OIL FURNACE
INSTALLATION INSTRUCTIONS
MODELS
FH085D36E
FH110D48E
FLF110D48E
FLR110D48E
FC085D36E
FH110D60E
FLF110D60E
FLR110D60E
FLF085D36E
FLR085D36E
FLR140D60E
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.
Manual:
Supersedes: 2100-422A
File:
Date:
2100-422B
Bard Manufacturing Company
Bryan, Ohio 43506
VOL. I, TAB 3
09-23-03
Since 1914...Moving ahead just as planned.
Copyright 2003
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.
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACCA
Air Conditioning Contractors of America
1712 New Hampshire Ave. N.W.
Washington, DC 20009
National Fuel Gas Code ........... ANSIZ223.1/NFPA54
National Electrical Code ...................... ANSI/NFPA70
Telephone: (202) 483-9370
Fax: (202) 234-4721
ANSI
American National Standards Institute
11 West Street, 13th Floor
New York, NY 10036
Standard for the Installation .............. ANSI/NFPA90A
of Air Conditioning and Ventilating Systems
Telephone: (212) 642-4900
Fax: (212) 302-1286
Standard for Warm Air...................... ANSI/NFPA90B
Heating and Air Conditioning Systems
ASHRAE American Society of Heating Refrigerating,
and Air Conditioning Engineers, Inc.
1791 Tullie Circle, N.E.
Standard for Chimneys, Fireplaces, Vents ... NFPA 211
and Solid Fuel Burning Appliances
Atlanta, GA 30329-2305
Telephone: (404) 636-8400
Fax: (404) 321-5478
Load Calculation for .......................... ACCA Manual J
Residential Winter and Summer Air Conditioning
NFPA
National Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: (800) 344-3555
Fax: (617) 984-7057
Duct Design for Residential .............. ACCA Manual D
Winter and Summer Air Conditioning
and Equipment Selection
Manual 2100-422
Page
1
INSTALLATION and OPERATING INSTRUCTIONS
LOCATING THE FURNACE
EQUIPMENT SELECTION
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 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.
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.
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.
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
Minimum Installation Clearnaces — Inches
Minimum Service
Clearances
Furnace
Front Back Sides
Plenum
1
Flue
Pipe
Model
Top
Sides Duct
Floor Front Back Sides
FH085D36E
FH110D48E
FH110D60E
4
4
4
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
9
9
9
C
C
C
24
24
24
—
—
—
—
—
—
FLF085D36E
FLR085D36E
FLF110D48E
FLF110D60E
6
6
6
6
0
18
0
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
9
9
9
9
NC
NC
NC
NC
24
24
24
24
24
24
24
24
18 *
18 *
18 *
18 *
0
FLR110D48E
FLR110D60E
FLR140D60E
FC085D36E
6
6
6
6
18
18
18
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
9
9
9
9
NC
NC
NC
24
24
24
24
24
24
24
—
18 *
18 *
18 *
—
NC **
j
For the first three (3) feet from plenum. After three (3) feet, no clearance required.
Combustible flooring
C
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.
Manual 2100-422
Page
2
FIGURE 1
FLF/R MODELS DIMENSIONS
TABLE 2
FLF/R MODELS DIMENSIONS (INCHES)
FLF/FLR 085, 110 AND 140
SPECIFICATION SHEET
Plenum
Cabinet
B
Openings
Flue Conection
G
Air Filters
Size
1
Model
Number
A
C
D x E D x F
No.
Used
J
TOP VIEW
Width Depth Height Supply Return Location Dia.
H
J
RETURN
DUCT
SUPPLY
DUCT
FLF085D36E
FLR085D36E
23 48.125 36.625 22x20 22x14
23 48.125 36.625 22x20 22x14
Front
Rear
6
6
31.625 5.125 16 x 20 x 1
31.625 5.125 16 x 20 x 1
1
1
FLF110D48E
FLF110D60E
FLR110D48E
FLR110D60E
23 48.125 40.625 22x20 22x14
23 48.125 40.625 22x20 22x14
23 48.125 40.625 22x20 22x14
23 48.125 40.625 22x20 22x14
Front
Front
Rear
Rear
6
6
6
6
35.625 5.125 20 x 20 x 1
35.625 5.125 20 x 20 x 1
35.625 5.125 20 x 20 x 1
35.625 5.125 20 x 20 x 1
1
1
1
1
D
FLR140D60E
26 50.250 47.625 25x20 25x16
Rear
6
42.125 - - - 20 x 25 x 1
1
j
Washable type filter 1” nom. thickness
"FLF" FLUE
KNOCKOUT
G
F
B
E
A
"FLF" FLUE
KNOCKOUT
REAR FLUE
ON "FLR" MODELS
"FLF" FLUE
KNOCKOUT
OPTIONAL
HIGH VOLTAGE
ENTRANCE
LOW VOLTAGE
ENTRANCE
OPTIONAL
LOW VOLTAGE
ENTRANCE
HIGH VOLTAGE
ENTRANCE
C
H
OIL
ENTRANCE
OPTIONAL
OIL
ENTRANCE
OPTIONAL
OIL ENTRANCE
FILTER
DOOR
FRESH AIR
KNOCKOUT
LEFT SIDE VIEW
FRONT VIEW
RIGHT SIDE VIEW
MIS-1815 A
FIGURE 2
FH MODELS DIMENSIONS
21 7/8"
TOP VIEW
FH085 AND FH110
SPECIFICATION SHEET
SUPPLY
OPENING
19 7/8"
30 1/2"
FLUE
KNOCKOUT
23"
FLUE
KNOCKOUT
FLUE
KNOCKOUT
OPTIONAL
HIGH VOLTAGE
ENTRANCE
REAR CLEANOUT
DOOR
OPTIONAL
LOW VOLTAGE
ENTRANCE
HIGH
VOLTAGE
ENTRANCE
OPTIONAL
OIL
ENTRANCE
53" (FH085)
59" (FH110)
OIL
ENTRANCE
LOW VOLTAGE
ENTRANCE
19 1/4"
FRESH AIR
KNOCKOUT
OPTIONAL
OIL
ENTRANCE
RETURN
OPENING
(CUT OUT)
RETURN
OPENING
(CUT OUT)
16"
VESTIBULE
DOOR
LEFT SIDE VIEW
RIGHT SIDE VIEW
FRONT VIEW
MIS-1814 A
FIGURE 3
FC085 MODEL DIMENSIONS
21 7/8"
SUPPLY
OPENING
FC085
SPECIFICATION
SHEET
19 7/8"
30 1/2"
TOP VIEW
FLUE
KNOCKOUT
23"
FLUE
KNOCKOUT
FLUE
KNOCKOUT
OPTIONAL
HIGH VOLTAGE
ENTRANCE
54 1/4"
REAR
CLEANOUT
DOOR
OPTIONAL
LOW VOLTAGE
ENTRANCE
LOW VOLTAGE
ENTRANCE
OIL ENTRANCE
HIGH VOLTAGE
ENTRANCE
OPTIONAL
OIL ENTRANCE
FRESH AIR
KNOCKOUT
OPTIONAL
OIL ENTRANCE
FRONT VIEW
LEFT SIDE VIEW
RIGHT SIDE VIEW
RETURN
OPENING
18 1/8"
BOTTOM VIEW
MIS-1826
19 1/8"
Manual 2100-422
Page
5
DUCT WORK
INSTALLING THE FURNACE
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.
INSTRUMENTSREQUIREDFORPROPER
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:
IMPORTANT
1. Oil pump pressure gauge that measures up to
150 PSI.
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.
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.
INSTALLING A COOLING UNIT
INSTALLATION
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 typical installation is shown in Figures 4 and 5. All
parts of the furnace installation (furnace, oil tank and
piping systems, combustion and ventilation air, venting,
etc.) must comply with NFPA31, Installation of Oil
Burning Equipment -- latest edition. This drawing
shows the typical connecting parts needed to correctly
install this furnace. Make sure that all parts of the
heating system comply with the local codes.
Check the furnace and your load calculation to verify
that the unit is properly sized. (Refer to Equipment
Selection” section on Page 2.)
*
A cooling unit is an air conditioning coil, heat
pump coil or chilled water coil.
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.
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.
INADEQUATE SUPPLY AIR and/or RETURN
AIR DUCT SYSTEMS
For top discharge FH and FL models, when coils are
installed without using Bard coil cabinets or coils of
another brand are used, the coil drain pan should be
located a minimum of two (2) inches above the top of
the furnace cabinet. If a greater clearance is specified
by the coil manufacturer then it would apply.
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
deliverycapabilities.
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
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.
ACCEPTABLE FOR USE WITH THESE
OIL FURNACES HAVING MAXIMUM
OUTLET AIR TEMPERATURE OF 200° F.
See CFM versus static pressure curves on pages 33-36
for additional information.
Manual 2100-422
Page
6
FIELD WIRING
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.
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.
TABLE 3
ELECTRICALDATA
Max. Time
Delay Fuse
or HACR
Blower Motor
Burner Motor
Minimum
Circuit
Total
Amps
HP
FLA
HP
FLA
Model
Volts-HZ-PH
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
115-60-1
Ampacity Circuit Breaker
FH085D36E
FH110D48E
FH110D60E
FLF085D36E
FLR085D36E
FLF110D48E
FLR110D48E
FLF100D60E
FLR100D60E
FLR140D60E
FC085D36E
9.2
1/3
1/2
3/4
1/3
1/3
1/2
1/2
3/4
3/4
3/4
1/3
7.5
10.5
12.5
5.6
1/7
1/7
1/7
1/7
1/7
1/7
1/7
1/7
1/7
1/7
1/7
1.7
1.7
1.7
1.7
1.7
1.7
1.7
1.7
1.7
1.7
1.7
15
16
19
15
15
16
16
19
19
19
15
15
20
20
15
15
20
20
20
20
20
15
12.2
14.2
17.3
17.3
12.2
12.2
14.2
14.2
14.2
7.3
5.6
10.5
10.5
12.5
12.5
12.5
5.6
Manual 2100-422
Page
7
FIGURE 4
TYPICAL UNIT SETUP
FLF UNIT SHOWN
WARNING
ALL WIRING MUST
CONFORM TO THE
NATIONAL ELECTRIC
CODE AND ALL LOCAL
CODES.
!
Left side
high voltage
(unit power)
entrance
Inspection
door
Left side
low voltage
(thermostat)
entrance
Right side
low voltage
(thermostat)
entrance
Left side oil
line entrance
for opt. air boot
To thermostat
and optional
A/C unit
Left side
oil line
entrance
To power
source
Oil line
(see burner
pump inst. for
hookup info.)
Shut off switch
(if not fused,
power line must
include fuse or
circuit breaker)
Air Boot
knockout
(optional)
Control panel
(junction box
in FH units)
Power Wires:
Black (HOT)
White (NEUTRAL)
Green (GROUND)
Right side
high voltage
(unit power)
entrance
Right side
oil line
MIS-1836
entrance
Manual 2100-422
Page
8
FIGURE 5
TYPICAL FLUE INSTALLATION REQUIREMENTS
FRONT FLUE LOWBOY MODEL SHOWN
(REPRESENTS ALL MODELS)
INSTALLER NOTE:
Thimble
Follow all appropriate
standards for installing
needed venting system.
Draft Regulator
(Be sure to follow
installation inst.
supplied with
regulator).
1/4 inch per
1 foot rise
L
i
n
e
d
90° Rotatable
Flue Box on front
flue models
(remove appropriate
cabinet knockout).
Mounting screws
located under flue
box cover.
Flue Box
Cover
C
h
i
m
n
e
y
Optional
Flue
Locations
Oil Burner
Clean-out Door
(keep closed)
Optional Fresh
Air Boot (remove
rect. knockout).
MIS-1825
Manual 2100-422
Page
9
OIL LINE PIPING
BECKETT AFG OIL BURNER
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.
This furnace is equipped with a high static Beckett AFG
oil burner which is designed to produce adequate draft in
nearly any vertically vented application. The burner
employs the latest time tested controls of the highest
quality. The controls consist of a high voltage Beckett
solid state igniter, a Beckett “CleanCut” oil pump with
an integral solenoid valve, and a Beckett R7184B
primary control.
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.
FIGURE 6
TYPICAL SINGLE INSIDE TANK INSTALLATION
Vent Cap
2" Cap
2" Fill Pipe
1-1/4"
Vent Pipe
Return Line
Guage
Bushing,
2" x 1-1/2" or
1-1/4"
Oil
Tank
Gate Valve
3/8" x 4"
nipple
6"
3/8" x 3/8"
Adapter
3/8" O.D. Copper
Fuel Tubing
Legs (either 1-1/4"x10"
or 1-1/2"x10" nipples)
MIS-1823
Bushing
Oil Filter
Manual 2100-422
Page 10
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.
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.
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.
BECKETT R7184B PRIMARY CONTROL
The R7184B Interrupted Electronic Oil Primary is a
line voltage, safety rated, interrupted ignition oil
primary control for residential oil burners. The R7184B
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.
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.
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 R7184B
primary control is provided following on
Page 12.
The following is a detailed explanation of each control
included in the Becket 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. This
pump requires a pre-purge style primary control such as
the R7184B primary. All installation and set up
instructions are outlined in the “Oil Pump
Specification” section of the installation instructions
manual.
Manual 2100-422
Page
11
BECKETT R7184B PRIMARY
OPERATIONAL GUIDE
Pre-Purge Delay – 15 seconds on delay
LED Codes – Flashing 1/2 second on / 1/2 second off – system is locked out or in restricted mode
(hard lockout).
– Flashing 2 seconds on / 2 seconds off – control is in recycle mode (soft lockout).
– ON – CAD cell is sensing flame
– OFF – CAD cell is not sensing flame.
Ignition Trials – On any given call for heat the
control will allow three ignition trials. After the three
trials the control will go into a soft lockout mode. The
LED will flash 2 seconds on and 2 seconds off when
in this recycle mode. The control may then be reset
by pressing the RED reset button on the control. If
within the same original call for heat the control will
again allow three ignition trials followed by another
soft lockout and a 2 second on / 2 second off LED
code. The control my be reset one additional time by
pressing the red reset button. This will allow three
final ignition trials. If all three of the final ignition trials
fail then the control goes into a hard lockout or
Restricted Mode. This series of ignition failures must
all occur with the original call for heat in order to
reach the Restricted Mode. The LED will now flash
1/2 second on / 1/2 second off indicating the
restricted mode. The control can be resurrected from
the restricted mode only by pressing and holding the
red reset button for approximately 30 seconds until
the LED flashes twice. Removing unit power or
resetting the thermostat will not reset the control
Checking CAD Cell – With a call for heat and the burner ignited, press and release the red reset button. The
LED will go out and then flash 1, 2, 3, or 4 times before returning to the run mode. The CAD cell resistance
must be below 1600 ohms for proper operation.
– 1 flash
–
–
–
–
Less than 400 ohms
– 2 flashes
– 3 flashes
– 4 flashes
More than 400 and less than 800 ohms
More than 800 and less than 1600 ohms
More than 1600 and less than 5000 ohms
Burner Option – Flame Quality Monitor
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 typical 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 no. QS7100F.
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 of the
Electronic Blower Control Board (EBC)
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:
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.
Heating Blower ON delay – 75 seconds from a call
for heat.
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
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 2100-422
Page
12
FIGURE 7
ELECTRONIC BLOWER CONTROL
TRANSFORMER 24V
SECONDARY
CONNECTIONS
THERMOSTAT
CONNECTIONS
3 AMP FUSE
HEATING BLOWER
OFF DELAY
ADJUSTMENT
IN SECONDS.
OIL PRIMARY T-T
CONNECTIONS
LINE VOLTAGE
CONNECTION (HOT)
HUMIDIFIER
CONNECTION
UNUSED BLOWER MOTOR
SPEED CONNECTIONS
HEATING BLOWER
SPEED CONNECTION
LINE VOLTAGE
CONNECTION (COM, L2)
MIS-1819
ELECTRIC AIR
CLEANER CONNECTION
COOLING BLOWER
SPEED CONNECTION
Manual 2100-422
Page
13
TABLE 4
FURNACE DATA
Furnace Installed Standard
Field Installed Options
2
2
2
1
Nozzle
Size
Heating
1
Heating
1
Heating
Capacity
BTUH
Input
BTUH
Capacity Nozzle
BTUH
Input
BTUH
Capacity Nozzle
Input
Model Number
FLF085D36E
FLR085D36E
FLF110D48E
FLR110D48E
FLF110D60E
FLR110D60E
FLR140D60E
FC085D36E
FH085D36E
FH110D48E
FH110D60E
Size
.65
.65
.85
.85
.85
.85
1.10
.65
.65
.85
.85
BTUH
74,000
74,000
96,000
96,000
96,000
96,000
125,000
74,000
74,000
96,000
96,000
Size
.55
.55
NA
NA
NA
NA
NA
.55
.55
NA
NA
BTUH
77,000
77,000
NA
.75
.75
105,000
105,000
140,000
140,000
140,000
140,000
175,000
105,000
105,000
140,000
140,000
85,000
91,000
91,000
63,000
63,000
NA
85,000
1.00
1.00
1.00
1.00
1.25
.75
113,000
113,000
113,000
113,000
142,000
85,000
119,000
119,000
119,000
119,000
154,000
91,000
NA
NA
NA
NA
NA
NA
NA
NA
77,000
77,000
NA
63,000
63,000
NA
.75
85,000
91,000
1.00
1.00
113,000
113,000
119,000
119,000
NA
NA
j
70 degree hollow cone spray pattern, 100 PSIG pump pressure
k
Annual fuel utilization efficiency and heating capacity based upon U.S. Government standard
test using D.O.E. isolated combustion rating procedure.
1. PREPARATION STEPS
BURNER SETUP AND ADJUSTMENT
PROCEDURES
A. Calibrate and Check Operation of
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.
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.
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.
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.
IMPORTANT
D. Nozzle Inspection Annual replacement of
nozzle is recommended. The nozzle size
should match the design load . DO NOT
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.
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.
Check all oil lines and connections for leaks.
Connect pressure gauge by removing bleed fitting and
screwing in pressure gauge. See Figure 9.
Manual 2100-422
Page
14
K. Adjust Air Setting Examine the smoke - CO2
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 CO2 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”
It 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.
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).
G. Check Burner Pressure Bleed air from
pump and nozzle piping. Check pump pressure
and adjust to 100 psi, if necessary.
Lock the air adjustment and repeat draft,
CO2 and smoke measurements to make sure
the setting has not shifted.
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.
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%.
I. Check Smoke Readings After burner has
been operating 5 or 10 minutes, make 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
If this cannot be reached, check the following:
1. Air leaks into the combustion chamber or
heat exchanger can dilute the combustion
gases and prevent normal CO2 readings.
Such leaks should be sealed with furnace
cement or other high-temperature sealant.
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.
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
properlysealed.
J. Develop Smoke - CO2 Curve Record
measurements of smoke and CO2 from the
flue. Then establish the smoke - CO2 curve by
taking 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 CO2
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.
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.
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.
It may be necessary to replace the
combustion head or try different settings.
Manual 2100-422
Page
15
4. FINAL CHECKS
SHORT FORM ADJUSTMENT
PROCEDURE
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.
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
ServiceManagers.
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.
Measure flue temperature by subtracting the
room air temperature from the thermometer
reading. Excessive stack loss is indicated of the
net stack temperature during steady operation
exceeds 600° F.
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.
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.
3. SMOKE TEST
Follow the instructions of the manufacturer of the
smoke tester and take a smoke sample. Adjust the
air to obtain a preliminary reading of about No. 3
spot. Then readjust the air to obtain the lowest
possible reading, but do not open the air
adjustment more than absolutely necessary to
obtain a trace or No. 0 spot.
4. CO2 TEST
Check CO2 levels. This level should be between
10% and 12%.
Manual 2100-422
Page
16
FIGURE 8
TYPICAL SMOKE – CO2 CHART WITH ADJUSTMENT RANGE
High
Air Settings
Low
8
6
4
2
0
CO2 Curve
from plotted
points
Plotted point
Normal
adjustment
range
Tolerance
to "knee"
"Best" air
setting
Plotted point
Plotted point
"Knee"
6
8
12
Percent CO in Flue Gas
10
14
2
Technician's
plotting area
8
6
4
2
0
12
Percent CO in Flue Gas
6
8
10
14
MIS-1827
2
Manual 2100-422
Page 17
FIGURE 9
PRESSURE GAUGE CONNECTION TO BLEED PORT
Remove Bleed
Port to attach
pressure guage.
Pressure Gauge
MIS-1660
Manual 2100-422
Page 18
TABLE 5
CORRELATION OF PERCENT OF CO2, O2
AND RESERVE AIR
Carbon
Dioxide
Reserve Air
(Approx.)
Oxygen
15.4
15.0
14.5
0.0
0.6
1.2
0.0
3.0
6.0
14.0
13.5
13.0
2.0
2.6
3.3
10.0
15.0
20.0
12.5
12.0
11.5
4.0
4.6
5.3
25.0
30.0
35.0
11.0
10.5
10.0
6.0
6.7
7.4
40.0
45.0
50.0
TABLE 6
NO. 2 FUEL OIL EFFICIENCY CHART
(NET STACK TEMP. DEGREES F)
% O2 200
250
88.4
88.2
87.9
87.7
87.3
87.0
86.5
300
87.3
87.0
86.7
86.4
86.0
85.5
85.0
350
86.2
85.9
85.5
400
450
500
82.9
82.4
550
81.7
81.2
80.7
80.0
79.3
78.5
77.5
600
650
700
78.4
77.7
77.0
76.2
75.3
74.2
73.0
750
77.3
76.6
75.8
74.9
73.9
72.8
71.5
800 % O2
1
2
3
4
5
6
7
89.6
89.4
89.2
88.9
88.7
88.4
88.0
85.1 84.0
80.6
79.5
76.2
75.4
74.6
73.6
72.6
71.4
70.0
14.7
14.0
13.2
12.5
11.7
11.0
10.3
84.7
84.3
83.6
80.1 78.9
83.1 81.9
79.4
78.7
77.9
77.0
76.0
78.2
77.5
76.6
75.6
74.5
85.1 83.8
84.6 83.3
84.1 82.7
83.5 82.0
82.6
82.0
81.3
80.5
81.3
80.6
79.9
79.0
TABLE 7
RECOMMENDED START-UP SETTINGS
Factory Installed
Field Installed Option
Air
Air
Air
Air
Air
Air
Furnace
Model No.
Burner Style
Part No.
1
Band Shutter
1
Band Shutter
1
Band Shutter
Nozzle Setting Setting Nozzle Setting Setting Nozzle Setting Setting
FH085D36E AFG/9020-026
FH110D48E AFG/9020-027
FH110D60E AFG/9020-027
FLF085D36E AFG/9020-026
.75
1.00
1.00
.75
0
2
2
0
6
.65
.85
.85
.65
0
0
0
0
5
8
8
5
.55
NA
NA
.55
0
NA
NA
0
5
NA
NA
5
10
10
6
FLF110D48E
AFG/9020-027
FLF110D60E
1.00
.75
2
0
2
10
6
.85
.65
.85
0
0
0
8
5
8
NA
.55
NA
NA
0
NA
5
FLR085D36E AFG/9020-031
FLR110D48E
AFG/9020-032
FLR110D60E
1.00
10
NA
NA
FLR140D60E AFG/9020-033
FC085D36E AFG/9020-026
1.25
.75
0
0
8
6
1.10
.65
0
0
6
5
NA
.55
NA
0
NA
5
j
70 degree hollow cone spray pattern, 100 PSIG pump pressure
Manual 2100-422
Page 19
SPACINGOFELECTRODES
COMBUSTION AIR REQUIREMENTS
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 Figure 10.
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.
GUNASSEMBLYADJUSTMENT
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.
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.
REMOVINGGUNASSEMBLY
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 10
ELECTRODE ADJUSTMENTS
1-1/8
5/32 GAP
5/16
1/16
NOZZLE
MIS-160
Manual 2100-422
Page 20
FIGURE 11
COMBINATION AIR BOOT ASSEMBLY
COMBUSTION
AIR BOOT
ASSEMBLY
USE THIS
KNOCKOUT
FOR OIL LINE
INTAKE
AIR
TUBE
BURNER
ASSEMBLY
REMOVE PUMP TO
ASSEMBLE INNER
AIR BOOT
REMOVE KNOCKOUT
IN LEFT SIDE
INSERT OUTER AIR
BOOT AND SECURE
FLANGE TO UNIT
MIS-1833
MAKE ALL SETTINGS
ACCORDING TO MANUAL
FOR AIR BOOT.
Manual 2100-422
Page 21
APPLIANCES LOCATED IN CONFINED
SPACES
TABLE 8
SQUARE FEET REQUIRED TO
QUALIFY AS UNCONFINED SPACE
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.
Unconfined Space
Total
Minimum Area In
BTUH
Square Feet
Input
8' Ceiling Height
60,000
80,000
375
500
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.
85,000
105,000
531
656
115,000
120,000
719
750
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.
140,000
145,000
875
906
160,000
200,000
1000
1250
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 20,
“Combustion Air Requirements”.
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.
FIGURE 12
APPLIANCES LOCATED
IN CONFINED SPACES
ALL AIR FROM INSIDE THE BUILDING
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.
MIS-1336
Manual 2100-422
Page
22
ALLVENTILATIONAIRFROMOUTDOORS
TABLE 9
MINIMUM VENTILATION OPENINGS
A. The confined space shall be provided with two
permanent openings, one in or near the top of the
enclosure and one in or near the bottom. The
openings shall communicate directly, or by means
of ducts with outdoors or to such spaces (crawl or
attic) that freely communicate with outdoors. (See
Figures 13, 14, & 15.)
Recommended
Opening
(2 Required)
Min. Ventilation
Opening
Model
Square Inch
Size
Sq. In.
FH085D36E
FH110D48E
FH110D60E
FLF085D36E
FLR085D36E
240
280
280
290
290
8 x 16
9 x 18
9 x 18
8 x 19
8 x 19
128
162
162
152
152
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.
FLF110D48E
FLF110D60E
340
340
9 x 19
9 x 19
171
171
FLR110D48E
FLR110D60E
FLR140D60E
FC085D36E
360
240
9.5 x 19
8 x 16
180
128
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.
MIS-1337
Manual 2100-422
Page
23
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.
MIS-1338
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.
MIS-1339
Manual 2100-422
Page 24
A barometric damper is supplied with the furnace and
must be installed in the flue pipe observing the
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.
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
HORIZONTALVENTING
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
ventingsystem.
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.
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.
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.
VERTICALVENTING
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.
Manual 2100-422
Page
25
TABLE 10
TEMPERATURE RISE RANGES, LIMIT CONTROL SETTINGS,
AND HEATING BLOWER SPEEDS
Maximum
1
Nozzle
Outlet Air
Temp.
Heating Blower
Speed
Model
Rise Ranges
.55
.65
.75
70 - 100
70 - 100
60 - 90
200
200
200
Low
Low
Med
FH085D36E
.85
1.00
70 - 100
60 - 90
200
200
Low
Med Low
FH110D48E
FH110D60E
.85
1.00
60 - 90
60 - 90
200
200
Low
Med Low
.55
.65
.75
60 - 90
60 - 90
60 - 90
200
200
200
Low
Low
Med
FLF085D36E
.85
1.00
60 - 90
60 - 90
200
200
Med Low
Med High
FLF110D48E
FLF110D60E
.85
1.00
60 - 90
60 - 90
200
200
Med Low
Med High
.55
.65
.75
60 - 90
60 - 90
60 - 90
200
200
200
Low
Low
Med
FLR085D36E
.85
1.00
60 - 90
60 - 90
200
200
Med Low
Med High
FLR110D48E
FLR110D60E
FLR140D60E
.85
1.00
60 - 90
60 - 90
200
200
Med Low
Med High
1.10
1.25
60 - 90
60 - 90
200
200
Med Low
Med High
.55
.65
.75
70 - 100
70 - 100
60 - 90
200
200
200
Low
Low
Med
FC085D36E
j
70 degree hollow cone spray pattern, 100 PSIG pump pressure
Manual 2100-422
Page 26
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.
TABLE 11
FILTER SIZES FOR OIL FURNACES
Model
Size
FH085D36E
Hi-Boy
(1)
(1)
(1)
16 x 25 x 1
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.
FH110D48E
Hi-Boy
16 x 25 x 1
20 x 25 x 1
FH110D60E
Hi-Boy
FLF085D36E
FLR085D36E (1)
Lo-Boys
16 x 20 x 1
20 x 20 x 1
FLF110D48E
FLR110D48E
FLF110D60E (1)
FLR110D60E
Lo-Boys
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.
FLR140D60E
(1)
20 x 25 x 1
16 x 20 x 1
Lo-Boy
FC085D36E
(2)
Counterflow
See Table 11 for filter sizes and quantities.
FIGURE 17
FIGURE 16
TYPICAL INSTALLATION OF FR25
FILTER KIT
TYPICAL INSTALLATION OF FR26 AND
FR27 FILTER RACKS
Optional
Filter
Box
"FC"
Unit
19 1/4"
16"
70 5/16"
Filter
Frame
(2) screws
Filter
Filter
Door
MIS-1839 A
MIS-1841
Manual 2100-422
Page 27
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 x1
FLF/FLR110 20 x 20 x1
FLR140
20 x 25 x 1
STEP 3:
SLIDE FILTER OUT
TOWARDS BLOWER
DOOR
STEP 2:
STEP 1:
REMOVE BLOWER DOOR
BY PULLING OUT ON
SWELL LATCHES AND
TILTING OUTWARDS
UNFASTEN SWELL
LATCHES BY PULLING
HANDLES OUTWARD
MIS-1835
Manual 2100-422
Page 28
MAINTENANCE
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.
LUBRICATION
No lubrication is required for either the burner or the
blower motor. Both are permanently lubricated.
INSPECT AIR FILTER
C. Power Failure – Turn off power supply
while burner is on. When burner goes out,
restore power and burner will restart.
Replace filters before each heating season begins. It is
recommended that filters also be replaced at least twice
during the heating season.
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 on
page 28.
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:
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. 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.
1. Make sure there is oil in tank and valve is open.
2. Make sure thermostat is set above room
temperature.
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. 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.
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.
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. 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.
5. Press thermal protector button of burner motor.
6. Make sure air filters are in place and are clean.
7. 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.
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
Manual 2100-422
Page
29
COMBINATION COMBUSTION
CHAMBER/BURNER MOUNTING
SYSTEM
WARNING
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.
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
REMOVAL OF BURNER ONLY
DANGER
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
!
STEP 2:
LOOSEN (3) BOLTS
ENOUGH TO ROTATE
BURNER ASSEMBLY.
STEP 3:
ROTATE BURNER
COUNTER-CLOCKWISE
STEP 4:
STEP 1:
PULL BURNER STRAIGHT
DISCONNECT "T-T" WIRES,
POWER CONNECTIONS, AIR
BOOT (OPTIONAL) AND OIL
LINES TO BURNER.
OUT TO PREVENT DAMAGE
TO CHAMBER DURING
REMOVAL.
MIS-1834
Manual 2100-422
Page 30
TO REMOVE THE ENTIRE COMBUSTION
CHAMBER MOUNTING SYSTEM
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.)
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
REMOVAL OF ENTIRE COMBUSTION CHAMBER MOUNTING SYSTEM
DANGER
!
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
STEP 3:
REMOVE (2) NUTS
IN THE TOP LEFT
AND RIGHT CORNERS
OF BURNER PLATE.
CHAMBER
BURNER
PLATE
STEP 2:
REMOVE (6) BOLTS
AROUND PERIMETER
OF BURNER PLATE
STEP 4:
PULL BURNER ASSEMBLY
STRAIGHT OUT TO PREVENT
DAMAGE TO CHAMBER
DURING REMOVAL.
STEP 1:
DISCONNECT "T-T" WIRES,
POWER CONNECTIONS, AIR
BOOT (OPTIONAL) AND OIL
LINES TO BURNER.
MIS-1837
Manual 2100-422
Page 31
PUMPSQUEALSORCHATTERS
COMMON CAUSES OF TROUBLE
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.
CAUTION
To avoid accidents, always open main switch
(OFF position) when servicing the burner.
INSUFFICIENTHEAT
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.
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.
Check and make sure the heat anticipator on the
thermostat is set correctly.
CARE OF FINISH
If burner runs but there is no flame the fuel pump may
be air bound. Follow instructions for bleeding fuel
pump.
This furnace cabinet is made with a very durable and
corrosion resistant finish. With normal cleaning it will
last for many years.
Check and make sure the solenoid valve on the oil
pump is being energized and opening.
BURNER STARTS OR STOPS TOO OFTEN
WARNING
Check heat anticipator setting on thermostat.
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.
NOZZLEPRODUCESASTRINGYFLAME
Worn tangential grooves in nozzle. Replace nozzle.
BASEMENTTANKHUM
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.
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.
HEAVYFIREORPULSATINGFLAME.
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.
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.
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.
Manual 2100-422
Page
32
BLOWER SYSTEM RESISTANCE CHARTS
CHART 1
CHART 4
FH085D36E DATA
FLF/FLR085D36E DATA
Blower Speed
Low
Blower Static
Blower Speed
Blower Static
.07
.15
.20
.13
.24
.30
.19
.33
.40
.25
.41
.50
Low
Medium
High
.10
.16
.20
.15
.24
.30
.23
.34
.40
.30
.43
.50
Medium
High
CHART 5
FLF/FLR110D48E DATA
CHART 2
FH110D48E DATA
Blower Speed
Low
Blower Static
Blower Speed
Blower Static
Low
.03
.09
.16
.20
.08
.16
.25
.30
.13
.23
.34
.40
.18
.32
.44
.50
.05
.09
.15
.20
.09
.16
.24
.30
.15
.23
.34
.40
.20
.31
.42
.50
Medium Low
Medium High
High
Medium Low
Medium High
High
CHART 3
FH110D60E DATA
CHART 6
FLF/FLR110D60E DATA
Blower Speed
Low
Blower Static
Blower Speed
Blower Static
.06
.10
.14
.20
.12
.17
.21
.30
.17
.23
.31
.40
.21
.30
.38
.50
Low
.08
.10
.13
.20
.12
.16
.21
.30
.17
.22
.29
.40
.21
.28
.36
.50
Medium Low
Medium High
High
Medium Low
Medium High
High
Manual 2100-422
Page 33
CHART 8
CHART 7
FC085D36E DATA
FLR140D60E DATA
Blower Speed
Blower Static
Blower Speed
Blower Static
Low
Low
Medium
High
.05
.08
.11
.20
.14
.17
.20
.30
.17
.22
.27
.40
.24
.30
.35
.50
.08
.16
.20
.14
.24
.30
.20
.36
.40
.26
.42
.50
Medium Low
Medium High
High
Manual 2100-422
Page
34
FH SERIES
WIRING DIAGRAM
UNIT
NOTES
PURPLE
PURPLE
PRIMARY
IF PRIMARY LIMIT WIRES
ARE TO BE REPLACED,
USE WIRE WITH INSUL.
TEMP. RATING OF 200°C.
LIMIT
BACKUP
LIMIT
1
CONTROL
BURNER ASS'Y
HEATING SPEED
CONNECTION POINT.
2
3
L1
L2
T T
COOLING SPEED
CONNECTION POINT.
VALVE
OIL VALVE
ONLY ONE HEATING
AND COOLING SPEED
CAN BE CONNECTED.
ALL OTHER TAPS
BURNER
MOTOR
BURNER
MOTOR
4
5
CONNECT TO "SPARE"
TERMINALS.
IGNITOR IGNITOR
CAD CELL
DASHED LINES
REPRESENT FIELD WIRING.
CAD CELL
DANGER
1
!
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
BLACK
WHITE
GREEN
HOT
NEUTRAL
GROUND
PLUG
#1
PLUG #2
1 2 3 4 5 6 7
8
9
1 2
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".
BLACK
BLACK
GREEN
DOOR
SWITCH
WHITE
5
GREEN
C
Rc
Y
G
W Rh
Y
BLUE
R
W
G
Y
C
COND.
150
180
210
240
THERMOSTAT
UNIT
24V
BLOWER CONTROL
3
T
T
T87F/Q539A1220
OR EQUIVELANT
24V.
CONN.
TRANSFORMER
120V COM
OPTIONAL AIR COND. SETTINGS
NOM.
L1
4
COOLING BLOWER CFM @
UNIT
A/C
TONS
2
2 1/2
3
2 1/2
3
3 1/2
4
SPEED (COLOR)
.50 WC
LOW (RED)
MED (BLUE)
730
900
FH085D36E
HIGH (BLACK)
LOW (RED)
MED-LOW (ORANGE)
MED-HIGH (BLUE)
HIGH (BLACK)
1160
1020
1280
1495
1640
1300
1460
1660
1970
BLACK
WHITE
2
WHITE
FH110D48E
FH110D60E
SEE CHART FOR
HEATING AND COOLING
WIRE COLORS
WHITE
3
LOW (RED)
PLUG #3
3 1/2
4
5
MED-LOW (ORANGE)
MID-HIGH (BLUE)
HIGH (BLACK)
1 2 3 4 5
BLOWER
CAPACITOR
FACTORY SETTINGS
INPUT
RATE
GPH
0.55
0.65
0.75
0.85
1
TEMP.
RISE
HEATING BLOWER COOLING BLOWER
SPEED (COLOR)
LOW
VOLTAGE
UNIT
SPEED (COLOR)
HIGH (BLACK)
RANGE
70°-100°
70°-100°
60°-90°
70°-100°
60°-90°
60°-90°
60°-90°
LOW (RED)
LOW (RED)
MED (BLUE)
FH085D36E
HIGH
VOLTAGE
LOW (RED)
MED-LOW (ORANGE)
LOW (RED)
FH110D48E
FH110D60E
0.85
1
MED-LOW (ORANGE)
FIELD
WIRING
BLOWER CAPACITOR RATING
UNIT MOTOR CAPACITOR
FH085D36E
FH110D48E
FH110D60E
1/3
1/2
3/4
5/370
7.5/370
15/370
4047-118 B
BLOWER ASSEMBLY
Manual 2100-422
Page
35
FLF/R SERIES
WIRING DIAGRAM
FACTORY SETTINGS
PRIMARY LIMIT
BACKUP LIMIT
HTG. BLWR SPD. TEMP. COLING BLWR.
UNIT
GPH INPUT
1
(COLOR)
LOW (RED)
LOW (RED)
MED (BLUE)
RISE
SPEED
0.55
0.65
0.75
0.85
1
60°-90° HIGH (BLACK)
60°-90° HIGH (BLACK)
60°-90° HIGH (BLACK)
FLF/R085D36E
BLACK
BLACK
BLACK
BLACK
FLF/R110D48E
FLF/R110D60E
MED. HIGH (BLUE)60°-90° HIGH (BLACK)
MED. HIGH (BLUE)60°-90° HIGH (BLACK)
MED. HIGH (BLUE)60°-90° HIGH (BLACK)
MED. HIGH (BLUE)60°-90° HIGH (BLACK)
1.1
1.25
FLR140D60E
PURPLE
PURPLE
5
BURNER ASS'Y
1
2
L1
L2
T T
THERMOSTAT
VALVE
OIL VALVE
C
Y
Rc
Y
G
W Rh
T87F/Q539A1220
OR EQUIVELANT
BURNER
MOTOR
BURNER
MOTOR
R
W
G
Y
C
COND.
150
COOLING BLOWER SPEEDS
180
210
240
UNIT
IGNITOR
IGNITOR
NOM. A/C
CFM@
.50" WC
775
BLOWER CONTROL
3
24V.
T
T
UNIT
SPEED (COLOR)
(TONS)
CONN.
2
2.5
3
2.5
3
3.5
4
3
LOW (RED)
MED (BLUE)
HIGH (BLACK)
CAD CELL
CAD CELL
FLF/R085D36E
FLF/R110D48E
1070
1275
1065
1235
1415
1525
1190
1400
1640
2250
L1
4
LOW (RED)
MED LOW (ORANGE)
MED HIGH (BLUE)
HIGH (BLACK)
2
LOW (RED)
FLF/R110D60E
FLR140D60E
3.5
4
5
MED LOW (ORANGE)
MED HIGH (BLUE)
HIGH (BLACK)
BLACK
BLACK
NOTES
IF PRIMARY LIMIT WIRES
ARE TO BE REPLACED,
USE WIRE WITH INSUL.
TEMP. RATING OF 200°C.
BLOWER CAPACITOR
BLOWER CAPACITOR RATING
1
BROWN
UNIT
MOTOR CAPACITOR
FLF/R085D36E
FLF/R110D48E
FLF/R110D60E
FLR140D60E
1/3
1/2
5/370
7.5/370
HEATING SPEED
2
3
CONNECTION POINT.
BROWN
COOLING SPEED
CONNECTION POINT.
3/4
15/370
COM 120V
1
2
3
4
ONLY ONE HEATING
AND COOLING SPEED
CAN BE CONNECTED.
ALL OTHER TAPS
CONNECT TO "SPARE"
TERMINALS.
BLACK
TRANSFORMER
24V
BLUE
4
5
DANGER
!
ORANGE
WHITE
GREEN
BLACK
NEUTRAL
GROUND
HOT
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
RED
DASHED LINES
REPRESENT FIELD WIRING.
5
SEE CHART FOR
"HEAT" AND "COOL"
WIRE COLORS.
WHITE
BLOWER ASSEMBLY
4047-119 C
CONTROL PANEL
FC SERIES
WIRING DIAGRAM
FACTORY SETTINGS
PRIMARY LIMIT
HTG. BLWR SPD. TEMP. COLING BLWR.
UNIT
GPH INPUT
1
(COLOR)
LOW (RED)
LOW (RED)
MED (BLUE)
RISE
SPEED
0.55
0.65
0.75
60°-90° HIGH (BLACK)
70°-100° HIGH (BLACK)
60°-90° HIGH (BLACK)
BLACK
BLACK
FC085D36E
PURPLE
PURPLE
5
BURNER ASS'Y
1
2
L1
L2
T T
THERMOSTAT
T87F/Q539A1220
VALVE
OIL VALVE
C
Y
Rc
Y
G
W Rh
OR EQUIVELANT
BURNER
MOTOR
BURNER
MOTOR
R
W
G
Y
C
COND.
150
180
210
240
UNIT
IGNITOR
IGNITOR
BLOWER CONTROL
3
24V.
T
T
CONN.
CAD CELL
CAD CELL
L1
BACKUP LIMIT
COOLING BLOWER SPEEDS
NOM. A/C
CFM@
.50" WC
775
1070
1230
UNIT
SPEED (COLOR)
(TONS)
4
2
2.5
3
LOW (RED)
MED (BLUE)
HIGH (BLACK)
2
FC085D36E
1
DOOR
SWITCH
BLACK
BLACK
2
3
4
BLACK
BLACK
NOTES
IF PRIMARY LIMIT WIRES
ARE TO BE REPLACED,
USE WIRE WITH INSUL.
TEMP. RATING OF 200°C.
BLOWER CAPACITOR
(5/370)
1
BROWN
HEATING SPEED
CONNECTION POINT.
2
3
DANGER
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
WHITE
!
COOLING SPEED
CONNECTION POINT.
BROWN
BLACK
BLUE
COM 120V
1
2
3
4
5
ONLY ONE HEATING
AND COOLING SPEED
CAN BE CONNECTED.
ALL OTHER TAPS
CONNECT TO "SPARE"
TERMINALS.
TRANSFORMER
24V
4
5
WHITE
GREEN
BLACK
NEUTRAL
GROUND
HOT
RED
DASHED LINES
REPRESENT FIELD WIRING.
SEE CHART FOR
"HEAT" AND "COOL"
WIRE COLORS.
WHITE
BLOWER ASSEMBLY (1/3 HP)
4047-120 B
CONTROL PANEL
|