,46

00.1 *

58.0000,911000,99

00.1 *

58.0000,911000,99

52.1 *

01.1000,451000,721

elzzoN

wolloH°07GISP001

wolloH°07GISP001

diloS°06GISP051

diloS°06GISP051

wolloH°07GISP001

diloS°06GISP051

diloS°06GISP051

wolloH°07GISP001

wolloH°07GISP001

wolloH°07GISP001

wolloH°07GISP001

gnitaeH

tupnI

HUTB

000,501 000,78

000,501 000,78

000,041 000,611

000,041 000,611

000,501 000,78

000,041 000,611

000,041 000,611

000,501 000,78

000,041 000,611

000,041 000,611

000,571 000,541

gnitaeH
tuptuO

HUTB

* 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-Burning
Equipment, 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 install oil-burning
equipment 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.

Manual 2100-540D
Page 24 of 45

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 12.

1. PREPARATION STEPS

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-line oil 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 Figures 13A & 13B.

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 CO
Then establish the smoke - CO

from the flue.

2

curve by taking

2

readings over a range of air settings, as shown
in Figure 11.

To do this, start with the air gate set at nearly
full open and then take smoke and CO
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 11. 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 - CO

plot and, keeping in mind the curve of Figure 11,
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 CO
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. COMBUSTION DIAGNOSIS

L. Check Performance A well-matched and

well-tuned burner 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:

2

2

2

Manual 2100-540D
Page 25 of 45

1. Air leaks into the combustion chamber or
heat exchanger can dilute the combustion
gases and prevent normal CO

readings.

2

Such leaks should be sealed with furnace
cement or other high-temperature sealant.

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.

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%.

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 ensure 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.

Manual 2100-540D
Page 26 of 45

TYPICAL SMOKE – CO

FIGURE 11

CHART WITH ADJUSTMENT RANGE

2

High

8

6

Normal

adjustment

4

range

Tolerance

Bacharach Smoke Number

to "knee"
"Best" air

2

setting

Plotted point

0

6

8

Air Settings

Plotted point

"Knee"

10

Percent CO in Flue Gas

2

12

CO Curve
from plotted
points

Plotted point

Low

2

14

8

6

4

Bacharach Smoke Number

2

0

6

810

12

Percent CO in Flue Gas

2

Technician's
plotting area

14

MIS-1827

Manual 2100-540D
Page 27 of 45

FIGURE 12

PRESSURE GAUGE CONNECTION TO BLEED PORT

Remove Bleed
Port to attach
pressure guage.

Manual 2100-540D
Page 28 of 45

Pressure Gauge

MIS-1660

TABLE 5 — CORRELATION OF PERCENT OF CO2, O2 AND RESERVE AIR

edixoiDnobraCnegyxO).xorppA(riAevreseR

4.51

0.51

5.41

0.41

5.31

0.31

5.21

0.21

5.11

0.11

5.01

0.01

0.0

6.0

2.1

0.2

6.2

3.3

0.4

6.4

3.5

0.6

7.6

4.7

0.0

0.3

0.6

0.01

0.51

0.02

0.52

0.03

0.53

0.04

0.54

0.05

TABLE 6 — NO. 2 FUEL OIL EFFICIENCY CHART (NET STACK TEMP. DEGREES F)

2

O%

16.984.883.782.681.580.489.287.186.085.974.873.772.677.41

24.982.880.789.587.486.384.282.181.089.877.776.674.570.41

32.989.787.685.583.481.389.187.084.972.870.778.576.472.31

49.887.784.681.588.386.283.180.087.875.772.679.476.375.21

57.883.780.686.483.380.286.083.979.776.673.579.376.277.11

64.880.785.581.487.283.189.975.870.776.572.478.274.170.11

70.885.680.585.380.285.080.975.770.675.470.375.170.073.01

002052003053004054005055006056007057008O%

2

TABLE 7 — RECOMMENDED START-UP SETTINGS

ledoM

rebmuN

A24V580CF

A24V580HF

A84V011HF

A06V011HF

A24V580FLF

A84V011FLF

A06V011FLF

A24V580RLF

A84V011RLF

A06V011RLF

A06V041RLF

elytSrenruB

.oNtraP

eziSepyTerusserPpmuP

57.0 *

040-0209/GFA

56.005—

55.005—

57.0 *

040-0209/GFA

56.005—

55.005—

58.0 *

440-0209/XN

57.0——3

58.0 *

440-0209/XN

57.0——3

57.0 *

040-0209/GFA

56.005—

55.005—

58.0 *

440-0209/XN

57.0——3

58.0 *

440-0209/XN

57.0——3

57.0 *

140-0209/GFA

56.005—

55.005—

00.1 *

240-0209/GFA

58.008—

00.1 *

240-0209/GFA

58.008—

52.1 *

340-0209/GFA

01.106—

elzzoN

wolloH°07GISP001

wolloH°07GISP001

diloS°06GISP051

diloS°06GISP051

wolloH°07GISP001

diloS°06GISP051

diloS°06GISP051

wolloH°07GISP001

wolloH°07GISP001

wolloH°07GISP001

wolloH°07GISP001

0 6 —

0 6 —

— — 57.3

— — 57.3

0 6 —

— — 57.3

— — 57.3

0 6 —

2 01 —

2 01 —

0 8 —

dnaBriA

gnitteS

riA

rettuhS

gnitteS

riA

tnemtsujdA

etalP

gnitteS

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

Manual 2100-540D
Page 29 of 45

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 13A & 13B.

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.

FIGURE 13A

ELECTRODE ADJUSTMENTS — AFG BURNERS

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 14. The air boot used for this
design is a Field Controls model number CAS-2B-90E
that 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: FH110V48A, FH110V60A,
FLF110V48A and FLF110V60A with NX burners.

ELECTRODE ADJUSTMENTS — NX BURNERS

Manual 2100-540D
Page 30 of 45

FIGURE 13B

FIGURE 14

KNOCKOUT

AIR BOOT

FOR OIL LINE

BOOT AND SECURE

INSERT OUTER AIR

USE THIS

ASSEMBLE INNER

FLANGE TO UNIT

FOR AIR BOOT.

ACCORDING TO MANUAL

IN LEFT SIDE

REMOVE KNOCKOUT

MAKE ALL SETTINGS

REMOVE PUMP TO

INTAKE

AIR

TUBE

MIS-1833

AFG BURNER

COMBUSTION

AIR BOOT

ASSEMBLY

AFG
BURNER
ASSEMBLY

COMBUSTION AIR BOOT ASSEMBLY

Note: This accessory is not currently available for Bard Models:
FH110V48A, FH110V60A, FLF110V48A, FLF110V60A with NX Burners

Manual 2100-540D
Page 31 of 45

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 16.

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 “Combustion
Air Requirements”.

FIGURE 15

APPLIANCES LOCATED

IN CONFINED SPACES

ALL AIR FROM INSIDE THE BUILDING

TABLE 8

SQUARE FEET REQUIRED TO

QUALIFY AS UNCONFINED SPACE

latoT

HUTB

tupnI

000,06
000,08

000,58
000,501

000,511
000,021

000,041
000,541

000,061
000,002

573
005

135
656

917
057

578
609

0001
0521

ecapSdenifnocnU

nIaerAmuminiM

teeFerauqS

thgieHgnilieC'8

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 15.) Also see Table 9 on the following
page for specific ventilation opening requirements for
the furnace only.

Manual 2100-540D
Page 32 of 45

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.

TABLE 9

MINIMUM VENTILATION OPENINGS

noitalitneV.niM

gninepO

ledoM

A24V580HF04261x8821

A84V011HF08281x9261

A06V011HF08281x9261

A24V580FLF09291x8251

A24V580RLF09291x8251

A84V011FLF
A06V011FLF

A84V011RLF
A06V011RLF

A06V041RLF06391x5.9081

A24V580CF04261x8821

hcnIerauqS

04391x9171

04391x9171

eziS.nI.qS

ALL VENTILATION AIR FROM OUTDOORS

A. The confined space shall be provided with two

dednemmoceR

gninepO

)deriuqeR2(

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 16, 17, & 18.)

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 16

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 2100-540D
Page 33 of 45

FIGURE 17

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 18

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 2100-540D
Page 34 of 45

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 30-35 percent free
area and metal louvers and grilles will have 60-75
percent free area.

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.

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-resistant material 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.

HORIZONTAL VENTING

This furnace is designed to be horizontally vented
through a side wall with an optional side wall power
vent. The recommended side wall vent is the Field
Controls model number SWG-4HDS for 085 and 110
models, and SWG-5S for 140 models only. This vent
can be purchased through your local distributor.
Follow all installation instructions packaged with the
vented 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 2100-540D
Page 35 of 45

TABLE 10

TEMPERATURE RISE RANGES, LIMIT CONTROL SETTINGS,

AND HEATING BLOWER SPEEDS

ledoM

rebmuN

A24V580CF

A24V580HF

A84V011HF

A06V011HF

A24V580FLF

A84V011FLF

A06V011FLF

A24V580RLF

A84V011RLF

A06V011RLF

A06V041RLF

renruB

epyT

GFA

GFA

eziSepyTerusserPpmuP

57.0 *

56.0001-07C

55.0001-07D

57.0 *

56.0001-07C

55.0001-07D

58.0 *

XN

57.0001-07C

58.0 *

XN

57.009-06C

57.0 *

GFA

56.009-06C

55.009-06D

58.0 *

XN

57.009-06C

58.0 *

XN

57.009-06C

57.0 *

GFA

56.009-06C

55.009-06D

00.1 *

GFA

58.009-06C

00.1 *

GFA

58.009-06C

52.1 *

GFA

01.109-06C

elzzoN

wolloH°07GISP001

wolloH°07GISP001

diloS°06GISP051

diloS°06GISP051

wolloH°07GISP001

diloS°06GISP051

diloS°06GISP051

wolloH°07GISP001

wolloH°07GISP001

wolloH°07GISP001

wolloH°07GISP001

segnaResiR

09-06

09-06

09-06

09-06

09-06

09-06

09-06

09-06

09-06

09-06

09-06

mumixaM

riAteltuO

)F°(pmeT

002

002

002

002

002

002

002

002

002

002

002

gnitaeH
rewolB

paT

A

A

A

A

A

A

A

A

A

A

A

* Factory Set Point.

Manual 2100-540D
Page 36 of 45

AIR FILTERS

Only Lo-Boy models are shipped with air filters. Filter
kits are available from your local distributor for
Upflow and Counterflow models. Knockouts are
provided in the sides of the FH series models to
facilitate the cutting of the return openings.

The upflow filter kit part numbers are FR23 for a
16x25x1 filter size and FR24 for a 20x25x1 filter size.
These filter kits come complete with the filter and all
necessary brackets for installing on the furnace. Each
comes with a washable aluminum mesh filter. When
installing a five ton AC unit on the furnace, one FR24
or Two FR23 must be used due to the high airflow
requirements. It is important to note that a minimum of
one inch spacing is required between the filter and the
unit side. Do not exceed 400 fpm for fiberglass
(disposable) type filters and 575 fpm for washable type
filters. See Figure 19.

The counterflow filter kit part number FR25 comes
with two washable filters. If not installing the FR25 kit
remember not to exceed 400 fpm for fiberglass
(disposable) type filters and 575 for washable type
filters. See Figure 20.

See Table 11 for filter sizes and quantities.

TABLE 11

FILTER SIZES FOR OIL FURNACES

ledoMeziS

A24V580HF

yoB-iH

yoB-iH

yoB-iH

syoB-oL

syoB-oL

yoB-oL

wolfretnuoC

)1(1x52x61

A84V011HF

)1(1x52x61

A06V011HF

)1(1x52x02

A24V580FLF

A24V580RLF

)1(2x02x61

A84V011FLF
A84V011RLF
A06V011FLF

)1(2x02x02

A06V011RLF

A06V041RLF

)1(2x52x02

A24V580CF

)2(1x02x61

FIGURE 19

TYPICAL INSTALLATION OF FR26 AND

FR27 FILTER RACKS

19 1/4"

(2) screws

Filter

FIGURE 20

TYPICAL INSTALLATION OF FR25

FILTER KIT

Optional

Filter

Box

"FC"

Unit

70 5/16"

16"

Filter
Frame

Filter
Door

MIS-1839 A

MIS-1841

Manual 2100-540D
Page 37 of 45

LO-BOY MODELS – FILTER LOCATIONS

Lo-boy models have the filter installed in the return air cabinet section of the furnace. It is accessible from the rear of
the furnace by removing the blower/filter access door. The electrical switch should be turned “off” prior to removing
the access door. Refer to Figure 21 below.

FIGURE 21

FILTER INSTALLATION – LO-BOY MODELS

UNIT FILTER SIZE
FLF/FLR085 16 x 20 x 2
FLF/FLR110 20 x 20 x 2

FLR140 20 x 25 x 2

STEP 3:

SLIDE FILTER OUT

TOWARDS BLOWER

DOOR

STEP 2:

REMOVE BLOWER DOOR

BY PULLING OUT ON

SWELL LATCHES AND

TILTING OUTWARDS

Manual 2100-540D
Page 38 of 45

STEP 1:

UNFASTEN SWELL

LATCHES BY PULLING

HANDLES OUTWARD

MIS-1835 A

MAINTENANCE

LUBRICATION

No lubrication is required for either the burner or the
blower motor. Both are permanently lubricated.

INSPECT AIR FILTER

Replace filters before each heating season begins. It is
recommended that filters also be replaced at least twice
during the heating season.

Be sure the new filters are set securely in the filter rack
so there can be minimal leakage around them.

FINAL INSPECTION AND TEST

Final inspection and test of an installation shall be
made to determine that the work has been done in full
accordance with regulations and according to the
highest standards for safety, performance and
appearance. Such an inspection and test should
indicate the following as a minimum:

1. Determine that all parts of the oil storage and
circulating system, including tank, piping and
burner, are free from oil leaks. Be sure that no oil
discharges from the nozzle when burner is not
operating.

2. Be sure that the suction line and pump have been
entirely vented of air so that the burner has
instantaneous oil shutoff at the nozzle and so that
the pump operates without an air noise.

3. Check the flame adjustment to determine that the
flame is clear, quiet, free of odor and oil nozzle is
of proper size for the furnace.

4. Test operation of burner by operating the
thermostat. First, set the thermostat above room
temperature. Burner should start. Second, set
thermostat below room temperature. Burner will
stop.

5. Check operation of burner primary control in
accordance with manufacturer’s instructions
included with the control. Following is the method
we recommend in checking the safety switch in
this primary control.

A. Flame Failure – Simulate by shutting off oil

supply manual valve while burner is on.
Within 9 seconds the control will shut the
burner down and flash a diagnostic code of
1/2 second on / 1/2 second off. Ignition and
motor stop and oil valve closes.

B. Ignition Failure – Test by closing oil supply

while burner is off. Run through starting
procedure. The primary control will attempt
three trials for ignition. After three attempts,
the control will lockout.

C. Power Failure – Turn off power supply

while burner is on. When burner goes out,
restore power and burner will restart.

D. If operation is not as described, check wiring

and installation first. If trouble appears to be
in the control circuit, replace the flame
detector. If trouble still persists, refer to
“Common Causes of Trouble” section.

SERVICE HINTS

Preventive maintenance is the best way to avoid
unnecessary expense, inconvenience, and retain
operating efficiency of your furnace. It is advisable to
have your heating system and burner inspected at
periodic intervals by a qualified serviceman. If trouble
develops, follow these simple checks before calling the
serviceman.

1. Make sure there is oil in tank and valve is open.

2. Make sure thermostat is set above room
temperature.

3. Make sure electrical supply to furnace is on and
fuses are not blown or circuit breakers tripped.

4. Reset safety switch of burner primary control.

CAUTION

Reset three (3) times only . More than three
resets can cause excessive oil to be pumped
into combustion chamber which could result
in explosion upon ignition.

5. Make sure air filters are in place and are clean.

6. Make sure all air openings in furnace, all
ventilation and combustion air openings, all return
air grilles, and all warm air registers are
unobstructed and open.

Manual 2100-540D
Page 39 of 45

COMBINATION COMBUSTION
CHAMBER/BURNER MOUNTING
SYSTEM

The furnace has been designed with a combustion
chamber mounting system that enables service
personnel to remove the combustion chamber, its
mounting system, and burner assembly as one unit for
inspection and/or service on the bench. It has also been
designed to remove the burner assembly independently
from the mounting system to perform basic annual
service and inspection. The mounting system is
completely adjustable so exact alignment between the
burner tube and combustion chamber may be assured
prior to installation into the furnace. See Figures 22
and 23.

REMOVAL OF BURNER ONLY

DANGER

!

*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.

WARNING

The procedures described in Figures 22 & 23
should be conducted only by a qualified
service technician.

Improper servicing could cause electric shock
hazard, fires or explosion resulting in damage,
injury or death.

FIGURE 22

BURNER REMOVAL

INSTRUCTIONS

STEP 2:

LOOSEN (3) BOLTS

ENOUGH TO ROTATE

BURNER ASSEMBLY.

STEP 4:
PULL BURNER STRAIGHT
OUT TO PREVENT DAMAGE
TO CHAMBER DURING
REMOVAL.

Manual 2100-540D
Page 40 of 45

STEP 3:
ROTATE BURNER
COUNTER-CLOCKWISE

STEP 1:
DISCONNECT "T-T" WIRES,
POWER CONNECTIONS, AIR
BOOT (OPTIONAL) AND OIL
LINES TO BURNER.

MIS-1834

TO REMOVE BURNER ONLY

Disconnect fuel line, power cord and wires from T, T
on primary control. Loosen (3) 1/4 inch bolts securing
burner mounting flange. Twist burner
counterclockwise and pull straight back away from the
furnace. (See Figure 22.)

REMOVAL OF ENTIRE COMBUSTION CHAMBER MOUNTING SYSTEM

DANGER

!

*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.

TO REMOVE THE ENTIRE COMBUSTION
CHAMBER MOUNTING SYSTEM

Disconnect fuel line, power cord and wires from T, T
on primary control. Remove (6) 5/16 inch bolts from
around front plate. Next remove (2) 5/16 inch nuts
from upper right and left hand corners of the front
plate. Pull entire assembly straight back away from
furnace. BE CAREFUL NOT TO TIP ASSEMBLY

UP OR DOWN AS IT MAY DAMAGE THE
COMBUSTION CHAMBER. (See Figure 23.)

FIGURE 23

BURNER AND COMB. CHAMBER

MOUNTING SYSTEM

REMOVAL INSTRUCTIONS

STEP 3:

REMOVE (2) NUTS

IN THE TOP LEFT

AND RIGHT CORNERS

OF BURNER PLATE.

STEP 4:
PULL BURNER ASSEMBLY
STRAIGHT OUT TO PREVENT
DAMAGE TO CHAMBER
DURING REMOVAL.

CHAMBER

BURNER
PLATE

STEP 2:
REMOVE (6) BOLTS
AROUND PERIMETER

OF BURNER PLATE
STEP 1:
DISCONNECT "T-T" WIRES,
POWER CONNECTIONS, AIR
BOOT (OPTIONAL) AND OIL
LINES TO BURNER.

MIS-1837 A

Manual 2100-540D
Page 41 of 45

COMMON CAUSES OF TROUBLE

CAUTION

PUMP SQUEALS OR CHATTERS

This may be caused by air in pipes. Check all joints in
the oil supply pipe for leaks. Check strainer in pump; if
dirty, clean.

To avoid accidents, always open main switch
(OFF position) when servicing the burner.

BURNER WILL NOT PRODUCE FLAME

Check oil level gauge to see that there is sufficient oil
in tank or tanks. Check the burner mounted relay
control. Do not adjust this control.

Check position of electrodes – incorrect position will
cause slow or delayed ignition. Clean electrodes and
nozzle. Check and clean strainer in pump. If oil line
filter is used, check filter condition.

If burner runs but there is no flame the fuel pump may
be air bound. Follow instructions for bleeding fuel
pump.

Check and make sure the solenoid valve on the oil
pump is being energized and opening.

BURNER STARTS OR STOPS TOO OFTEN

Check heat anticipator setting on thermostat.

NOZZLE PRODUCES A STRINGY FLAME

Worn tangential grooves in nozzle. Replace nozzle.

BASEMENT TANK HUM

Occasionally with a two-pipe installation there may be
a low return line hum. Eliminate hum by installing a
special anti-hum valve in the return line near pump.

HEAVY FIRE OR PULSATING FLAME.

These may occur after burner starts. It may be caused
by a slight oil leak in the fuel pump and cannot be
corrected except by replacing the pump. This happens
only when the burner is started.

CHATTERING SOUND OR HIGH PITCH NOISE

This noise from motor can usually be traced to where a
conduit or BX cable is fixed rigidly or attached to some
part of the building. Relieving this strain may eliminate
noise.

INSUFFICIENT HEAT

Check limit control setting. It may be that flame is not
allowed to stay on long enough to generate sufficient
heat in furnace to heat the house properly. If the proper
size furnace has been selected according to house
requirements and satisfactory heat is not obtained,
recheck the heating plant for size and capacity in
relation to house. Check for clogged filters.

Check and make sure the heat anticipator on the
thermostat is set correctly.

CARE OF FINISH

This furnace cabinet is made with a very durable and
corrosion resistant finish. With normal cleaning it will
last for many years.

WARNING

Under no circumstance should a soot
deterioration device be used in the
combustion chamber. These product s known
as “soot busters” or “soot sticks” are
comprised of chemicals that burn at very high
temperatures, which may exceed the
temperature rating of the combustion
chamber material.

Use of these products are detrimental to the
life expectancy of the combustion chamber
and will destroy the chamber. Refer to the
“Cleaning of Furnace” section for proper
cleaning methods.

CLEANING OF THE HEAT EXCHANGER

All of these units have four clean out plugs for easy
cleaning of the heat exchanger. They are accessible
from the front and back of these units by removing the
clean out access cover in the burner compartment and at
the back of unit. The furnace should be checked
annually by a qualified service technician.

Manual 2100-540D
Page 42 of 45

FH SERIES

*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.

DANGER

!

L2 (IGN)

TW

TR

IGNITER

BURNER

MOTOR

OIL

VALVE

CAD

CELL

L1 - LIMIT

L2 (VLV)

CAD

CELL

L2

VALVE

L2 (MTR)

MOTOR

IGNITER

CONDITIONER OR HEAT

1

NOTES

2

IF PRIMARY LIMIT WIRES
ARE TO BE REPLACED,
USE WIRE WITH INSUL.
TEMP. RATING OF 200°C.

REMOVE PURPLE JUMPER
WIRE FOR 2 STAGE AIR

PUMP.

ORANGE

16 PIN WIRING

HARNESS DETAIL

BLACK

YELLOW

BLUE/BLACK

GRAY

BLACK/WHITE

BROWN

BLACK/WHITE

YELLOW/BLACK

65471382

911 101214 131516

BLUE

PURPLE/WHITE

RED

RED/WHITE

RED/YELLOW

PURPLE

YELLOW /RED

IF ANY OF THE ORIGINAL WIRE AS
SUPPLIED WITH THIS APPLIANCE
MUST BE REPLACED, IT MUST BE
REPLACED WITH WIRING MATERIAL
HAVING A TEMP. RATING OF AT
LEAST 105°C EXCEPT PRIMARY
LIMIT WIRES. SEE NOTE "1".

WARNING

!

White

White

White

White

White

White

NEUTRAL

White

Purple

Purple

Purple

Purple

Orange

Orange

GROUND

Green

9

24 VAC C

Red/White

8

Red

Red

Red

Red

1

23

4

56

7

HEATING DELAY PROFILE TAPS

MODEL

SWITCH #1SWITCH #2ON DELAY

SECONDS

ON

DELAY

% CFM

PRE-RUN

TIME

SECONDS

PRE-RUN %

CFM

OFF DELAY

SECONDS

OFF
DELAY
% CFM

ALL

OFF OFF 30 0 60 50 300 82

ON OFF 30 0 60 50 240 100

OFF ON 45 0 120 50 300 88

ON ON 60 0 0 100 180 100

BLOWER

Black

BLOWER

BACKUP

ASSEMBLY

HOT

2112

34567

12

8

9

345

7

PLUG

Black

Black

Black

3 PIN

CONTROL

9 PIN

PLUG

CONTROL PA NEL

VOLTAGE

HIGH

HEAT EXCHA NGER AREA

UNIT

WIRING

PRIMARY

AND COND. UNIT 24V CONNECTIONS

CFM INDICA T OR

(RED LED 6)

21

OFF

ON

HEAT

21

OFF

ON

ADJ.

21

OFF

ON

COOL

21

ON

5

FIELD CONNECTIONS TO THERMOSTAT

(GREEN LED 7)

LIMIT SWITCH

CONTROL PLUG

Y1C

Y/Y2

OFF

DELAY

NEUTRALS

16 PIN BLOWER

CONTROL PLUG

3

24V

120V COM

TRANSFORMER

DOOR SWITCH

GDH

Black/White

PLUG

14

5 PIN

LOW

Black

Black

3

W

Black

VOLTAGE

LIMIT

RETURN AREA

FIELD

Black/White

R

20

16 PIN BLOWER

Black

LIMIT

CONTROL

Black

17

1

2

BURNER

ASS'Y

16

4

O

120 VAC

9

18

21

4047-121 A

120 VAC

HUM

22

DIP SW1 DIP SW2

0.75 60°-90° OFF* OFF* 1075

0.75 60°-90° ON OFF 1035

0.65 60°-90° OFF ON 930

0.55 60°-90° ON ON 790
1 60°-90° OFF* OFF* 1280
1 60°-90° ON OFF 1225

0.85 60°-90° OFF ON 1060

0.85 60°-90° ON ON 1060

HEATING

CFM

HEAT SWITCH SETT INGS

HEAT SWITCH

UNIT

GPH

INPU

FH085V42A

FH110V48A
FH110V60A

TEMP.

RISE

DIP SW1 DIP SW2 FULL PART

3.5* OFF* OFF* 1400 1000
3 ON OFF 1200 850

2.5 OFF ON 1000 725
2 ON ON 800 5 75
4* OFF* OFF* 1600 1150

3.5 ON OFF 1400 1000
3 OFF ON 1200 850

2.5 ON ON 1000 725
5* OFF* OFF* 2000 1450
4 ON OFF 1600 1150

3.5 OFF ON 1400 1000
3 ON ON 1200 850

COOL S WIT CH SETTIN GS

CFM LOAD

FH110V60A

FH085V42A

FH110V48A

UNIT

(TONS)

COOL SWITCH

WIRING DIAGRAM

NOM. A/C

Manual 2100-540D
Page 43 of 45

CFM

HEATING

HEAT SWITCH

DIP SW1 DIP SW2

RISE

TEMP.

HEAT SW ITCH SETT INGS

0.75 60°-90° OFF* OFF* 1075

0.75 60°-90° ON OFF 1035

GPH

INPU

UNIT

FLF/R085V42A

PRIMARY LIMIT

16

RED

FLF/R SERIES

WIRING DIAGRAM

BACKUP LIMIT

OFF

DELAY

% CFM

SECONDS

OFF DELAY

% CFM

PRE-RUN

TIME

PRE-RUN

SECONDS

ON

DELAY

% CFM

SECONDS

ON DELAY

#2

SWITCH

#1

ON OFF 30 0 60 50 240 100

OFF OFF 30 0 60 50 300 82

SWITCH

MODEL

HEATING DEL AY PROFILE TAPS

ALL

0.65 60°-90° OFF ON 930

OFF ON 45 0 120 44 300 88

0.55 60°-90° ON ON 790

ON ON 60 0 0 100 180 100

BLACK/WHITE

BROWN

BLACK/WHITE

CFM LOAD

* FACTORY SETTINGS

16 PIN WIRING

HARNESS DETAIL

COOL SWITCH

DIP SW1 DIP SW2 FULL PART

3 ON OFF 1200 850

2 ON ON 800 575

3 OFF ON 1200 850

4 ON OFF 1600 1150

4* OFF* OFF* 1600 1150

2.5 OFF ON 1000 725

3.5 ON OFF 1400 1000

1 60°-90° OFF* OFF* 1280

1 60°-90° ON OFF 1225

0.85 60°-90° OFF ON 1060

FLF/R110V48A

FLF/R110V60A

HEAT EX. AREA

1.1 60°-90° OFF ON 1645

0.85 60°-90° ON ON 1060

1.1 60°-90° ON ON 1645

1.25 60°-90° OFF* OFF* 1860

1.25 60°-90° ON OFF 1790

FLR140V60A

RED

COOL SWI TCH SETTI NGS

20

3.5* OFF* OFF* 1400 1000

(TONS)

NOM. A/C

UNIT

FLF/R085V42A

2

ADJ.

Y1

OFF

Y/Y2

G

DELAY

OFF

2.5 ON ON 1000 725

FLF/R110V48A

12

HEAT

ON

ON

OFF

12

COOL

ON

ON

OFF

3 ON ON 1200 850

5* OFF* OFF* 2000 1450

3.5 OFF ON 1400 1000

DANGER

!

FLR140V60A

FLF/R110V60A

1
2

Black

120 VAC

1
2

Black

White

GRAY

BLUE/BLACK

YELLOW

BLACK

YELLOW/BLACK

*ELECTRICAL SHOCK HAZARD

*DISCONNECT POWER BEFORE

SERVICING.

Black

14

911 1012

65471382

14 13
1516

NOTES

White

Green

19

1

IF PRIMARY LI MIT WIRES ARE TO BE REPLACED,

1

120V

BLUE

PURPLE/WHITE

RED

RED/WHITE

RED/YELLOW

PURPLE

ORANGE

YELLOW/RED

ADJU STMEN T

DELAY SWITCH

ADJUSTMENT SWITCH SET TINGS

REMOVE PURPLE JUMPER WIRE FOR 2 STAGE AIR

CONDITIONER OR HEAT PUMP.

USE WIRE WITH INSUL. TEMP. RATING OF 200°C.

2

4047-123 A

DETAILS

ON OFF +10% CFM

ON ON NO CHANGES

OFF ON -10% CFM

OFF* OFF* NO CHANGES*

DIP SW1 DIP SW2

24V

HUM
120 VAC

7

98

Orange

ASS'Y

BURNER

CAD

CAD

White

15

COM

TRANSFORMER

9

Red/White

3

16 PIN WIRE HARNESS

7

17

Black/White

10

18

RED

5 PIN

PLUG

4

3

251

CONTROL PANEL

5

BLACK

CELL

BLACK

16 PIN BLOWER

CONTROL PLUG

CELL

DOOR

SWITCH

RETURN AREA

BLOWER ASSEMBLY

CFM BLINK

WODH

(GREEN LED 7)

R

AND COND. UNIT 24V CONNECTIONS

FIELD CONNECT IONS TO THERMOST AT

C

BLACK

4

BLOWER

CONTROL

16 PIN BLOWER

CONTROL PLUG

(RED LED 6)

LIMIT SWITCH

NEUTRALS

White

1

Black

54
6

32

C24 VAC

BLACK

1

3

2

PLUG

3 PIN

Black

Orange

Purple

L2 (IGN)

MOTOR

IGNITER

White

L2

L2 (VLV)

L2 (MTR)

VALVE

L1 - LIMIT

Purple

IGNITER

TR

MOTOR

BURNER

TW

OIL

VALVE

Manual 2100-540D
Page 44 of 45

CFM

HEATING

HEAT SWITCH

DIP SW1 DIP SW2

RISE

TEMP.

HEAT SWITCH SET T INGS

0.75 60°-90° OFF* OFF* 1075

GPH

INPUT

UNIT

FC SERIES

PRIMARY LIMIT

WIRING DIAGRAM

1

RED

16

OFF

DELAY

% CFM

OFF

DELAY

PRE-RUN

PRE-RUN

ON

2ONON800575

ON DELAY

SWITCH

SWITCH

HEATING DEL AY PROFILE TAPS

20

2

Y1

Y/Y2

G

TIME

DELAY

MODEL

SECONDS

% CFM

SECONDS

% CFM

SECONDS

#2

#1

ON ON 60 0 0 100 180 100

ON OFF 30 0 60 50 240 100

OFF ON 45 0 120 50 300 88

OFF OFF 30 0 60 50 300 82

ALL

12

ADJ.

ON

OFF

12

DELAY

ON

OFF

CFM LOA D

COOL SW ITCH

DIP SW1 DIP SW2 FULL PART

3 ON OFF 1200 850

2.5 OFF ON 1000 725

3.5* OFF* OFF* 1400 1000

0.75 60°-90° O N OFF 1035

COOL SWI TCH SETTING S

0.65 60°-90° OFF ON 930

0.55 60°-90° O N O N 790

FC085V42A

(TONS)

NOM. A/C

UNIT

FC085V42A

HEAT EX. AREA

HEAT

COOL

DETAILS

ADJUSTMENT

16 PIN WIRING

HARNESS DETAIL

ON OFF +10% CFM

ON O N NO CHANGES

OFF ON -10% CFM

OF F * OF F* NO CH ANGES*

DELAY SWITCH

DIP SW1 DIP SW2

ADJUSTMENT SWITCH SETT INGS

4

BLOWER

1
2

ON

OFF

120 VAC

1

2

ON

OFF

CONTROL

Black

White

BLACK/WHITE

BROWN

BLACK/WHITE

GRAY

BLUE/BLACK

YELLOW

BLACK

YELLOW/BLACK

DANGER

!

Black

14

911 1012

65471382

14 13
1516

*ELECTRICAL SHOCK HAZARD

*DISCONNECT POWER BEFORE

SERVICING.

NOTES

White

Green

19

BLUE

PURPLE/WHITE

RED

RED/WHITE

RED/YELLOW
PURPLE
ORANGE

YELLOW/RED

REMOVE PURPLE JUMPER WIRE FOR 2 STAGE AIR

CONDITIONER OR HEAT PUMP.

IF PRIMARY LI MIT WIRES ARE TO BE REPLACED,

USE WIRE WITH INSUL. TEMP. RATING OF 200°C.

2

1

4047-122 A

120V

24V

White

3

24 VAC

Orange

RED

15

Black

BLACK

16 PIN WIRE HARNESS

7

BLACK

BLACK

COM

TRANSFORMER

9

Red/White

Black/White

10

18

RED

5 PIN

PLUG

4

3

251

CONTROL PANEL

5

CFM BLINK

WODH

RED

AND COND. UNIT 24V CONNECTIONS

FIELD CONNECT IONS TO THERMOST AT

(GREEN LED 7)

R
C

White

(RED LED 6)

NEUTRALS

LIMIT SWITCH

1

54
6

32

C

HUM
120 VAC

7

98

16 PIN BLOWER

CONTROL PLUG

Black

White

1

3

2

PLUG

3 PIN

Black

Orange

White

BURNER

ASS'Y

Purple

L2 (IGN)

MOTOR

IGNITER

Purple

IGNITER

BURNER

MOTOR

L2 (MTR)

L2

L1 - LIMIT

TR

TW

VALVE

OIL

VALVE

CAD

CELL

L2 (VLV)

CAD

BACKUP LIMIT

CELL

17

16 PIN BLOWER

CONTROL PLUG

DOOR

SWITCH

RETURN AREA

BLOWER ASSEMBLY

Manual 2100-540D
Page 45 of 45