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INSTALLATION INSTRUCTIONS
FLF075V42A
FLR100V60A
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.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE
VICINITY OF THIS OR ANY OTHER APPLIANCE.
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.
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.
OIL FURNACE
MODELS
FLR075V42A
FLR130V60A
WARNING
FOR YOUR SAFETY
IMPORTANT NOTICE
WARNING
CARBON MONOXIDE POISONING HAZARD
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
FLR100V48A
Manual:
2100-579A
Supersedes:
2100-579
File:
VOL. I, TAB 3
Date:
04-24-13
Manual
2100-579A
Page
1 of 41
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Table of Contents
Troubleshooting
Related Manuals for Bard FLF075V42A
Summary of Contents for Bard FLF075V42A
- Page 1 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.
-
Page 2: Table Of Contents
CONTENTS Getting Other Information and Publications ..3 Filters Lo-Boy Models – Filter Locations ......36 Installation and Operating Instructions Equipment Selection ..........4 Maintenance Locating the Furnace ..........4 Lubrication ............37 Installing the Furnace ..........6 Inspect Air Filter ............37 Duct Work ...............6 Final Inspection and Test ........37 Installing a Cooling Unit ..........6 Service Hints ............37 Wiring... -
Page 3: Getting Other Information And Publications
GETTING OTHER INFORMATION and PUBLICATIONS FOR MORE INFORMATION, CONTACT THESE These publications can help you install the furnace. You PUBLISHERS: can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard. ACCA Air Conditioning Contractors of America 1712 New Hampshire Ave. -
Page 4: Installation And Operating Instructions
Floor Front Back Sides Duct Pipe Front Back Sides Sides FLF075V42A 18 * FLR075V42A 18 * FLR100V48A 18 * FLR100V60A 18 * FLR130V60A 18 * For the first three (3) feet from plenum. After three (3) feet, no clearance required. -
Page 5: Table 2 Dimensions Flf/R Models
Manual 2100-579A Page 5 of 41... -
Page 6: Installing The Furnace
The correct size of unit needed may be substantially Bard supplied coils, when used with Bard supplied coil smaller than the unit being replaced due to home cabinets, are automatically positioned. -
Page 7: Wiring
TABLE 3 ELECTRICAL DATA Max. Time Blower Motor Burner Motor Minimum Delay Fuse Total Model Volts-Hz-PH Circuit or HACR Amps Ampacity Circuit Breaker FLF075V42A 115-60-1 10.3 FLR075V42A 115-60-1 10.3 FLR100V48A 115-60-1 10.3 12.5 FLR100V60A 115-60-1 15.2 13.5 18.6 FLR130V60A 115-60-1 14.5... -
Page 8: Figure 2 Flf Models Dimensions
FIGURE 2 TYPICAL UNIT SETUP FLF UNIT SHOWN TYPICAL UNIT WARNING ALL WIRING MUST SETUP CONFORM TO THE NATIONAL ELECTRIC (FLF UNIT SHOWN) CODE AND ALL LOCAL CODES. Left side high voltage (unit power) entrance Inspection door Left side low voltage (thermostat) Right side entrance... -
Page 9: Figure 3 Typical Flue Install. Require
FIGURE 3 TYPICAL FLUE INSTALLATION REQUIREMENTS FRONT FLUE LO-BOY MODEL SHOWN TYPICAL FLUE INSTALLATION REQUIREMENTS (REPRESENTS ALL MODELS) 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. -
Page 10: Oil Line Piping
OIL LINE PIPING BECKETT NX OIL BURNER First determine whether the pipe system is to be This furnace is equipped with a high static Beckett a single line system or a two line system. All NX oil burner which employs the latest time tested connections must be absolutely air tight or you will controls of the highest quality. -
Page 11: Beckett "Cleancut" Oil Pump
BECKETT SOLID STATE IGNITER These controls were selected for their proven high quality, dependability, and serviceability. With proper This igniter differs from the traditional iron core maintenance this burner assembly will provide many transformer in that it produces a 14,000 volt spark years of reliable service. -
Page 12: Beckett Genisys 7505
BECKETT GENISYS BECKETT R7184 B 1032 MODEL 7505 MIS-2491 PRIMARY OPERATIONAL GUIDE BECKETT GENISYS 7505 If the control locks out three times without completing a successful call for heat, the control enters Sequence of Operation Restricted (Hard) Lockout, and must be reset by a technician. -
Page 13: Table Areset Button Operation
TABLE A RESET BUTTON OPERATION Pushing the Reset Button Will: If the burner is in the Button Click Button Hold Button Hold below state: (press < 1 second) (press > 1 second) (press 15+ seconds) Reset from Restricted Lockout Reset from Soft Lockout (Hard) Lockout Valve-on Delay, Go to Pump Prime... - Page 14 5. At burner start up, tap the reset button within PRIMING THE PUMP the first 10 seconds of the ignition cycle. This WARNING 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.
- Page 15 RESETTING FROM RESTRICTED LOCKOUT Electronic Blower Control Interface • If the control locks out three times without a This furnace is equipped with an Electronic Blower satisfied call for heat, or due to other significant Control Interface, which through its set points events such as a relay contact weld, the Lockout determines what the blower does with the 24 VAC becomes restricted in order to prevent repetitious...
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Page 16: Figure 5 Electronic Blower Control
FIGURE 5 ELECTRONIC BLOWER CONTROL HUMIDIFIER 120 VAC LINE VOLTAGE LINE VOLTAGE OUTPUT LINE VOLTAGE "NEUTRAL" TERMINAL (ENERGIZES "HOT" CONNECTION WITH OIL BURNER MOTOR) COOLING SPEED TAP SELECT SWITCHES TRANSFORMER HEATING SPEED 24V SECONDARY TAP SELECT CONNECTIONS SWITCHES 3 AMP FUSE HEATING BLOWER DELAY SELECT SWITCHES... -
Page 17: Table C Heating Tap Select Settings
TABLE C HEATING TAP SELECT SETTINGS BY MODEL Heating CFM Model GPH Input Tap Letter Switch #1 Switch #2 (0" - 0.5" E.S.P.) 1035 FLF075V42A 0.65 FLR075V42A 1280 1225 FLR100V48A 0.85 1060 1060 1280 1225 FLR100V60A 0.85 1060 1060 1860... -
Page 18: Table Eadjustment Tap Selects
TABLE E ADJUSTMENT TAP SELECTS Model Tap Letter Switch #1 Switch #2 Function No Change + 10% Heating Airflow -10% Heating Airflow No Change TABLE F HEATING DELAY PROFILE TAPS Pre-Run Switch Switch Pre-Run Model Delay Delay Time Delay Delay % Letter % CFM Seconds... -
Page 19: Troubleshooting Ge Ecm2.3
Manual 2100-579A Page 19 of 41... -
Page 20: Troubleshooting Ge Ecm 5.0
TROUBLESHOOTING GE ECM 5.0 MOTORS ™ CAUTION: Symptom Cause/Procedure • Check for loose blower housing, panels, etc. • Noisy blower or cabinet Disconnect power from unit before removing or replacing • High static creating high blower speed? connectors, or servicing motor. To avoid electric shock from - Check for air whistling through seams in the motor’s capacitors, disconnect power and wait at least 5 ducts, cabinets or panels... -
Page 21: Figure 6 Control Disassembly
TROUBLESHOOTING GE ECM MOTORS CONT’D. ™ 7. Verify that the replacement control is correct for your application. Replacing ECM Control Module Refer to the manufacturer’s authorized replacement list. USING THE To replace the control module for the GE variable-speed indoor blower WRONG CONTROL WILL RESULT IN IMPROPER OR NO motor you need to take the following steps: BLOWER OPERATION. -
Page 22: Burner Setup And Adjustments
Number Type Type Size Type BTUH BTUH Pressure FLR075V42A Lo-Boy 0.50 60 DEG. SOLID 175 PSIG 91,000 77,000 FLF075V42A Lo-Boy 0.50 60 DEG. SOLID 175 PSIG 91,000 77,000 FLR100V48A Lo-Boy 0.75 60 DEG. SOLID 150 PSIG 119,000 101,000 FLR100V60A Lo-Boy 0.75... - Page 23 unburned fuel, indicating very poor combustion 1. PREPARATION STEPS (and likely high emissions of carbon monoxide A. Calibrate and Check Operation of and unburned hydrocarbons). This condition Measuring Equipment Follow can sometimes be caused by too much air, or by manufacturer’s recommended procedures for other factors.
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Page 24: Short Form Adjustment Procedure
SHORT FORM ADJUSTMENT 1. Air leaks into the combustion chamber or PROCEDURE heat exchanger can dilute the combustion gases and prevent normal CO readings. Some burner service organizations may wish to Such leaks should be sealed with furnace perform a shorter procedure for the adjustment of oil cement or other high-temperature sealant. -
Page 25: Figure 9 Typical Smoke-Co Characteristic
FIGURE 9 TYPICAL SMOKE – CO CHART WITH ADJUSTMENT RANGE Typical Smoke - CO chart with adjustment range. High Air Settings CO Curve from plotted points Plotted point Normal adjustment range Tolerance to "knee" "Best" air Plotted point setting Plotted point "Knee"... -
Page 26: Figure 10 Pressure Gauge Connection To Bleed Port
FIGURE 10 PRESSURE GAUGE CONNECTION TO BLEED PORT Remove Bleed Port to attach pressure guage. Pressure Gauge MIS-1660 Manual 2100-579A Page 26 of 41... -
Page 27: Table 5 Correlation Of % Of Co
Air Adjustment Pump Number Type Plate Setting Size Type Pressure FLR075V42A 0.50 60 DEG. SOLID 175 PSIG 2.50 FLF075V42A 0.50 60 DEG. SOLID 175 PSIG 2.50 FLR100V48A 0.75 60 DEG. SOLID 150 PSIG 3.25 FLR100V60A 0.75 60 DEG. SOLID 150 PSIG 3.25... -
Page 28: Removing Gun Assembly
COMBUSTION AIR REQUIREMENTS SPACING OF ELECTRODES The electrodes should be spaced 5/32" apart. They This furnace must be installed in a location where a should extend 1/16" beyond the end and 5/16" above the sufficient supply of combustion air is available for the center of the nozzle tip as shown in Figures 11A &... -
Page 29: Figure 12 Combustion Air Boot Assembly
FIGURE 12 COMBUSTION AIR BOOT ASSEMBLY Manual 2100-579A Page 29 of 41... -
Page 30: Unconfined Space
TABLE 8 APPLIANCES LOCATED IN CONFINED SPACES SQUARE FEET REQUIRED TO In unconfined spaces in buildings, infiltration may be QUALIFY AS UNCONFINED SPACE adequate to provide air for combustion, ventilation, and dilution of flue gases. However, in buildings of Unconfined Space unusually tight construction, additional air shall be Total Minimum Area in... -
Page 31: Table 9 Minimum Ventilation Openings
(See Size Sq. In. Inch Figures 14, 15 & 16.) FLF075V42A 8 x 19 B. When directly communicating with outdoors or by FLR075V42A 8 x 19 means of vertical ducts, each opening shall have... -
Page 32: Figure 15 All Air From Outdoors Through Ventilated Attic
FIGURE 15 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. -
Page 33: Louvers And Grilles
LOUVERS AND GRILLES SWG-5S for 140 models only. This vent can be purchased through your local distributor. Follow all In calculating free area for ventilation and combustion installation instructions packaged with the vented system. air requirements, consideration shall be given to the blocking effect of louvers, grilles, or screens protecting openings. -
Page 34: Table 10 Temperature Rise Ranges, Limit Control Settings, And Heating Blower Speeds
Number Type Ranges Size Type Temp. (F) Pressure FLR075V42A 0.50 60 DEG. SOLID 175 PSIG 60 - 90 FLF075V42A 0.50 60 DEG. SOLID 175 PSIG 60 - 90 FLR100V48A 0.75 60 DEG. SOLID 150 PSIG 60 - 90 FLR100V60A 0.75 60 DEG. -
Page 35: Table 11 Filter Sizes For Oil Furnaces
Model Size The upflow filter kit part numbers are FR23 for a 16x25x1 filter size and FR24 for a 20x25x1 filter size. FLF075V42A These filter kits come complete with the filter and all FLR075V42A (1) 16 x 20 x 2 necessary brackets for installing on the furnace. -
Page 36: Lo-Boy Models - Filter Locations
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. -
Page 37: Maintenance
MAINTENANCE LUBRICATION B. Ignition Failure – Test by closing oil supply while burner is off. Run through starting No lubrication is required for either the burner or the procedure. The primary control will attempt blower motor. Both are permanently lubricated. three trials for ignition. -
Page 38: Combination Combustion Chamber/Burner Mounting System
COMBINATION COMBUSTION WARNING CHAMBER/BURNER MOUNTING SYSTEM The furnace has been designed with a combustion chamber mounting system that enables service personnel The procedures described in Figures 19 & to remove the combustion chamber, its mounting 20 should be conducted only by a qualified system, and burner assembly as one unit for inspection service technician. -
Page 39: To Remove Burner Only
TO REMOVE BURNER ONLY TO REMOVE THE ENTIRE COMBUSTION CHAMBER MOUNTING SYSTEM Disconnect fuel line, power cord and wires from T, T on primary control. Loosen (3) 1/4 inch bolts Disconnect fuel line, power cord and wires from T, T securing burner mounting flange. -
Page 40: Common Causes Of Trouble
COMMON CAUSES OF TROUBLE PUMP SQUEALS OR CHATTERS This may be caused by air in pipes. Check all joints in CAUTION the oil supply pipe for leaks. Check strainer in pump; if dirty, clean. To avoid accidents, always open main switch INSUFFICIENT HEAT (OFF position) when servicing the burner. -
Page 41: Wiring Diagram
Manual 2100-579A Page 41 of 41...
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