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Airco BFL Installation, Operation & Maintenance Manual

Oil fired warm air furnaces lowboy model/ high capacity lowboy model
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BCL-S BFL
(Lowboy Model)
BCL
(High Capacity Lowboy Model)
Oil Fired Warm Air Furnaces
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 253 7900
www.ecrinternational.com
PN 28141 REV. K [10/30/2018]

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  • Page 1 BCL-S BFL (Lowboy Model) (High Capacity Lowboy Model) Oil Fired Warm Air Furnaces INSTALLATION, OPERATION & MAINTENANCE MANUAL Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com PN 28141 REV. K [10/30/2018]...

  • Page 2: Contents Dimensions

    Dimensions BFL - FRONT BREECH BCL-S - REAR BREECH BCL - 190/225 HIGH CAPACITY REAR BREECH Cabinet Plenum Openings Flue Shipping Furnace Filter Weight (Permanent) Width Length Height Supply Return Diameter Height Model (LB) D x E F x G BCL-S 51½...

  • Page 3: Table Of Contents

    Appendix B - Wiring Diagrams ....................21 Chimney Vent Direct Drive Furnace Wiring Diagram BCL-S & BFL 5-Ton Models With Fan and Limit Control ..21 Chimney Vent Belt Drive Furnace Wiring Diagram BCL High Capacity with Fan and Limit Control ..22 Chimney Vent Furnace Wiring Diagram BCL-S &...

  • Page 4: General

    3. Introduction • Models BCL (90, 100, 120, 130, 145) S Furnace installation shall be completed by qualified agency. BCL-S models are rear breech oil fired forced air lowboy furnaces with output capacity range of 90,000 to 141,000 WARNING Btu/hr.

  • Page 5: Locating The Unit - [See Table 1]

    • Locate furnace so flue connection to chimney is short, Clearance to Combustibles (Inches) Location direct and consists of as few elbows as possible. BCL-S and BFL BCL High Capacity • Centralize furnace location with respect to supply and return air ductwork. Central location minimizes trunk Bottom duct sizing.

  • Page 6: Combustion Air

    7. Combustion Air WARNING WARNING Asphyxiation hazard. Chimney vented versions of Asphyxiation hazard. Failure to provide adequate furnace must be connected to flue having sufficient combustion and ventilation air could result in death draft at all times. Failure to follow these instructions or serious injury.

  • Page 7: Barometric Damper Control

    10. Optional Side Wall Venting • Electronic fan timer board works in conjunction with Certain BCL-S and BFL furnace models are manufactured snap disc limit controls, performing a safety function, as sidewall vented units. Refer to Direct Venting Instructions, and breaks power to oil burner primary control, P/N 240006979 included with Vent Kit for details.

  • Page 8: 11B. Models With Mechanical Fan And Limit Control

    CONTROL ABOVE FACTORY SETTINGS. source, there is risk of damaging accessories. Model Factory Limit Control Setting • Thermostat wiring connections are shown in wiring BCL-S 230°F diagrams in Appendix B. Some micro-electronic 190°F thermostats require additional controls and wiring. Refer to thermostat manufacturer's instructions.

  • Page 9: Humidifier

    13. Humidifier NOTICE • Humidifier is optional accessory available through Set up sidewall vented models to deliver zero (0) most heating supplies outlets. smoke. • Follow humidifier manufacturer's installation instructions NOTICE • Protect furnace heat exchanger from water or water Before operating furnace check burner alignment droplets from humidifier.

  • Page 10: Circulating Air Blower

    Failure to follow these 21. Circulating Air Blower instructions could result in death or serious injury. • BCL-S and BFL furnace models may be equipped with either direct drive or belt drive blower systems. • BCL high capacity furnace models are equipped with Belt drive blower systems can be modified for speed and belt drive blower systems.

  • Page 11: Maintenance And Service

    Annual Service By Contractor WARNING NOTICE Electrical shock hazard. Turn OFF electrical power Combustion chamber (firepot) is fragile. Use care supply at service panel before opening blower when inspecting and cleaning this area access door. Failure to do so could result in death or serious injury.

  • Page 12: Operating Instructions

    WARNING Fire, burn, explosion, asphyxiation hazard. • Do not start burner when excess oil has accumulated, furnace is full of vapor, or combustion chamber is very hot. • Do not burn garbage or paper in furnace. • Do not leave paper or rags around furnace. Failure to follow these instructions could result in death or serious injury.

  • Page 13: Appendix A - Check Out And Adjustments

    APPENDIX A - CHECK OUT AND ADJUSTMENTS Check out and adjustments BCL and BFL furnaces may be used with following oil burners. Beckett AF, Beckett NX and Riello 40F oil burners are for applications using indoor air for combustion only. Sidewall venting applications utilizing outdoor air for combustion, use Beckett AFII oil burners only.

  • Page 14: Oil Burner Air Adjustment

    APPENDIX A - CHECK OUT AND ADJUSTMENTS Table A-2 Beckett AFII Oil Burner Set-Up Beckett AFII Series Oil Burners (For use with sidewall vented units with outdoor combustion air,) Burner Delavan Pump Furnace Model Flow Rate Head Model Nozzle Pressure BCL90SB2U2 AFII-85 0.70 / 60°A...

  • Page 15: Burner Electrodes

    APPENDIX A - CHECK OUT AND ADJUSTMENTS A.2 Burner Electrodes Check system temperature rise. Temperature rise is the difference between return air temperature measured at Adjustment of electrode tips with respect to each other, a point near return air inlet, and supply air temperature nozzle, burner head is very important to ensure smooth measured near furnace outlet.

  • Page 16: Special Instructions For Units Equipped With Riello Burners

    APPENDIX A - CHECK OUT AND ADJUSTMENTS Set heat anticipator adjustment in thermostat (if so Where oil shut-off valve from oil storage tank is located. equipped), by removing "R" or "W" wire to thermostat. Thermostat operation, and other related accessories. Read amperage draw between the two wires.

  • Page 17: Blower Setup Tables

    APPENDIX A - CHECK OUT AND ADJUSTMENTS PN 28141 REV. K [10/30/2018]...
  • Page 18 APPENDIX A - CHECK OUT AND ADJUSTMENTS PN 28141 REV. K [10/30/2018]...

  • Page 19: Airflow Characteristics Tables

    APPENDIX A - CHECK OUT AND ADJUSTMENTS PN 28141 REV. K [10/30/2018]...
  • Page 20 APPENDIX A - CHECK OUT AND ADJUSTMENTS PN 28141 REV. K [10/30/2018]...

  • Page 21: Appendix B - Wiring Diagrams

    APPENDIX B - WIRING DIAGRAMS Chimney Vent Direct Drive Furnace Wiring Diagram BCL-S & BFL 5-Ton Models With Fan and Limit Control PN 28141 REV. K [10/30/2018]...

  • Page 22: Chimney Vent Belt Drive Furnace Wiring Diagram Bcl High Capacity With Fan And Limit Control

    APPENDIX B - WIRING DIAGRAMS Chimney Vent Belt Drive Furnace Wiring Diagram BCL High Capacity with Fan and Limit Control PN 28141 REV. K [10/30/2018]...

  • Page 23: Chimney Vent Furnace Wiring Diagram Bcl-S & Bfl With Fan Timer Control

    APPENDIX B - WIRING DIAGRAMS Chimney Vent Furnace Wiring Diagram BCL-S & BFL with Fan Timer Control PN 28141 REV. K [10/30/2018]...

  • Page 24: Direct Vent Furnace Wiring Diagram Bcl-S & Bfl With Fan Timer Control

    APPENDIX B - WIRING DIAGRAMS Direct Vent Furnace Wiring Diagram BCL-S & BFL with Fan Timer Control PN 28141 REV. K [10/30/2018]...

  • Page 25: Appendix C - Sequence Of Operation And Troubleshooting

    APPENDIX C - SEQUENCE OF OPERATION AND TROUBLESHOOTING Table C-1: 1158-120 Electronic Fan Timer Board (EFT) Detailed Sequence Of Operati Mode Action System Response EFT closes the oil primary control T - T connections. Ignition system and the oil primary control start the furnace. Oil flows as long as the oil Thermostat calls for heat.

  • Page 26: Troubleshooting

    APPENDIX C - SEQUENCE OF OPERATION AND TROUBLESHOOTING C.1 Troubleshooting WARNING Electrical shock hazard. Only a trained, experienced service technician should perform troubleshooting procedure. Failure to do so could result in death or serious injury. C.2 Preliminary Steps: Consult Beckett or Riello instruction manuals provided with oil burner for specific information regarding oil burner primary control sequence of operation, diagnostics and troubleshooting.
  • Page 27 APPENDIX C - SEQUENCE OF OPERATION AND TROUBLESHOOTING WARNING Electrical shock hazard. Only a trained, experienced service technician should perform troubleshooting procedure. Failure to do so could result in death or serious injury. Table C2: System and General Troubleshooting Problem Possible Cause Remedy Check thermostat and adjust.
  • Page 28 APPENDIX C - SEQUENCE OF OPERATION AND TROUBLESHOOTING Table C-2: System and General Troubleshooting continued Problem Possible Cause Remedy If cad cell is dirty, clean it. Determine why cad cell is getting dirty. If cad Furnace starts, but cuts cell is poorly aimed, realign it. out requiring manually NOTE: Photocell should have resistance of 100 KΩ...
  • Page 29 APPENDIX C - SEQUENCE OF OPERATION AND TROUBLESHOOTING Table C-2: System and General Troubleshooting continued Problem Possible Cause Remedy Insufficient combustion air Adjust oil burner combustion air band and draft regulator to gain highest adjustment at oil burner, or practical CO2 or lowest practical O2 content in flue gases. improper draft pressure.

  • Page 30: Parts Listing

    PARTS LISTING Model BCL High Capacity Diagram PN 28141 REV. K [10/30/2018]...
  • Page 31 PARTS LISTING PARTS LISTING: BCL 170-2/190/200/225 HIGH CAPACITY MODELS Ref. No. Description Part No. Left Side Panel Heating Compartment 29040AD Right Side Panel Heating Compartment 29040AD Left Side Panel Blower Compartment 29048AD Right Side Panel Blower Compartment 29047AD Upper Rear Panel Blower Compartment 29062AD Blower Partition Panel 29052AD...
  • Page 32 PARTS LISTING PARTS LISTING: BCL 170-2/190/200/225 HIGH CAPACITY MODELS Ref. No. Description Part No. Blower Assembly, ¾ HP 8756B2 Blower Housing and Wheel, G12 2040008 Blower Motor, 3/4 HP Single Speed 28007 Motor Pulley, 3 1/2 X 5/8 Adjustable With Keyway 19779 Blower Pulley, 7 X 3/4 2240008...

  • Page 33: Model Bcl-S Diagram (Fan And Limit Control Shown)

    PARTS LISTING Model BCL-S Diagram (Fan and Limit Control Shown) PN 28141 REV. K [10/30/2018]...
  • Page 34 PARTS LISTING PARTS LISTING: CHIMNEY VENT MODELS BCL-(S2, SRF2) Ref. No. Description Part No. Left Side Panel Assembly 28423AD Right Side Panel Assembly 28422AD Upper Rear Panel 26048AD Blower Division Panel Assembly 550002146 Base Panel Assembly 28459 Inner Front Panel (for use with Fan Timer Control) 109009279 Blower Access Door 26586AD...
  • Page 35 PARTS LISTING PARTS LISTING: CHIMNEY VENT MODELS BCL-(S2, SRF2) conti. Ref. No. Description Part No. Draft Regulator 6” 12240 Side Panel Insulation Retainer (2 per unit) 26047 Beckett Oil Burner AF65XN (0.75, 0.85, 1.00 GPH) Wired for Fan Timer Control 240010428 Beckett Oil Burner AF65YB (1.10, 1.20 GPH) Wired for Fan Timer Control 240010429...
  • Page 36 PARTS LISTING Ref. No. Part No. PARTS LISTING: CHIMNEY VENT MODELS BCL-ST2 All parts are the same as listed on the previous pages for Model BCL-S2 except where noted below. Blower Division Panel Assembly 29107 Inner Front Panel (For use with Fan and Limit Control) 28425 Junction Box 21318...
  • Page 37 PARTS LISTING PARTS LISTING: DIRECT VENT MODELS BCL-SB2U2 Ref. No. Part No. Description All parts are the same as listed on the previous pages for Model BCL-S2 except where noted below. Heat Exchanger Assembly for Beckett AFII Burner 550001631 Replacement Combustion Chamber 27000B for Beckett AFII Burner 27000WP Pouch Gasket (Second gasket required for Direct Vent) 2080175...

  • Page 38: Model Bfl Diagram (Fan And Limit Control Shown)

    PARTS LISTING Model BFL Diagram (Fan and Limit Control Shown) PN 28141 REV. K [10/30/2018]...
  • Page 39 PARTS LISTING PARTS LISTING: CHIMNEY VENT MODELS BFL-(2,RF2) Ref. No. Part No. Description Left Side Panel Assembly 28423AD Right Side Panel Assembly 28422AD Upper Rear Panel 21421AD Blower Division Panel Assembly 28469 Base Panel Assembly 28459 Inner Front Panel ( for use with Fan Timer Control) 109009280 Blower Access Door 26586AD...
  • Page 40 PARTS LISTING PARTS LISTING: CHIMNEY VENT MODELS BFL-(2,RF2) conti. Ref. No. Part No. Description Draft Regulator 6” 12240 Side Panel Insulation Retainer (2 per unit) 26047 Beckett Oil Burner AF65XN (0.75, 0.85, 1.00 GPH) Wired for Fan Timer Control 240010428 Beckett Oil Burner AF65YB (1.10, 1.20 GPH) Wired for Fan Timer Control 240010429 Beckett Oil Burner NX70LFHS (1.10, 1.20 GPH) Wired for Fan Timer Control...
  • Page 41 PARTS LISTING PARTS LISTING: CHIMNEY VENT MODELS BFL-T2 Part No. Ref. No. Description All parts are the same as listed on the previous pages for Model BFL-2 except where noted below. Blower Division Panel Assembly 29114 Inner Front Panel (For use with Fan and Limit Control) 28428 Junction Box 21318...
  • Page 42 PARTS LISTING PARTS LISTING: DIRECT VENT MODELS BFL-B2U2 Part No. Ref. No. Description All parts are the same as listed on the previous pages for Model BFL-2 except where noted below. Heat Exchanger Assembly for Beckett AFII Burner 550001634 Replacement Combustion Chamber 27000B for Beckett AFII Burner 27000WP Pouch Gasket (Second gasket required for Direct Vent) 2080175...

  • Page 43: Beckett Burner Replacement Parts

    PARTS LISTING PARTS LISTING: BECKETT BURNER REPLACEMENT PARTS Part No. Description Burner Motor 1/7 HP 3450 RPM PSC for AF/NX Burners 1050008 Burner Motor 1/7 HP 3450 RPM PSC for AFII Burner 28907 Beckett Cleancut Oil Pump A2EA6520 29688 Solid State Igniter for AF/NX Burner 1050007 Solid State Igniter for AFII Burner 28558...

  • Page 44: Homeowner's Reference Table

    HOMEOWNER’S REFERENCE TABLE Model No. Serial No. Date Installed Contractor Contact Address Postal Code Telephone No. After Hours No. Fuel Supplier Fuel Oil Supplier Contact Telephone No. After Hours No. 2201 Dwyer Avenue, Utica, NY 13501 All specifications subject to change without notice. Tel.

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