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Airco BCL-190, Installation, Operation & Maintenance Manual

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Airco BCL-190 Installation, Operation & Maintenance Manual Download Page 3

3

PN 28141 REV. K [10/30/2018]

Check our website frequently for updates: www.ecrinternational.com

Information and specifications outlined in this manual in effect at the

time of printing of this manual. Manufacturer reserves the right to

discontinue, change specifications or system design at any time without 

notice and without incurring any obligation, whatsoever.

Contents

Dimensions ................................................................................................................................. 2

1. General .................................................................................................................................. 4

2. Safety Symbols ....................................................................................................................... 4

3. Introduction ............................................................................................................................ 4

4. Heat Loss ............................................................................................................................... 4

5. Locating the Unit - [See Table 1] ................................................................................................ 5

6. Furnace Used In Conjunction With Air Conditioning ....................................................................... 5

7. Combustion Air ........................................................................................................................ 6

8. Chimney Venting ..................................................................................................................... 6

9.  Barometric Damper Control ...................................................................................................... 7

10.  Optional Side Wall Venting ...................................................................................................... 7

11a.  Models with Electronic Fan Timer Control and Snap-Disc Limit Control (See Figure 3) ................... 7

11b.  Models with Mechanical Fan And Limit Control ......................................................................... 8

12.  Electrical Connections ............................................................................................................ 8

13.  Humidifier

 ............................................................................................................................ 9

14.  Piping Installation ................................................................................................................. 9

15.  Oil Filter .............................................................................................................................. 9

16.  Oil Burner Nozzles ................................................................................................................. 9

17.  Oil Burner Adjustment ........................................................................................................... 9

18.  Burner Electrodes.................................................................................................................. 9

19.  Burner Primary (Safety) Control .............................................................................................. 9

20.  Combustion Chamber ............................................................................................................ 9

21. Circulating Air Blower  ...........................................................................................................10

22.  Maintenance And Service ......................................................................................................11

23.  Operating Instructions ..........................................................................................................12

Appendix A - Check out and Adjustments ................................................................................ 13

A.1 Oil Burner Air Adjustment ...................................................................................................14

A.2 Burner Electrodes ..............................................................................................................15

A.3 Start Up ...........................................................................................................................15

A.4 Special Instructions For Units Equipped With Riello Burners .....................................................16

A.5 Final Check Out ................................................................................................................16

Blower Setup Tables ................................................................................................................17

Airflow Characteristics Tables

 ....................................................................................................19

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 & BFL with Fan Timer Control ....................................23

Direct Vent Furnace Wiring Diagram BCL-S & BFL with Fan Timer Control .......................................24

Appendix C - Sequence of Operation and Troubleshooting ...................................................... 25

C.1 Troubleshooting ................................................................................................................26

C.2 Preliminary Steps: .............................................................................................................26

C.3 Check Oil Primary Control ...................................................................................................26

Parts Listing.............................................................................................................................30

Model BCL High Capacity Diagram .............................................................................................30

Model BCL-S Diagram (Fan and Limit Control Shown) ...................................................................33

Model BFL Diagram (Fan and Limit Control Shown) ......................................................................38

Beckett Burner Replacement Parts ............................................................................................43

Homeowner's Reference Table ................................................................................................ 44

Summary of Contents for BCL-190

Page 1: ...h 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: ... Length B Height C Supply D x E Return F x G Diameter H Height J BCL S 22 51 41 20 x 18 20 x 18 6 37 20 x 25 x 1 270 BFL 22 51 41 20 x 18 20 x 18 6 38 20 x 25 x 1 260 BCL High Capacity 26 49 56 24 x 22 24 X 22 7 47 20 x 25 x 1 2 450 Dimensions BCL S REAR BREECH BFL FRONT BREECH BCL 190 225 HIGH CAPACITY REAR BREECH ...

Page 3: ...9 Burner Primary Safety Control 9 20 Combustion Chamber 9 21 Circulating Air Blower 10 22 Maintenance And Service 11 23 Operating Instructions 12 Appendix A Check out and Adjustments 13 A 1 Oil Burner Air Adjustment 14 A 2 Burner Electrodes 15 A 3 Start Up 15 A 4 Special Instructions For Units Equipped With Riello Burners 16 A 5 Final Check Out 16 Blower Setup Tables 17 Airflow Characteristics Tab...

Page 4: ... for each heated space shall be calculated in accordance with the procedures described in the manuals of Canada The Heating Refrigeration and Air Conditioning Institute of Canada HRAI or by other means prescribed or approved by the local authority having jurisdiction United States Manual J titled Load Calculation published by the Air Conditioning Contractors of America describes a suitable procedu...

Page 5: ...ing Manually operated dampers must have a control to prevent operation of either system unless dampers are in full heat or full cool position Air heated by the furnace shall not pass through evaporator coil unless coil is specifically approved for such service Check and adjust blower speed to compensate for pressure drop caused by evaporator coil Maintain required clearance between bottom of coil ...

Page 6: ...Venting Flue pipe should be as short as possible with horizontal pipes sloping upward toward the chimney at a rate of one quarter inch per foot Flue pipe should not be smaller in cross sectional area than flue collar on the furnace Flue pipe should connect to chimney so the flue pipe extends into and terminates flush with the inside surface of chimney liner Seal the joint between pipe and lining C...

Page 7: ...Timer integrates control of burner and circulator fan operations Control is central wiring point for most of furnace electrical components United Technologies 1158 120 has an adjustable fan on time set by selecting dipswitch combination displayed in Chart 1 Fan on delay can be set at 30 60 90 or 120 seconds Provides a delay between burner ignition and blower start up to eliminate excessive flow of...

Page 8: ... 1 and by local codes where they prevail United States all field wiring shall conform to National Fire Protection Association NFPA 70 National Electrical Code and with local codes and regulations Wire furnace to separate dedicated circuit in main electrical panel Suitably located circuit breaker can be used as service switch separate service switch is advisable Service switch is necessary if circu...

Page 9: ...ly build up on air moving components of oil burner assembly resulting in decreased air supply with potential soot build up in flue gas passageways of heat exchanger Soot behaves as insulator and impairs good heat transfer Stack temperature increases and efficiency decreases To avoid this problem adjust the air supply to provide no more than trace smoke spot on Bacharach Scale See Venting Instructi...

Page 10: ...t drive or belt drive blower systems BCL high capacity furnace models are equipped with belt drive blower systems Direct Drive Blower Systems Direct drive blower speed adjustments are not normally required in properly sized extended plenum duct systems Motor RPM and air CFM delivery will vary automatically to accommodate conditions within usual range of external static pressures typical of residen...

Page 11: ...furnace and remove burner Use stiff brush with wire handle brush off scale and soot from inside drum and flue pipe Clean radiator remove clean out cap screws Remove caps carefully to avoid tearing gaskets Wire brush can be used to loosen dirt and debris on the inside surfaces of radiator Clean out all accumulated dirt soot and debris with a wire handled brush and an industrial vacuum cleaner Befor...

Page 12: ...tops 4 Air circulation blower continues to operate as long as temperature remaining in furnace is above the FAN OFF setting Fan control adjustments may be altered if air at room registers is high upon blower start up or shutdown 5 Restore thermostat setting to comfortable temperature To Shut Down Unit 1 Set thermostat to lowest possible setting 2 Set manual switch if installed in electrical power ...

Page 13: ...0 85 usgph F3 2 in BFL120 2 BFL120T2 AF65XN 1 00 80 A 100 psig 1 00 usgph F3 2 in BCL130S2 BCL130ST2 AF65YB 1 10 70 A 100 psig 1 10 usgph F6 2 in BCL145S2 BCL145ST2 AF65YB 1 20 60 A 100 psig 1 20 usgph F6 2 in BFL130 21 BFL130T21 AF65YB 1 10 70 A 100 psig 1 10 usgph F6 2 in BFL145 21 BFL145T21 AF65YB 1 20 60 A 100 psig 1 20 usgph F6 2 in BFL130NX2 BFL130TNX2 NX70LFHS 1 00 60 W 140 PSIG 1 10 USGPH ...

Page 14: ...nter clockwise to decrease combustion air Re tighten locking screw after obtaining proper setting Beckett NX Burner Chimney Vent Loosen splined nut on nozzle line about one turn Turn adjustment screw clockwise to increase air and counter clockwise to decrease air Tighten splined nut after obtaining proper setting Riello 40F3 Burner Chimney Vent Combustion air is adjusted by removing burner cover L...

Page 15: ...rt in the supplied appliance connector to take smoke readings 9 When furnace has reached steady state after approximately 10 minutes Set combustion air damper to get TRACE of smoke for chimney vented units and ZERO smoke for sidewall vented units 10 Check system temperature rise Temperature rise is the difference between return air temperature measured at a point near return air inlet and supply a...

Page 16: ...ith Burner for specific information concerning burner adjustments operation and trouble shooting A 5 Final Check Out Verify all safety devices and electrical components have been set for normal operation Verify all electrical connections are tight and wiring is secure Verify homeowner is informed and understands Where circuit breaker or fuse is located in main electrical panel Where furnace switch...

Page 17: ... HP 1300 2000 BCL120ST2 120 11T Low 1 HP Low 1 HP 3 5 1 HP 1300 2000 BCL130ST2 120 11T Medium 1 HP Medium 1 HP 3 5 1 HP 1300 2000 BCL145ST2 120 11T Medium 1 HP Medium 1 HP 3 5 1 HP 1300 2000 TABLE A 4 BCL S DIRECT DRIVE BLOWER SET UP Table A 5 BFL DIRECT DRIVE BLOWER SET UP Furnace Model Blower Blower Set Up Cooling Capacity 0 20 in w c 0 50 in w c Tons Motor CFM Range Speed Motor Speed Motor BFL9...

Page 18: ...ge Pulley Belt Motor Pulley Belt Motor Motor Blower Motor Blower BFL90 2 100 10R 3 x 7 x 4L420 1 3 HP 3 x 6 x 4L410 1 2 HP 3 4 1 2 HP 1000 1600 BFL100 2 100 10R 3 x 7 x 4L420 1 3 HP 3 x 6 x 4L410 1 2 HP 3 4 1 2 HP 1000 1600 BFL120 2 100 10R 3 x 7 x 4L420 1 3 HP 3 x 6 x 4L410 1 2 HP 3 4 1 2 HP 1000 1600 BFL130 2 100 10R 3 x 6 x 4L410 1 2 HP 3 x 5 x 4L390 1 2 HP 3 4 1 2 HP 1000 1600 BFL145 2 100 10R...

Page 19: ...20 11T 85 F 12 3 14 0 MAX High 2188 2161 2133 2069 2016 1933 Medium 1742 1730 1718 1702 1670 1604 Low 1410 1410 1410 1390 1374 1326 TABLE A 10 BCL S BFL AIRFLOW CHARACTERISTICS BELT DRIVE Furnace Model Motor HP Motor FLA ΔT Blower Blower Pulley Motor Pulley Turns Out CFM External Static Pressure Inches w c 0 20 0 25 0 30 0 40 0 50 0 60 BCL S2 BFL 2 1 3 HP 5 4 85 F 100 10R 7 x 0 1425 1355 1280 1125...

Page 20: ...ches w c 0 20 0 25 0 30 0 40 0 50 0 60 BCL High Capacity 3 4 HP 13 0 85 F G12 7 x 0 2274 2177 2080 1847 1532 1099 2 2107 2017 1927 1712 1420 1019 4 1939 1857 1775 1576 1308 939 6 1772 1697 1622 1441 1196 859 BCL High Capacity 1 HP 14 0 85 F G12 6 x 2 2601 2525 2449 2334 2164 2007 3 2549 2474 2399 2288 2120 1967 4 2497 2424 2350 2241 2077 1927 5 2444 2373 2301 2194 2034 1887 APPENDIX A CHECK OUT AN...

Page 21: ...21 PN 28141 REV K 10 30 2018 APPENDIX B WIRING DIAGRAMS Chimney Vent Direct Drive Furnace Wiring Diagram BCL S BFL 5 Ton Models With Fan and Limit Control ...

Page 22: ...22 PN 28141 REV K 10 30 2018 APPENDIX B WIRING DIAGRAMS Chimney Vent Belt Drive Furnace Wiring Diagram BCL High Capacity with Fan and Limit Control ...

Page 23: ...23 PN 28141 REV K 10 30 2018 Chimney Vent Furnace Wiring Diagram BCL S BFL with Fan Timer Control APPENDIX B WIRING DIAGRAMS ...

Page 24: ...24 PN 28141 REV K 10 30 2018 Direct Vent Furnace Wiring Diagram BCL S BFL with Fan Timer Control APPENDIX B WIRING DIAGRAMS ...

Page 25: ...cool speed Thermostat ends call for cool G and Y terminals are de energized Cooling contactor is de energized immediately Circulator fan turns off immediately FAN Thermostat begins call for fan G terminal is energized Circulator fan is energized immediately at cooling speed Thermostat ends call for fan G terminal is de energized Circulator fan is de energized immediately LIMIT Limit switch string ...

Page 26: ...may burn out heat anticipator of standard 24 vac thermostat or cause harm to components within micro electronic thermostat Before checking oil primary control perform these preliminary checks repair or replace controls as necessary Check power supply fuse box or breaker any service switches all wiring connections and burner motor reset button if equipped Check limit switches to ensure switch conta...

Page 27: ...epair light leak if necessary Open safety switch Check for open limit or auxiliary limit Check internal wiring connections loose connectors etc Furnace will not start without first pushing oil primary control reset button Happens on frequent basis No fuel oil Check fuel oil supply Check all hand operated fuel oil valves are in open position Fill oil storage tank if necessary Clogged nozzle Replace...

Page 28: ...e Gently warm oil line Insulate oil line Outdoor piping size may require increased diameter Oil burner sputtering at nozzle Electrodes out of adjustment or defective Check electrode settings Check electrodes for dirt build up or cracks in porcelain Poor igniter connections or defective igniter Check contacts between the igniter and electrodes If OK replace the igniter Fuel oil filter clogged Repla...

Page 29: ...peed up blower fan Defective high limit control Test high limit function of all limit switches Use duct thermometer to verify accuracy of limit control Check for obstructions to airflow around limit switch bimetal elements Replace control if necessary Under sized nozzle Check nozzle If problem is not caused by air flow problems use larger nozzle if permitted by rating plate Blower fan motor stoppi...

Page 30: ...30 PN 28141 REV K 10 30 2018 Model BCL High Capacity Diagram PARTS LISTING ...

Page 31: ...r unit 240007841 Cleanout Cap Gasket 2 per unit 240006333 14 Front Panel 29220AD Logo Bezel 28479 Logo Label 28563 15 Fan Limit Control 8 Insertion Set 200º F 29041 16 Junction Box 21318 17 Fuse Holder 27089 18 Fuse ABC 15 2200096 19 Wire Retainer Channel 27510 20 Blower Access Door 29053AD 21 Front Panel Baffle 3022140A 22 Top Front Panel Baffle 29223 23 Oil Burner assembly Beckett AF81WF 29597 2...

Page 32: ...3B2 Blower Base Feet RH 8173B1 Blower Base Feet Rubber Grommet 4 required 26415 34 Blower Assembly 1 HP 29217 Blower Housing and Wheel G12 With Ball Bearings 29222 Blower Motor 1 HP Single Speed 102000156 Motor Pulley 3 1 2 X 5 8 Adjustable With Keyway 19779 Blower Pulley 6 X 3 4 2240006 Fan Belt 4L410 2240020 Blower Base Feet LH 8173B2 Blower Base Feet RH 8173B1 Blower Base Feet Rubber Grommet 4 ...

Page 33: ...33 PN 28141 REV K 10 30 2018 Model BCL S Diagram Fan and Limit Control Shown PARTS LISTING ...

Page 34: ...ckett AF Burner 550001630 Heat Exchanger Assembly for Riello Burner 550001631 11 Flue Pipe Assembly 28497 12 Firepot Bracket Assembly 4141185A 13 Replacement Combustion Chamber 9200C for Beckett AF Burner 8823B1 Replacement Combustion Chamber 27000B for Riello Burner 27000WP 14 Top Front Baffle 21485 15 Inner Front Baffle 21425 16 Right Side Panel Baffle 21344 17 Oil Burner Mounting Plate Assembly...

Page 35: ...Rubber Grommet 4 per unit 26415 Not Shown 28 Draft Regulator 6 12240 30 Side Panel Insulation Retainer 2 per unit 26047 31 Beckett Oil Burner AF65XN 0 75 0 85 1 00 GPH Wired for Fan Timer Control 240010428 32 Blower Assembly Complete Belt Drive 1 2 HP 6033C7 Blower Housing and Wheel 100 10R BD 30625 Blower Motor HP SS 102000154 Motor Pulley 3 1 4 X 1 2 Adjustable 2240001 Blower Pulley 6 X 3 4 2240...

Page 36: ...y R8228B1012B 26854 27 Fan Limit Control 11 or 11 Insertion 230º F 18002 29 Fan Limit Support Insulation Retainer 26973 31 Beckett Oil Burner AF65XN 0 75 0 85 1 00 GPH Wired for Fan and Limit Control 29592 31 Beckett Oil Burner AF65YB 1 10 1 20 GPH Wired for Fan and Limit Control 29594 Not Shown 32 Blower Assembly Complete Direct Drive 1 HP 26812 Blower Housing and Wheel 120 11T 240006678 Blower M...

Page 37: ... 13 Replacement Combustion Chamber 27000B for Beckett AFII Burner 27000WP 18 Pouch Gasket Second gasket required for Direct Vent 2080175 31 Beckett Oil Burner AFII 150 Wired for Fan Timer Control 240010452 Pressure Switch 0 33 WC 30734 10 Second Bypass Timer GPS00C9X10 30699 Appliance Vent Adapter 6 Breech to 4 Vent 240006905 Combustion Air Intake Collar 4 for AFII Burner 109005950 Wire Harness Fa...

Page 38: ...38 PN 28141 REV K 10 30 2018 PARTS LISTING Model BFL Diagram Fan and Limit Control Shown 33 ...

Page 39: ...bly for Beckett AF or NX Burner 550001633 Heat Exchanger Assembly for Riello Burner 550001634 12 Firepot Bracket Assembly 4141185A 13 Replacement Combustion Chamber 9200C for Beckett AF or NX Burner 8823B1 Replacement Combustion Chamber 27000B for Riello Burner 2700WP 14 Top Front Baffle 21485 15 Inner Front Baffle 21425 16 Right Side Panel Baffle 21344 17 Oil Burner Mounting Plate Assembly 109007...

Page 40: ...ve 1 2 HP 6033C7 Blower Housing and Wheel 100 10R BD 30625 Blower Motor HP SS 102000154 Motor Pulley 3 1 4 X 1 2 Adjustable 2240001 Blower Pulley 6 X 3 4 2240006 Fan Belt 4L410 2240020 Blower Base Feet 2 per unit 109005826 Blower Base Feet Rubber Grommet 4 per unit 26415 28 Draft Regulator 6 12240 30 Side Panel Insulation Retainer 2 per unit 26047 31 Beckett Oil BurnerAF65XN 0 75 0 85 1 00 GPH Wir...

Page 41: ...imit Control 11 or 11 Insertion 190º F 12356 29 Fan Limit Support Insulation Retainer 26973 31 Beckett Oil BurnerAF65XN 0 75 0 85 1 00 GPH Wired for Fan and Limit Control 29592 31 Beckett Oil Burner AF65YB 1 10 1 20 GPH Wired for Fan and Limit Control 29594 31 Beckett Oil Burner NX70LFHS 1 10 1 20 GPH Wired for Fan and Limit Control 240010234 32 Blower Assembly Complete Direct Drive 1 HP 26812 Blo...

Page 42: ...n Chamber 27000B for Beckett AFII Burner 27000WP 18 Pouch Gasket Second gasket required for Direct Vent 2080175 31 Beckett Oil Burner AFII 150 Wired for Fan Timer Control 240010452 33 Flue Connector Assembly 6 to 4 90º Elbow 240008224 Appliance Adaptor 4 Breech to 4 Vent 240006903 Pressure Switch 0 33 WC 30734 10 Second Bypass Timer GPS00C9X10 30699 Combustion Air Intake Collar 4 for AFII Burner 1...

Page 43: ... 7505B1500 for AF NX Burner 240008816 Air Tube Combination AF65XN for AF Burner on BCL BFL 90 100 120 11986 Air Tube Combination AF65YB for AF Burner on BCL BFL 130 145 20877 Air Tube Combination FBX80HGXS for AFII Burner on BCL BFL 100 120 Direct Vent 28561 Flame Retention Head F3 for AF Burner on BCL BFL 90 100 120 1050002 Flame Retention Head F6 for AF Burner on BCL BFL 130 145 1050004 Flame Re...

Page 44: ...No After Hours No Fuel Supplier Fuel Oil Supplier Contact Telephone No After Hours No HOMEOWNER S REFERENCE TABLE All specifications subject to change without notice 2018 ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com BDR THERMEA GROUP ...

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