OIL FURNACE INSTALLATION INSTRUCTIONS MODELS FC085V42A FH110V60A FLF110V60A FLR110V60A FH085V42A FLF085V42A FLR085V42A FLR140V60A FH110V48A FLF110V48A FLR110V48A 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.
CONTENTS Getting Other Information and Publications ........ 3 Installation and Operating Instructions Equipment Selection ............................................. 4 Locating the Furnace ............................................ 4 Installing the Furnace ........................................... 8 Duct Work ............................................................. 8 Installing a Cooling Unit ........................................ 8 Wiring ......................................................
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.
INSTALLATION and OPERATING INSTRUCTIONS EQUIPMENT SELECTION LOCATING THE FURNACE 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.
Manual Page 2100-540D 5 of 45 H D F G FILTER DOOR E LEFT SIDE VIEW FRESH AIR KNOCKOUT OPTIONAL OIL ENTRANCE OIL ENTRANCE OPTIONAL LOW VOLTAGE ENTRANCE OPTIONAL HIGH VOLTAGE ENTRANCE "FLF" FLUE KNOCKOUT TOP VIEW REAR FLUE ON "FLR" MODELS RETURN DUCT SUPPLY DUCT J FLF/FLR 085, 110 AND 140 SPECIFICATION SHEET 23 23 23 23 26 FLF110V48A FLF110V60A FLR110V48A FLR110V60A FLR140V60A FRONT VIEW A 23 23 "FLF" FLUE KNOCKOUT Plenum Openings 40.625 40.625 40.625 40.625 C 50.250 47.625 48.
Manual 2100-540D Page 6 of 45 16" LEFT SIDE VIEW RETURN OPENING (CUT OUT) 19 1/4" VESTIBULE DOOR FRESH AIR KNOCKOUT OIL ENTRANCE OPTIONAL OIL ENTRANCE OPTIONAL LOW VOLTAGE ENTRANCE OPTIONAL HIGH VOLTAGE ENTRANCE FLUE KNOCKOUT FLUE KNOCKOUT 19 7/8" TOP VIEW FRONT VIEW 23" 21 7/8" HIGH VOLTAGE ENTRANCE OPTIONAL OIL ENTRANCE LOW VOLTAGE ENTRANCE RIGHT SIDE VIEW RETURN OPENING (CUT OUT) MIS-1814 A FH085 AND FH110 SPECIFICATION SHEET REAR CLEANOUT DOOR FLUE KNOCKOUT 53" (FH085) 59" (FH
FIGURE 3 FC085 MODEL DIMENSIONS 22" COUNTERFLOW SPECIFICATION SHEET RETURN OPENING 20" 30 5/8" TOP VIEW 23" FLUE KNOCKOUT FLUE KNOCKOUT FLUE KNOCKOUT OPTIONAL HIGH VOLTAGE ENTRANCE 54 1/4" OPTIONAL LOW VOLTAGE ENTRANCE REAR CLEANOUT DOOR LOW VOLTAGE ENTRANCE OIL ENTRANCE HIGH VOLTAGE ENTRANCE OPTIONAL OIL ENTRANCE FRESH AIR KNOCKOUT FRONT VIEW OPTIONAL OIL ENTRANCE LEFT SIDE VIEW RIGHT SIDE VIEW SUPPLY OPENING 18 1/8" BOTTOM VIEW 19 1/8" MIS-1826 A Manual Page 2100-540D 7 of 45
INSTALLING THE FURNACE DUCT WORK INSTRUMENTS REQUIRED FOR PROPER SETUP OF 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. It is important that a set of instruments capable of the following requirements be used for the setup of this furnace to ensure proper and safe operation: 1. Oil pump pressure gauge that measures up to 150 PSI. 2.
WIRING FIELD WIRING FACTORY 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. 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.
FIGURE 4 TYPICAL UNIT SETUP FLF UNIT SHOWN WARNING ! TYPICAL UNIT SETUP (FLF UNIT SHOWN) 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.
FIGURE 5 TYPICAL FLUE INSTALLATION REQUIREMENTS FRONT FLUE LO-BOY MODEL SHOWN (REPRESENTS ALL MODELS) INSTALLER NOTE: Follow all appropriate standards for installing needed venting system. Thimble 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.
OIL LINE PIPING BECKETT AFG OR NX 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.
These controls were selected for their proven high quality, dependability, and serviceability. With proper maintenance this burner assembly will provide many years of reliable service. All units are shipped with the oil burner installed, and with high rate oil nozzle installed designed for use with No. 1 or No. 2 fuel oil. Inspect firepot refractory before firing to be sure it has not been jarred out of position in shipment. Burner air tube must not extend beyond inside surface of firepot.
BECKETT GENISYS MODEL 7505 MIS-2491 PRIMARY OPERATIONAL GUIDE BECKETT GENISYS 7505 Sequence of Operation If the control locks out three times without completing a successful call for heat, the control enters Restricted (Hard) Lockout, and must be reset by a technician. Hold the reset button for 15 seconds until the red light shuts off to reset from Restricted Lockout. 5. Ignition Carryover: Once flame is established, the igniter remains on for 10 additional seconds to ensure flame stability. 6.
TABLE A RESET BUTTON OPERATION Pus hing the Re s e t button will: If the burne r is in the be low s ta te : Button Click (pre s s < 1 s e cond) Button Hold (pre s s > 1 s e cond) Lockout Reset from Soft Lockout Valve- on Delay, Trial for Ignition, Ignition C arryover Go to Pump Prime (see Below) Run (igniter is shut off) Yellow LED flashes to indicate cad cell resistance. See "C ad C ell Resistance Indicator" for table of resistance values.
PRIMING THE PUMP WARNING Hot Gas Puff-Back & Heavy Smoke Hazard Failure to bleed the pump properly could result in unstable combustion, hot gas puffback and heavy smoke. • Do not allow oil to spray into a hot combustion chamber while bleeding air from the pump. • Install a gauge in the nozzle discharge port tubing or fully open the pump bleed valve to prevent oil spray from accumulating in the combustion chamber during the air bleed procedure.
RESETTING FROM RESTRICTED LOCKOUT • If the control locks out three times without a satisfied call for heat, or due to other significant events such as a relay contact weld, the Lockout becomes restricted in order to prevent repetitious resetting by the homeowner. Electronic Blower Control Interface This furnace is equipped with an Electronic Blower Control Interface, which through its set points determines what the blower does with the 24 VAC inputs from the home thermostat.
FIGURE 7 ELECTRONIC BLOWER CONTROL LINE VOLTAGE "HOT" LINE VOLTAGE "NEUTRAL" CONNECTION HUMIDIFIER 120 VAC LINE VOLTAGE OUTPUT TERMINAL (ENERGIZES WITH OIL BURNER MOTOR) COOLING SPEED TAP SELECT SWITCHES HEATING SPEED TAP SELECT SWITCHES HEATING BLOWER DELAY SELECT SWITCHES +/- ADJUSTMENT TAP SELECT SWITCHES TRANSFORMER 24V SECONDARY CONNECTIONS 3 AMP FUSE LIMIT LIGHT CFM BLINK LIGHT (100 CFM/BLINK) INPUT SIGNAL LIGHTS REMOVE FACTORY INSTALLED JUMPER WIRE FOR 2-STAGE AIR CONDITIONER OR HEAT PUMP
TABLE C HEATING TAP SELECT SETTINGS BY MODEL Mo del GP H Input F C 085V 42A Tap Letter Switch #1 Switch #2 H eating C FM (0" - 0.5" E.S.P.) A OFF OFF 1075 0.75 B ON OFF 1035 F LF 085V 42A FH085V42A 0.65 C OFF ON 930 FLR085V42A 0.55 D ON ON 790 A OFF OFF 1280 B ON OFF 1225 FH110V48A 1.00 FLF110V48A FLR110V48A FH110V60A 0.85 1.00 FLF110V60A FLR110V60A 0.85 1.25 FLR140V60A 1.
TABLE E ADJUSTMENT TAP SELECTS Mo del Tap Letter Switch #1 Switch #2 Functio n A OFF OFF No C hange B ON OFF + 10% Heati ng Ai rflow C OFF ON -10% Heati ng Ai rflow D ON ON No C hange ALL TABLE F HEATING DELAY PROFILE TAPS Mo del Tap Letter Switch #1 Switch #2 On D elay Seco nds On D elay % C FM P re-R un Time Seco nds P re-R un % C FM Off D elay Seco nds Off D elay % C FM A OFF OFF 30 0 60 50 300 82 B ON OFF 30 0 60 50 2 40 100 C OFF ON 45 0 120 50 3
Manual Page 2100-540D 21 of 45 H eat P ump 2-Stage H eat 2-Stage H eat P ump Single Stage P ump C o o ling, C o o ling, C o o ling P art Lo ad Full Lo ad 1 2 2 Adjustment Tap Profi les; Vari ed Half-Wave Si gnals Based Upon Setti ngs. D C Volts "-" Output i n D i rect C orrelati on to C FM. P in #8 D C Volts "+" Output i n D i rect C orrelati on to C FM. X X X X X X 1 Requi res "Y1" to "Y2" jumper wi re i nstalled on Integrated Blower Interface.
TROUBLESHOOTING GE ECM 2.3™ MOTORS CAUTION: Symptom Cause/Procedure Disconnect power from unit before removing or replacing connectors, or servicing motor. To avoid electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor. • Noisy blower or cabinet • Check for loose blower housing, panels, etc.
TROUBLESHOOTING GE ECM™ MOTORS CONT’D. Replacing ECM Control Module To replace the control module for the GE variable-speed indoor blower motor you need to take the following steps: 1. You MUST have the correct replacement module. The controls are factory programmed for specific operating modes. Even though they look alike, different modules may have completely different functionality. USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS. 2.
TABLE 4 FURNACE DATA Mo del N umber B urner Type Furnace Type H eating Input B TU H H eating Output B TU H 105,000 87,000 91,000 76,000 77,000 64,000 105,000 87,000 91,000 76,000 77,000 64,000 140,000 116,000 119,000 99,000 140,000 116,000 0.75 119,000 99,000 0.75 * 105,000 87,000 91,000 76,000 77,000 64,000 140,000 116,000 N o z z le Siz e Type P ump P ressure 0.75 * FC 085V42A A FG C ounterflow 0.65 70° Hollow 100 PSIG 0.55 0.75 * FH 085V42A A FG Hi -Boy 0.
1. PREPARATION STEPS A. Calibrate and Check Operation of Measuring Equipment Follow manufacturer’s recommended procedures for calibration and equipment check out. B. Prepare Heating Unit for Testing Drill two 1/4 inch holes in the flue between the heating plant and the barometric draft regulator. If space permits, the holes should be located in a straight section of the flue, at least two flue diameters from the elbow in the flue pipe and at least one diameter from the draft regulator.
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. 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.
FIGURE 11 TYPICAL SMOKE – CO2 CHART WITH ADJUSTMENT RANGE High Air Settings Low Bacharach Smoke Number 8 CO2 Curve from plotted points 6 Plotted point Normal adjustment range 4 Tolerance to "knee" "Best" air setting 2 Plotted point Plotted point "Knee" 0 6 8 12 10 Percent CO2 in Flue Gas Technician's plotting area 8 Bacharach Smoke Number 14 6 4 2 0 6 8 12 10 Percent CO2 in Flue Gas 14 MIS-1827 Manual Page 2100-540D 27 of 45
FIGURE 12 PRESSURE GAUGE CONNECTION TO BLEED PORT Remove Bleed Port to attach pressure guage.
TABLE 5 — CORRELATION OF PERCENT OF CO2, O2 AND RESERVE AIR C arbo n D io xide Oxyge n R eserve Air (Appro x.) 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 200 250 300 350 400 450 500 550 600 650 700 750 800 % O2 1 89.6 88.4 87.3 86.2 85.1 84.0 82.9 81.7 80.6 79.5 78.4 77.
SPACING OF ELECTRODES 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 Figures 13A & 13B. 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.
FIGURE 14 COMBUSTION AIR BOOT ASSEMBLY AFG BURNER COMBUSTION AIR BOOT ASSEMBLY INTAKE AIR TUBE USE THIS KNOCKOUT FOR OIL LINE AFG BURNER ASSEMBLY REMOVE PUMP TO ASSEMBLE INNER AIR BOOT REMOVE KNOCKOUT IN LEFT SIDE INSERT OUTER AIR BOOT AND SECURE FLANGE TO UNIT MAKE ALL SETTINGS ACCORDING TO MANUAL FOR AIR BOOT.
APPLIANCES LOCATED IN CONFINED SPACES In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation, and dilution of flue gases. However, in buildings of unusually tight construction, additional air shall be provided using the method described under “All Air From Outdoors” in Figure 16. An unconfined space (such as an open basement) must have a minimum volume of 50 cubic feet per 1,000 BTUH of total of all appliances in area.
TABLE 9 MINIMUM VENTILATION OPENINGS Mo del Min. Ventilatio n Opening Square Inch FH085V42A ALL VENTILATION AIR FROM OUTDOORS R eco mmended Opening (2 R equired) Siz e Sq. In. 240 8 x 16 128 FH110V48A 280 9 x 18 162 FH110V60A 280 9 x 18 162 F LF 085V 42A 290 8 x 19 152 FLR085V42A 290 8 x 19 152 FLF110V48A FLF110V60A 340 9 x 19 171 FLR110V48A FLR110V60A 340 9 x 19 171 FLR140V60A 360 9.5 x 19 180 F C 085V 42A 240 8 x 16 128 A.
FIGURE 17 APPLIANCES LOCATED IN CONFINED SPACES ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC NOTE: The inlet and outlet air openings shall each have a free area of not less than one square inch per 4,000 BTU per hour (35 square inches per gallon per hour) of the total input rating of all appliances in the enclosure.
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.
TABLE 10 TEMPERATURE RISE RANGES, LIMIT CONTROL SETTINGS, AND HEATING BLOWER SPEEDS Model Number Burner Type Noz z le Rise Ranges Siz e Type Pump Pressure 0.75 * F C 085V 42A F H 085V 42A A FG A FG 0.65 60 - 90 70° Hollow 100 PSIG 60 - 90 A 0.65 70° Hollow 100 PSIG 150 PSIG 150 PSIG C 0.75 * 60 - 90 A 0.65 70° Hollow 100 PSIG 150 PSIG 150 PSIG C 0.75 * 60 - 90 A 0.65 70° Hollow 100 PSIG A FG 100 PSIG 100 PSIG 0.85 C A 200 60 - 90 1.25 * C 60 - 90 70° Hollow 1.
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 The upflow filter kit part numbers are FR23 for a 16x25x1 filter size and FR24 for a 20x25x1 filter size.
LO-BOY MODELS – FILTER LOCATIONS Lo-boy models have the filter installed in the return air cabinet section of the furnace. It is accessible from the rear of the furnace by removing the blower/filter access door. The electrical switch should be turned “off” prior to removing the access door. Refer to Figure 21 below.
MAINTENANCE LUBRICATION No lubrication is required for either the burner or the blower motor. Both are permanently lubricated. INSPECT AIR FILTER Replace filters before each heating season begins. It is recommended that filters also be replaced at least twice during the heating season. Be sure the new filters are set securely in the filter rack so there can be minimal leakage around them.
COMBINATION COMBUSTION CHAMBER/BURNER MOUNTING SYSTEM The furnace has been designed with a combustion chamber mounting system that enables service personnel to remove the combustion chamber, its mounting system, and burner assembly as one unit for inspection and/or service on the bench. It has also been designed to remove the burner assembly independently from the mounting system to perform basic annual service and inspection.
TO REMOVE BURNER ONLY Disconnect fuel line, power cord and wires from T, T on primary control. Loosen (3) 1/4 inch bolts securing burner mounting flange. Twist burner counterclockwise and pull straight back away from the furnace. (See Figure 22.) TO REMOVE THE ENTIRE COMBUSTION CHAMBER MOUNTING SYSTEM Disconnect fuel line, power cord and wires from T, T on primary control. Remove (6) 5/16 inch bolts from around front plate.
COMMON CAUSES OF TROUBLE CAUTION To avoid accidents, always open main switch (OFF position) when servicing the burner. BURNER WILL NOT PRODUCE FLAME Check oil level gauge to see that there is sufficient oil in tank or tanks. Check the burner mounted relay control. Do not adjust this control. Check position of electrodes – incorrect position will cause slow or delayed ignition. Clean electrodes and nozzle. Check and clean strainer in pump. If oil line filter is used, check filter condition.
FH SERIES WIRING DIAGRAM UNIT IGNITER BACKUP LIMIT MOTOR L2 OIL VALVE VALVE CAD CELL CAD CELL 16 L2 (VLV) Red TW Red L1 - LIMIT Black L2 (MTR) TR 1 2 ! IF PRIMARY LIMIT WIRES ARE TO BE REPLACED, USE WIRE WITH INSUL. TEMP. RATING OF 200°C. REMOVE PURPLE JUMPER WIRE FOR 2 STAGE AIR CONDITIONER OR HEAT PUMP. 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.
BLACK CAD CELL BLACK 17 7 BURNER ASS'Y BLOWER ASSEMBLY 16 PIN BLOWER CONTROL PLUG DOOR SWITCH CAD CELL L2 (VLV) VALVE White L2 TW OIL VALVE Black Orange L1 - LIMIT L2 (MTR) 1 2 3 4 5 2 1 3 3 PIN PLUG TR BURNER MOTOR MOTOR L2 (IGN) IGNITER 4 BLOWER CONTROL BLACK 18 RED 5 PIN PLUG 3 3 2 1 6 5 4 9 8 7 16 PIN WIRE HARNESS Orange Purple 24 VAC C Purple CFM BLINK (GREEN LED 7) NEUTRALS LIMIT SWITCH (RED LED 6) 16 PIN BLOWER CONTROL PLUG C 16 ON 2 1 OFF 9 24V 5 T
Manual Page 2100-540D 45 of 45 BURNER ASS'Y 17 BLOWER ASSEMBLY BLACK BLACK 7 RED BACKUP LIMIT CAD CELL 16 PIN BLOWER CONTROL PLUG DOOR SWITCH CAD CELL L2 (VLV) VALVE White L2 TW OIL VALVE Black Orange L1 - LIMIT L2 (MTR) MOTOR 1 2 3 4 5 2 1 3 3 PIN PLUG TR BURNER MOTOR L2 (IGN) IGNITER Purple Orange 18 RED 5 PIN PLUG Black 3 3 2 1 6 5 4 9 8 7 16 PIN WIRE HARNESS BLACK White RED CFM BLINK (GREEN LED 7) COM 120V 15 9 24V 5 19 4 2 20 14 Black White Green BL
