Bard FLF110D60F, FLR085D36F, FH085D36F, FH110D60F, FLF085D36F User Manual

...
OIL FURNACE
INSTALLATION INSTRUCTIONS
MODELS
FH085D36F FH110D48F FH110D60F FLF085D36F FLF110D48F FLF110D60F FLR085D36F FLR110D48F FLR110D60F FLR140D60F FC085D36F
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: 2100-422M Supersedes: 2100-422L File: VOL. I, TAB 3 Date: 11-21-11
Manual 2100-422M Page 1 of 42
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 R7184B Primary Control ........................ 13
Beckett R7184B Primary Operational Guide ...... 14
Beckett GeniSys 7505 ................................ 14 – 17
Burner States, Reset Button Op., Priming the Pump, Cad Cell Resistance Indicator, Reset Restricted Lockout
Burner Set up and Adjustments ............ 19, 20 & 21
Short Form Adjustment Procedure ..................... 21
Combustion Air Requirements ............................ 25
Louvers and Grilles ............................................. 30
Venting Options .................................................. 30
Thermostat .......................................................... 30
TABLES
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 4 Furnace Data ....................................... 19
Table 5 Correlation of % of CO
Reserve Air .......................................... 24
Table 6 No. 2 Fuel Oil Efficiency Chart ............. 24
Table 7 Recommended Start-Up Settings ........ 24
Table 8 Sq.Ft. Required as
Unconfined Space ............................... 27
Table 9 Minimum Ventilation Openings ............ 28
Table 10 Temperature Rise Ranges, Limit
Control Settings, and
Heating Blower Speeds ....................... 31
Table 11 Filter Sizes for Oil Furnaces ................ 32
CHARTS
Chart 1 FH085D36F Data ................................. 38
Chart 2 FH110D48F Data ................................. 38
Chart 3 FH110D60F Data ................................. 38
Chart 4 FLF/FLR085D36F Data ....................... 38
Chart 5 FLF/FLR110D48F Data ....................... 38
Chart 6 FLF/FLR110D60F Data ....................... 38
Chart 7 FLR140D60F Data ............................... 39
Chart 8 FC085D36F Data ................................. 39
, O2 and
2
Filters
Lo-Boy Models – Filter Locations...................... 33
Maintenance
Lubrication .......................................................... 34
Inspect Air Filter .................................................. 34
Final Inspection and Test .................................... 34
Service Hints ....................................................... 34
Combination Combustion Chamber/Burner
Mounting System ................................................ 35
To Remove Burner Only ..................................... 36
To Remove Entire Combustion Chamber
Mounting System ................................................ 36
Common Causes of Trouble ............................... 37
Care of Finish ..................................................... 37
Cleaning of the Heat Exchanger ......................... 37
Blower System Resistance Charts................. 38-39
Wiring Diagrams ............................................ 40-42
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 Installation
Requirements - FLF ........................ 11
Figure 6 Typical Single Inside
Tank Installation ............................... 12
Figure 7 Electronic Blower Control ................ 18
Figure 8 Typical Smoke-CO2 Characteristic .. 22 Figure 9 Pressure Gauge Connection to
Bleed Port ....................................... 23
Figure 10 Electrode Adjustments ..................... 25
Figure 11 Combustion Air Boot Assembly ....... 26
Figure 12 All Air From Inside Building ............. 27
Figure 13 All Air From Outdoors ...................... 28
Figure 14 All Air From Outdoors Through
Ventilated Attic................................. 29
Figure 15 All Air From Outdoors - Inlet Air
From Ventilated Crawl Space and
Outlet Air to Ventilated Attic ............. 29
Figure 16 Typical Installation of FR26 and FR27.
Filter Rack ....................................... 32
Figure 17 Typical Installation of FR25 Filter
Kit .................................................... 32
Figure 18 Filter Installation - Lo-Boy Models ... 33
Figure 19 Removal of Burner Only .................. 35
Figure 20 Removal of Entire Combustion
Chamber Mounting System ............. 36
Manual 2100-422M Page 2 of 42
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: (202) 483-9370 Fax: (202) 234-4721
ANSI American National Standards Institute
11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286
ASHRAE American Society of Heating Refrigerating,
and Air Conditioning Engineers, Inc.
1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478
Duct Design for Residential ................. ACCA Manual D
Winter and Summer Air Conditioning and Equipment Selection
NFPA National Fire Protection Association
Batterymarch Park P.O. Box 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057
Manual 2100-422M Page 3 of 42
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
sehcnIsecanraelCnoitallatsnImuminiM
1
ledoM
F63D580HF F84D011HF F06D011HF
1FLF
F63D5
80CF
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
F63D580FLF
6
F63D580RLF
6
F84D01
6 6
F06D011FLF
F84D011RLF
6
F06D011RLF
6
F06D041RLF
6 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 **
42 42 42
42 42 42 42
42 42 42 42
— — —
ecivreSmuminiM
secnaraelCecanruFmunelP
— — —
42 42 42 42
42 42 42
*81 *81 *81 *81
*81 *81 *81
Manual 2100-422M Page 4 of 42
desU
.oN
J eziS
111
1
1
1x02x61
1x02x61
521.5
521.5
526.13
526.13
1
1x02x02
1x02x02
1x02x02
1x02x02
521.5
521.5
521.5
521.5
526.53
526.53
526.53
526.53
521.24---1x52x021
MIS-1815 A
.aiDH
G
nruteRnoitacoL
FxD
sgninepOnoitcenoCeulFsretliFriA 1
TABLE 2
munelP
ylppuS
ExD
thgieH
C
FLF/R MODELS DIMENSIONS (INCHES)
tenibaC
htpeD
B
htdiW
A
FIGURE 1
rebmuN
ledoM
FLF/R MODELS DIMENSIONS
666
6
6
tnorF
raeR
41x22
41x22
02x22
02x22
526.63
526.63
521.84
521.84
6
tnorF
tnorF
raeR
raeR
B
41x22
41x22
41x22
41x22
"FLF" FLUE
KNOCKOUT
02x22
02x22
02x22
02x22
526.04
526.04
526.04
526.04
521.84
521.84
521.84
521.84
Washable type filter 1” nom. thickness
LOW VOLTAGE
ENTRANCE
ENTRANCE
HIGH VOLTAGE
C
OPTIONAL
OIL ENTRANCE
RIGHT SIDE VIEWFRONT VIEWLEFT SIDE VIEW
1
323232
32
32
F63D580RLF
F63D580FLF
32
F06D041RLF62052.05526.7402x5261x52raeR6
F06D011RLF
F84D011RLF
F06D011FLF
F84D011FLF
A
FLF/FLR 085, 110 AND 140
SPECIFICATION SHEET
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 2100-422M Page 5 of 42
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 2100-422M Page 6 of 42
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
BOTTOM VIEW
SUPPLY OPENING
FRONT VIEW
19 1/8"
OPTIONAL OIL ENTRANCE
RIGHT SIDE VIEW
18 1/8"
MIS-1826 A
Manual 2100-422M Page 7 of 42
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 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 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 CFM versus static pressure curves on pages 38-39 for additional information.
Manual 2100-422M Page 8 of 42
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
F63D580HF1-06-5113.73/16.57/17.19 51
F84D011HF1-06-5112.212/15.017/17.15102
F06D011HF1-06-5112.414/35.217/17.18102
F63D580FLF1-06-5113.73/16.57/17.19
F63D580RLF1-06-5113.73/16.57/17.19 51
F84D011FLF1-06-5112.212/15.017/17.15102
F84D011RLF1-06-5112.212/15.017/17.15102
F06D011FLF1-06-5112.414/35.217/17.18102
F06D011RLF1-06-5112.414/35.217/17.18102
F06D041RLF1-06-5112.414/35.217/17.18102
F63D580CF1-06-5113.73/16.57/17.19
spmA
PHALFPHALF
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
emiT.xaM muminiM tiucriC
yticapmA
esuFyaleD
RCAHro
rekaerBtiucriC
51
51
Manual 2100-422M Page 9 of 42
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 2100-422M Page 10 of 42
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: FH110D48F, FH110D60F, FLF110D48F, FLF110D60F with NX Burners
Optional Fresh Air Boot (remove rect. knockout).
Oil Burner
MIS-1825
Manual 2100-422M Page 11 of 42
OIL LINE PIPING
First determine whether the pipe system is to be a single line system or a two line system. All connections must be absolutely air tight or you will have a malfunction of the burner. When installing the piping, a good oil filter should be installed close to the burner. A single line system is recommended for gravity feed.
A typical single inside tank installations shown in Figure 6. For installation details for this and other tank configurations, refer to NFPA31 -- latest edition. All tank and pipe setups must comply with NFPA31.
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 2100-422M Page 12 of 42
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. See Figures 19 and 20.
WARNING
Never attempt to use gasoline in your furnace. Gasoline is more combustible than fuel oil and could result in a serious explosion causing damage, injury or death.
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 2100-422M Page 13 of 42
BECKETT GENISYS
MODEL 7505
MIS-2491
PRIMARY OPERATIONAL GUIDE
BECKETT GENISYS 7505
Sequence of Operation
BURNER STATES
1. Standby: The burner is idle, waiting for a call
for heat.
2. Valve-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 2100-422M Page 14 of 42
TABLE A
"
RESET BUTTON OPERATION
ehtnisirenrubehtfI
:etatswoleb
kcilCnottuB
)dnoces1<sserp(
tuokcoLtuokcoLtfoSmorfteseR tuokcoL)draH(detcirtseRmorfteseR
,yaleDno-evlaV
,noitingIroflairT
revoyrraCnoitingI
)ffotuhssiretingi(nuR
ybdnatS,yaleDffO-rotoMnoitcaoN
emirPpmuPnoitcaoNybdnatSotnruterdnaedomemirPpmuPtixE
emirPpmuPotoG
)woleBees(
otsehsalfDELwolleY
.ecnatsiserllecdacetacidni
ecnatsiseRlleCdaC"eeS
foelbatrof"rotacidnI
.seulavecnatsiser
dloHnottuB
)dnoces1>sserp(
:renruBehtelbasiD
,gninnursirenrubehtemitynA nottubteserehtdlohdnasserp
.renrubehtelbasidot
saffoniamerlliwrenrubehT
.dlehsinottubehtsagnol
TABLE B
STATUS LIGHTS
:lliwnottubteseRehtgnihsuP
dloHnottuB
)sdnoces+51sserp(
:gnimirPpmuPselbanE
rofdlehneebsahnottubteserehtretfA
ebnehtnacnottubeht,sdnoces51
ecneuqesnoitingitxenehtgniruddeppat
.edomemirPpmuPretneot
DEL
roloC
ylsuounitnoCnOgnihsalF
deRtuokcoL)drah(detcirtseRtuokcoLtfoS
neerG)thgilyartsroemalfebdluoC(detceteDemalFelcyceR
wolleY
edomemirPpmuPnisilortnoC ro
sdnoces+51rofdlehyltnerrucnottubteseR
rotacidnIecnatsiseRlleCdaC"eeS.ecnatsiserlleCdaC
.seulavecnatsiserfoelbatrofnoitces
Manual 2100-422M Page 15 of 42
PRIMING THE PUMP
WARNING
Hot Gas Puff-Back & Heavy Smoke Hazard
Failure to bleed the pump properly could result in unstable combustion, hot gas puff­back and heavy smoke.
Do not allow oil to spray into a hot combustion chamber while bleeding air from the pump.
Install a gauge in the nozzle discharge port tubing or fully open the pump bleed valve to prevent oil spray from accumulating in the combustion chamber during the air bleed procedure.
Ensure that all bubbles and froth are purged from the oil supply system before tightening the pump air bleed valve.
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:
sehsalFDELwolleYegnaRnoitceteDemalF
1)smho004-0(lamroN
2)smho008-004(lamroN
3)smho0061-008(lamroN
4)tuokcoL-smho0061(detimiL
Manual 2100-422M Page 16 of 42
RESETTING FROM RESTRICTED LOCKOUT
If the control locks out three times without a
satisfied call for heat, or due to other significant events such as a relay contact weld, the Lockout becomes restricted in order to prevent repetitious resetting by the homeowner.
CAUTION
Before resetting the control from restricted
lockout state, troubleshoot the heating
system for the root cause(s) of lockout and
make necessary repairs or adjustment to
ensure a safe start condition.
Then, to reset, hold the button down for 15 seconds until the red light turns off and the yellow LED turns on. Observe at least one full control sequence of operation from startup to shutdown. Simulate a flame failure lockout by following the procedure (within this manual). If the operation is erratic, or not to specifications, then replace the control. Always verify the control functions according to all specifications before leaving the installation site.
DISABLE FUNCTION
Any time the burner is running, press and hold the
reset button to disable the burner. The burner will remain off as long as the button is held.
Burner OptionFlame Quality Monitor
This control is trained to recognize and remember a good flame based on initial burner set up. Control then monitors the flame via the CAD cell signal for deviation in the combustion characteristics of the burner. If the control senses a deviation on the high side or on the low side from the original set up condition for three consecutive cycles, it will trigger an alarm circuit which can be tied to an audible local device to signal the home owner or into the home security system. Upon being notified of the alarm, the security agency will notify the dealer of choice based upon information supplied by the home owner. The system will also be capable of being connected to a phone line that will contact the dealer directly with the alarm. This alarm will typically sound 3 to 5 days prior to the primary control going into lockout giving the service agency a prior notice before a sooting condition or other failure can occur resulting in untold savings. This monitor system is available through your local distributor under the Honeywell Part #QS7100F.
Electronic Blower Control Board (EBC)
This furnace is equipped with an Electronic Blower Control (EBC), which controls all comfort air blower operations. This EBC has three relays; one for heating speed, one for cooling speed, and one which isolates the T–T signal from the oil primary control.
NOTE: If a jumper wire is placed across “R” and
“W” prior to turning on power to the unit and then power is applied, the comfort air blower will start and run for the ignition period and through the entire call for heat.
Once this call for heat is satisfied, the blower will function according to the regular blower on and blower off delay cycles.
This EBC is designed to be very simple and dependable. This basic control allows for easy troubleshooting and maintenance. As illustrated in Figure 7 all connections are well marked. The blower on and off timings for both heating and cooling speeds are timed automatically. The heating blower off delay can be selected from four different timings by moving the selection jumper. The timings are as follows:
Heating Blower ON delay – 75 seconds from a call for heat.
Heating Blower OFF delay – Selectable in seconds: 150, 180, 210 or 240. Factory shipped at 240.
Cooling Blower ON delay – 6 seconds from a call for cooling.
Cooling Blower OFF delay – 60 seconds.
Manual 2100-422M Page 17 of 42
FIGURE 7
ELECTRONIC BLOWER CONTROL
HEATING BLOWER
OFF DELAY
ADJUSTMENT
IN SECONDS.
THERMOSTAT
CONNECTIONS
TRANSFORMER 24V SECONDARY CONNECTIONS
3 AMP FUSE
OIL PRIMARY T-T CONNECTIONS
LINE VOLTAGE CONNECTION (HOT)
HUMIDIFIER
CONNECTION
HEATING BLOWER
SPEED CONNECTION
SPEED CONNECTION
Manual 2100-422M Page 18 of 42
COOLING BLOWER
UNUSED BLOWER MOTOR SPEED CONNECTIONS
LINE VOLTAGE CONNECTION (COM, L2)
ELECTRIC AIR CLEANER CONNECTION
MIS-1819
TABLE 4
FURNACE DATA
ledoM
rebmuN
F63D580CF
F63D580HF
F84D011HF
F06D011HF
F63D580FLF
F84D011FLF
F06D011FLF
F63D580RLF
F84D011RLF
F06D011RLF
F06D041RLF
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.
Always use combustion test instruments when making burner adjustments and draft gauge when setting the barometric damper. It is virtually impossible to make accurate and reliable adjustments using the “eyeball” method.
Check all oil lines and connections for leaks.
Connect pressure gauge by removing bleed fitting and screwing in pressure gauge. See Figure 9.
IMPORTANT
Manual 2100-422M Page 19 of 42
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 Figure 10.
F. Operate Burner Operate burner, adjust air
setting for good flame by visual observation, and run for at least 10 minutes or until operation has stabilized.
G. Check Burner Pressure Bleed air from
pump and nozzle piping. Check pump pressure and adjust to nameplate pump pressure, if necessary.
2. COMBUSTION ADJUSTMENT STEPS
H. Set Draft Check the draft reading over the
fire with a draft gauge through a hole in the inspection door. The hole is above the flame level. Adjust the barometric draft regulator on the flue to give the over fire of -.02" W.C.
I. Check Smoke Readings After burner has
been operating 5 or 10 minutes, take a smoke
measurement in the flue, following the smoke tester instructions. Oily or yellow smoke spots on the filter paper are usually a sign of unburned fuel, indicating very poor combustion (and likely high emissions of carbon monoxide and unburned hydrocarbons). This condition can sometimes be caused by too much air, or by other factors. If this condition cannot be corrected, major renovation or even burner replacement may be necessary.
J. Develop Smoke - CO2 Curve Record
measurements of smoke and 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 8.
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 8. Usually 3 or 4 readings are enough to establish the curve.
In adjusting each air setting, it is helpful to note the various positions of air gate at which measurements are made so that the final setting can be located quickly.
K. Adjust Air Setting Examine the smoke - CO
plot and, keeping in mind the curve of Figure 6, note the location of the “knee” where the smoke number begins to rise sharply. Noting the air gate position marks, adjust the air setting to a CO2 level 1/2 to 1 percent lower than the 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 2100-422M Page 20 of 42
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 CO
at as high a point as possible over
2
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
measured in the flue. A difference of
CO
2
more than 1 percent CO
between the flue
2
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 insure prompt ignition on starting.
O. Check Pump Cutoff Slow pump cutoff at the
end of a firing cycle can cause smoke and other pollutant emissions. Check for prompt pump cutoff by observing flame or by testing smoke at shutdown. If poor cutoff is observed, make sure air is purged from the pump and nozzle line. Air trapped in the pump or nozzle line will expand when heated, thus causing oil to drip into the combustion chamber after shutdown. If poor cutoff persists, repair or replace pump. Also make sure the pump solenoid is working - if not replace.
Manual 2100-422M Page 21 of 42
TYPICAL SMOKE – CO
FIGURE 8
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
Plotted point
"Knee"
10
Percent CO in Flue Gas
2
12
Low
CO Curve
2
from plotted points
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 2100-422M Page 22 of 42
FIGURE 9
PRESSURE GAUGE CONNECTION TO BLEED PORT
Remove Bleed Port to attach pressure guage.
Pressure Gauge
MIS-1660
Manual 2100-422M Page 23 of 42
TABLE 5 — CORRELATION OF PERCENT OF CO2, O2 AND RESERVE AIR
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
F63D580CF
F63D580HF
F84D011HF
F06D011HF
F63D580FLF
F84D011FLF
F06D011FLF
F63D580RLF
F84D011RLF
F06D011RLF
F06D041RLF
elytSrenruB
.oNtraP
930-0209/XN
930-0209/XN
930-0209/XN
930-0209/XN
eziSepyTerusserPpmuP
57.0 *
430-0209/GFA
56.005
55.005
57.0 *
430-0209/GFA
56.005
55.005
58.0 *
57.0—3
58.0 *
57.0—3
57.0 *
430-0209/GFA
56.005
55.005
58.0 *
57.0—3
58.0 *
57.0—3
57.0 *
630-0209/GFA
56.005
55.005
00.1 *
730-0209/GFA
58.008
00.1 *
730-0209/GFA
58.008
52.1 *
830-0209/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
Manual 2100-422M Page 24 of 42
* Factory Installed Nozzle. Also shown are optional approved nozzle size/type.
SPACING OF ELECTRODES
The electrodes should be spaced 5/32" apart. They should extend 1/16" beyond the end and 5/16" above the center of the nozzle tip as shown in Figures 10A & 10B.
GUN ASSEMBLY ADJUSTMENT
The gun assembly can be adjusted in the slot inside of fan housing by loosening screw holding slot cover in position. Nozzle tip should ordinarily be located 1-1/8" behind the front face of the cone.
REMOVING GUN ASSEMBLY
Disconnect the oil line at the fan housing and remove lock nuts on copper tube fitting. Loosen igniter hold down clamps, then swing igniter up and backward. Gun assembly can now be removed through this opening.
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 11. 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: FH110D48F, FH110D60F, FLF110D48F and FLF110D60F with NX burners.
FIGURE 10A
FIGURE 10B
ELECTRODE ADJUSTMENTS — NX BURNERS
Manual 2100-422M Page 25 of 42
AFG BURNER
COMBUSTION
AIR BOOT
ASSEMBLY
INTAKE
AIR
TUBE
FOR OIL LINE
FIGURE 11
COMBUSTION AIR BOOT ASSEMBLY
USE THIS
KNOCKOUT
AFG BURNER ASSEMBLY
REMOVE PUMP TO ASSEMBLE INNER AIR BOOT
REMOVE KNOCKOUT IN LEFT SIDE
INSERT OUTER AIR BOOT AND SECURE FLANGE TO UNIT
MAKE ALL SETTINGS
MIS-1833
ACCORDING TO MANUAL FOR AIR BOOT.
Note: This accessory is not currently available for Bard Models: FH110D48F, FH110D60F, FLF110D48F, FLF110D60F with NX Burners
Manual 2100-422M Page 26 of 42
APPLIANCES LOCATED IN CONFINED SPACES
In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation, and dilution of flue gases. However, in buildings of unusually tight construction, additional air shall be provided using the method described under “All Air From Outdoors” in Figure 13.
An unconfined space (such as an open basement) must have a minimum volume of 50 cubic feet per 1,000 BTUH of total of all appliances in area. Adjoining rooms may be counted as one area only if there are not doors between the rooms.
Shown in Table 8 are the required minimum areas in square feet to qualify as an unconfined space for various total BTUH input ratings. The table is based on a room(s) with 8 foot ceiling heights.
If the unconfined space is within a building having insufficient air because of tight construction, the air for combustion and ventilation shall be obtained from outdoors or from spaces freely communicating with the outdoors. Under these conditions a permanent opening or openings have a total free area of not less than one square inch per 5,000 BTU per hour (28 square inches per hour ) of total input rating of all appliances shall be provided. For combustion air options see Page 25, “Combustion Air Requirements”.
FIGURE 12
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
ecapSdenifnocnU
nIaerAmuminiM
teeFerauqS
thgieHgnilieC'8
0001 0521
ALL AIR FROM INSIDE BUILDING
The confined space shall be provided with two permanent openings, one near the top of the enclosure and one near the bottom. Each opening shall have a free area of not less than one square inch per 1,000 BTU per hour (140 square inches per gallon per hour) of the total input rating of all appliances in the enclosure freely communicating with interior areas having in turn adequate infiltration from the outside. (See Figure 12.) Also see Table 9 on the following page for specific ventilation opening requirements for the furnace only.
The flow of combustion and ventilating air must not be obstructed from reaching the furnace.
NOTE: Each opening shall have a free area of
not less than one square inch per 1,000 BTU per hour (140 square inches per gallon per hour) of the total input rating of all appliances in the enclosure.
Manual 2100-422M Page 27 of 42
TABLE 9
MINIMUM VENTILATION OPENINGS
noitalitneV.niM
gninepO
ledoM
F63D580HF04261x8821
F84D011HF08281x9261
F06D011HF08281x9261
F63D580FLF09291x8251
F63D580RLF09291x8251
F84D011FLF F06D011FLF
F84D011RLF F06D011RLF
F06D041RLF06391x5.9081
F63D580CF04261x8821
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 13, 14, & 15.)
B. When directly communicating with outdoors or by
means of vertical ducts, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour (35 square inches per gallon per hour) of total input rating of all appliances in the enclosures. If horizontal ducts are used, each opening shall have a free area of not less than one square inch per 2,000 BTU per hour (70 square inches per gallon per hour) of total input of all appliances in the enclosure.
FIGURE 13
APPLIANCES LOCATED IN CONFINED SPACES
ALL AIR FROM OUTDOORS
NOTE: Each air duct opening shall have a
free area of not less than one square inch per 2,000 BTU per hour (70 square inches per gallon per hour) of the total input rating of all appliances in the enclosure.
Manual 2100-422M Page 28 of 42
FIGURE 14
APPLIANCES LOCATED IN CONFINED SPACES
ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC
NOTE: The inlet and outlet air openings shall
each have a free area of not less than one square inch per 4,000 BTU per hour (35 square inches per gallon per hour) of the total input rating of all appliances in the enclosure.
FIGURE 15
APPLIANCES LOCATED IN CONFINED SPACES
ALL AIR FROM OUTDOORS
INLET AIR FROM VENTILATED CRAWL SPACE AND OUTLET AIR TO VENTILATED ATTIC
NOTE: The inlet and outlet air openings shall
each have a free area of not less than one square inch per 4,000 BTU per hour (35 square inches per gallon per hour) of the total input rating of appliances in the enclosure.
Manual 2100-422M Page 29 of 42
LOUVERS AND GRILLES
In calculating free area for ventilation and combustion air requirements, consideration shall be given to the blocking effect of louvers, grilles, or screens protecting openings. Screens used shall not be smaller than 1/4 inch (6.3 mm) mesh and shall be readily accessible for cleaning. If the free area through a design of louver or grille is known, it shall be used in calculating the size opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 30-35 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 venter is the Field Controls model number SWG-4HDS for 085 and 110 models, and SWG-5S for 140 models only. This venter can be purchased through your local distributor. Follow all installation instructions packaged with the venter system.
THERMOSTAT
These furnaces are designed to be controlled with any 24V heating or heating/cooling thermostat. The heat/cool thermostats must be designed for independent heat/cool transformer circuits to assure that the 24V transformer built into the oil primary control does not conflict with the main furnace 24V transformer. The heat anticipator should be set at 0.20A. This is a nominal setting. The thermostat circuit should be checked to verify setting.
Manual 2100-422M Page 30 of 42
TABLE 10
TEMPERATURE RISE RANGES, LIMIT CONTROL SETTINGS,
AND HEATING BLOWER SPEEDS
ledoM
rebmuN
F63D580CF
F63D580HF
F84D011HF
F06D011HF
F63D580FLF
F84D011FLF
F06D011FLF
F63D580RLF
F84D011RLF
F06D011RLF
F06D041RLF
renruB
epyT
GFA
GFA
eziSepyTerusserPpmuP
57.0 *
56.0001-07woL
55.0001-07woL
57.0 *
56.0001-07woL
55.0001-07woL
58.0 *
XN
57.0001-07woL
58.0 *
XN
57.009-06woL
57.0 *
GFA
56.009-06woL
55.009-06woL
58.0 *
XN
57.009-06woLmuideM
58.0 *
XN
57.009-06woLmuideM
57.0 *
GFA
56.009-06woL
55.009-06woL
00.1 *
GFA
58.009-06woLmuideM
00.1 *
GFA
58.009-06woLmuideM
52.1 *
GFA
01.109-06woLmuideM
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
deepS
muideM
woLmuideM
woLmuideM
muideM
muideM
hgiHmuideM
hgiHmuideM
muideM
hgiHmuideM
hgiHmuideM
hgiHmuideM
* Factory Set Point.
Manual 2100-422M Page 31 of 42
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 16.
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 17.
See Table 11 for filter sizes and quantities.
TABLE 11
FILTER SIZES FOR OIL FURNACES
ledoMeziS
F63D580HF
yoB-iH
yoB-iH
yoB-iH
syoB-oL
syoB-oL
yoB-oL
wolfretnuoC
)1(1x52x61
F84D011HF
)1(1x52x61
F06D011HF
)1(1x52x02
F63D580FLF F63D580RLF
)1(2x02x61
F84D011FLF
F84D011RLF
F06D011FLF
)1(2x02x02
F06D011RLF
F06D041RLF
)1(2x52x02
F63D580CF
)2(1x02x61
FIGURE 16
TYPICAL INSTALLATION OF FR26 AND
FR27 FILTER RACKS
19 1/4"
(2) screws
Filter
FIGURE 17
TYPICAL INSTALLATION OF FR25
FILTER KIT
Optional
Filter
Box
"FC"
Unit
70 5/16"
16"
Filter Frame
Manual 2100-422M Page 32 of 42
Filter Door
MIS-1839 A
MIS-1841
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 18 below.
FIGURE 18
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
STEP 1:
UNFASTEN SWELL
LATCHES BY PULLING
HANDLES OUTWARD
MIS-1835 A
Manual 2100-422M Page 33 of 42
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 2100-422M Page 34 of 42
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 Figure 19 and 20.
REMOVAL OF BURNER ONLY
DANGER
!
*ELECTRICAL SHOCK HAZARD *DISCONNECT POWER BEFORE SERVICING.
WARNING
The procedures described in Figures 19 and 20 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 19
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.
STEP 3: ROTATE BURNER COUNTER-CLOCKWISE
STEP 1: DISCONNECT "T-T" WIRES, POWER CONNECTIONS, AIR BOOT (OPTIONAL) AND OIL LINES TO BURNER.
MIS-1834
Manual 2100-422M Page 35 of 42
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 19.)
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 20.)
FIGURE 20
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 2100-422M Page 36 of 42
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 products 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 2100-422M Page 37 of 42
BLOWER SYSTEM RESISTANCE CHARTS
CHART 1
FH085D36F DATA
deepSrewolBcitatSrewolB
woL
muideM
hgiH
CHART 2
FH110D48F DATA
deepSrewolBcitatSrewolB
woL
woLmuideM
hgiHmuideM
01.51.32.03.
61.42.43.34.
02.03.04.05.
30.80.31.81.
90.61.32.23.
61.52.43.44.
CHART 4
FLF/FLR085D36F DATA
deepSrewolBcitatSrewolB
woL
muideM
hgiH
FLF/FLR110D48F DATA
deepSrewolBcitatSrewolB
woL
woLmuideM
hgiHmuideM
70.31.91.52.
51.42.33.14.
02.03.04.05.
CHART 5
50.90.51.02.
90.61.32.13.
51.42.43.24.
hgiH
CHART 3
FH110D60F DATA
deepSrewolBcitatSrewolB
woL
woLmuideM
hgiHmuideM
hgiH
02.03.04.05.
60.21.71.12.
01.71.32.03.
41.12.13.83.
02.03.04.05.
hgiH
FLF/FLR110D60F DATA
deepSrewolBcitatSrewolB
woL
woLmuideM
hgiHmuideM
hgiH
02.03.04.05.
CHART 6
80.21.71.12.
01.61.22.82.
31.12.92.63.
02.03.04.05.
Manual 2100-422M Page 38 of 42
CHART 7
deepSrewolBcitatSrewolB
woL
80.41.02.62.
muideM
61.42.63.24.
hgiH
02.03.04.05.
FLR140D60F DATA
deepSrewolBcitatSrewolB
CHART 8
FC085D36F DATA
woL
woLmuideM
hgiHmuideM
hgiH
50.41.71.42.
80.71.22.03.
11.02.72.53.
02.03.04.05.
Manual 2100-422M Page 39 of 42
FH SERIES
)
)
WIRING DIAGRAM
T
PLUG #1
BURNER ASS'Y
T
VALVE
BURNER MOTOR
IGNITOR
CAD CELL
PURPLE
PURPLE
PURPLE
PURPLE
L1 L2
OIL VALVE
BURNER MOTOR
IGNITOR
CAD CELL
56789
BLACK
BLACK
WHITE
GREEN
BLACK
211234
UNIT
WHITE
PLUG #2
BACKUP
LIMIT
BLACK
BLACK
BLACK
1
BLACK WHITE
GREEN
BLACK
PRIMARY
LIMIT
CONTROL
BLACK
DOOR SWITCH
NOTES
IF PRIMARY LIMIT WIRES ARE TO BE REPLACED,
1
USE WIRE WITH INSUL. TEMP. RATING OF 200°C.
HEATING SPEED
2
CONNECTION POINT. COOLING SPEED
3
CONNECTION POINT. ONLY ONE HEATING
AND COOLING SPEED CAN BE CONNECTED.
4
ALL OTHER TAPS
HEAT EXCHANGER AREA
CONNECT TO "SPARE"
BLACK
TERMINALS. DASHED LINES
5
REPRESENT FIELD WIRING.
DANGER
!
*ELECTRICAL SHOCK HAZARD *DISCONNECT POWER BEFORE SERVICING.
HOT NEUTRAL GROUND
WARNING
!
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".
5
150 180 210 240
HUM
2
LOW
VOLTAGE
HIGH
VOLTAGE
FIELD
WIRING
RWGYC
BLOWER CONTRO L
3
HEAT
COOL
EAC
L2
WHITE
PLUG #3
BLOWER CAPACITOR
BROWN
COM
SPR2
SPR3
SPR1
WHITE
1234
BLUE
BLACK
BROWN
BLOWER ASSEMBLY
SEC2
T T
L1
4
WHITE
ORANGE
SEC1
SEE CHART FOR HEATING AND COOLING WIRE COLORS
5
WHITE
RED
RETURN AREA
YELLOW
BLUE
TRANSFORMER
BLACK
24V
COM
120V
UNIT
FH085D36F
FH110D48F
FH110D60F
BLOWER CAPACITOR RATING
UNIT MOTOR CAPACITOR FH085D36F 1/3 5/370 FH110D48F 1/2 7.5/370 FH110D60F 3/4 15/370
YC
Rc
WRh
G
Y
COND.
UNIT
24V.
CONN.
FH085D36F
CONTROL PA NEL
FH110D48F
FH110D60F
INPUT RATE
FACTORY SE TTIN GS
HEATING BLOWER
SPEED (COLOR)
GPH
0.55 LOW (RED) 70°-100°
0.65 LOW (RED) 70°-100°
0.75 MED (BLUE) 60°-90°
0.85 LOW (RED) 70°-100° 1 MED-LOW (ORANGE
0.85 LOW (RED) 60°-90° 1 MED-LOW (ORANGE
THERMOSTAT
T87F/Q539A1220 OR EQUIVELANT
OPTIONAL A I R COND. SETTINGS
NOM.
UNIT
COOLING BLOWER
A/C
SPEED (COLOR)
TONS
2 LOW (RED) 730
2 1/2 MED (B LUE ) 900
3 HIGH (BLACK) 1 160
2 1/2 LOW (RED) 1020
3 MED-LOW (ORANG E) 1 280
3 1/2 MED-HIGH (BL UE ) 1495
4 HIGH (BLACK) 1 640 3 LOW (RED) 1300
3 1/2 ME D-LOW (ORA NGE ) 1 460
4 MID- H IGH ( BLUE) 1660 5 HIGH (BLACK) 1 970
COOLING BLOWER
SPEED (COLOR)
HIGH (B LACK)
CFM @ .50 WC
TEMP.
RISE
RANGE
60°-90°
60°-90°
4047-118 F
Manual 2100-422M Page 40 of 42
)
)
)
)
GPH INPUT
CFM@
.50" WC
SPEED
COLING BLWR.
RISE
TEMP.
60°-90° HIGH (BLACK)
60°-90° HIGH (BLACK)
60°-90° HIGH (BLACK)
60°-90° HIGH (BLACK)
5
T87F/Q539A1220
OR EQUIVELANT
THERMOSTAT
SPEED (COLOR)
NOTES
4047-119 E
DASHED LINES
ONLY ONE HEATING
AND COOLING SPEED
CAN BE CONNECTED.
COOLING SPEED
CONNECTION POINT.
HEATING SPEED
IF PRIMARY LIMIT WIRES
CONNECTION POINT.
ARE TO BE REPLACED,
USE WIRE WITH INSUL.
TEMP. RATING OF 200°C.
1
3
2
REPRESENT FIELD WIRING.
ALL OTHER TAPS
CONNECT TO "SPARE"
TERMINALS.
4
5
HTG. BLW R
SPD. (COLOR)
FACTORY SETTINGS
0.55 LOW (RED) 60°-90° HIGH (BLACK)
0.65 LOW (RED) 60°-90° HIGH (BLACK)
UNIT
FLF/R085D36F
FLF/R SERIES
WIRING DIAGRAM
PRIMARY LIMIT
BLACK
1
Rh
W
ED. HIGH (BLUE
ED. HIGH (BLUE
ED. HIGH (BLUE
ED. HIGH (BLUE
G
NOM. A/C
COOLING BLOWER SPEEDS
3 HIGH (BLA CK ) 1275
2.5 MED (BLUE ) 1070
2.5 LOW (RED) 1065
3 MED LOW (ORANGE) 1 235
3.5 M E D HIGH (B L UE ) 1415
2 LOW (RE D) 775
(TONS)
Y
1
1.1
0.75 MED (BLUE ) 60°-90° HIGH (BLACK)
1.25
0.85
Rc
UNIT
FLF/R085D36F
FLF/R110D48F
Y C
FLR140D60F
FLF/R110D48F
FLF/R110D60F
HEAT EX. AREA
24V.
UNIT
COND.
SEC1
T
SEC2
CONN.
T
L1
4
4 HIGH (BLA CK ) 1525
3 LOW (RE D) 1190
YELLOW
BLACK
3.5 M E D LO W (ORA NGE ) 1 400
FLF/R110D60F
4 MED HIGH (BLUE) 1640
FLR140D60F
5 HIGH (BLA CK ) 2250
DANGER
3/4 15/370
UNIT MOTOR CAPACITOR
BLOWER CAPACITOR RATING
BLUE
BLACK
FLR140D60F
FLF/R085D36F 1/3 5/370
FLF/R110D48F 1/2 7.5/370
FLF/R110D60F
!
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
HOT
WHITE NEUTRAL
BLACK
GREEN GROUND
SPR3 SPR2 SPR1
GYC W
R
PURPLE
PURPLE
BLACK
BLOWER CONTROL
240
210
180
150
COM L2
3
EAC COOL
HEAT HUM
WHITE WHITE WHITE
2
120V
COM
24V
TRANSFORMER
CONTROL PANEL
WIRE COLORS.
SEE CHART FOR
"HEAT" AND "COOL"
1
2
BLACK
BLACK
BLACK
IGNITOR
MOTOR
BURNER
OIL VALVE
L1
L2
BURNER ASS'Y
BACKUP LIMIT
VALVE
BURNER
MOTOR
TT
CAD CELL
BLOWER CAPACITOR
BLACK
IGNITOR
CAD CELL
BROWN
2
1
BLACK
BROWN
5
4
3
BLUE
ORANGE
WHITE
RED
RETURN AREA
BLOWER ASSEMBLY
Manual 2100-422M Page 41 of 42
T
COLING BLWR.
SPEED
RISE
TEMP.
5
T87F/Q539A1220
OR EQUIVELANT
THERMOSTAT
CFM@
.50" WC
NOTES
AND COOLING SPEED
CAN BE CONNECTED.
4
DASHED LINES
ALL OTHER TAPS
CONNECT TO "SPARE"
TERMINALS.
ONLY ONE HEATING
COOLING SPEED
CONNECTION POINT.
HEATING SPEED
IF PRIMARY LIMIT WIRES
CONNECTION POINT.
ARE TO BE REPLACED,
USE WIRE WITH INSUL.
TEMP. RATING OF 200°C.
1
3
2
4047-120 D
REPRESENT FIELD WIRING.
5
HTG. BLWR
SPD. (COLOR)
FACTORY SETTINGS
0. 55 LOW (RE D) 6 0° -9 0° HIG H ( B LACK )
0.65 LOW (RED) 70°-100° HIGH (BLACK)
UNIT GPH INPU
FC085D36F
FC SERIES
WIRING DIAGRAM
PRIMARY LIMIT
BLACK
1
Rh
SPEED (COLOR)
W G
Y
0.75 MED (BLUE) 60°-90° HIGH (BLACK)
Rc
NOM. A / C
COOLING BLOWER SPEEDS
Y C
HEAT EX. AREA
24V.
UNIT
COND.
SEC1
T
SEC2
CONN.
T
L1
DLOW (RED)775
(TONS)
UNIT
YELLOW
4
BLACK
2.5 MED (B LUE) 1070
FC085D36F
3 HIGH (BLA CK) 1230
DANGER
!
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
HOT
NEUTRAL
WHITE
BLACK
BLACK
GREEN GROUND
SPR3
C
RWGY
PURPLE
PURPLE
BLACK
BLOWER CONTROL
240
210
180
150
SPR2 SPR1 COM L2
3
EAC
WHITE WHITE WHITE
COOL HEAT HUM
2
120V
24V
COM
TRANSFORMER
WHITE
CONTROL PANEL
WIRE COLORS.
SEE CHART FOR
"HEAT" AND "COOL"
1
2
IGNITOR
MOTOR
BURNER
OIL VALVE
L1
L2
BURNER ASS'Y
VALVE
BURNER
MOTOR
TT
CAD CELL
BACKUP LIMIT
IGNITOR
CAD CELL
1
BLACK
DOOR
2
BLACK
SWITCH
3
4
BLACK
(5/370)
BLACK
BROWN
BLOWER CAPA CITOR
3
4
2
1
BLACK
BROWN
5
BLUE
WHITE
RED
RETURN AREA
BLOWER ASSEMBLY (1/ 3 HP)
Manual 2100-422M Page 42 of 42
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