Airco BCL-S Instruction manual

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. [phone]
www.ecrinternational.com
PN 28141 REV. K [10/30/2018]

2PN 28141 REV. K [10/30/2018]
Furnace
Model
Cabinet Plenum Openings Flue Filter
(Permanent)
Shipping
Weight
(LB)
Width
A
Length
B
Height
C
Supply
D x E
Return
F x G
Diameter
H
Height
J
BCL-S 22 51½ 41 20½ x 1820½ x 186 37¼ 20 x 25 x 1 270
BFL 22 51½ 41 20½ x 1820½ x 18638¼ 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

3PN 28141 REV. K [10/30/2018]
Check our website frequently for updates: www.ecrinternational.com
Information and specications outlined in this manual in eect at the
time of printing of this manual. Manufacturer reserves the right to
discontinue, change specications 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. Humidier ............................................................................................................................ 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
Airow 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

4PN 28141 REV. K [10/30/2018]
3. Introduction
• Models BCL (90, 100, 120, 130, 145) S
BCL-S models are rear breech oil red forced air lowboy
furnaces with output capacity range of 90,000 to 141,000
Btu/hr.
• Models BFL (90, 100, 120, 130, 145)
BFL models are front breech oil red forced air lowboy
furnaces with output capacity range of 88,000 to 139,000
Btu/hr.
• Models BCL (170-2, 190, 200, 225)
BCL models are rear breech high capacity oil red
forced air lowboy furnaces with output capacity
range of 177,000 to 237,000 Btu/hr. Shipped in two
pieces; furnace section and blower section, which are
assembled together at the installation site.
Furnace models are either factory equipped for chimney
venting or factory equipped for direct venting.
Chimney vent models and direct vent models are not
eld convertible. Direct vent installation instructions are
included with the direct vent models.
Installation shall conform to requirements of
authority having jurisdiction or in absence of such
requirements:
• Canada - CAN/CSA - B139, Installation Code for Oil-
Burning Equipment.
• United States - National Electrical Code, NFPA31,
Standard for the Installation of Oil-Burning Equipment.
Models are CSA listed, (NRTL/C) for use with No. 1
(Stove) and No. 2 (Furnace) Oil.
Refer to tables in Appendix A for performance data.
4. Heat Loss
Maximum hourly heat loss 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 procedure for calculating
maximum hourly heat loss.
1. General
Furnace installation shall be completed by qualied agency.
WARNING
Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.
!
NOTICE
Used to address practices not related to personal
injury.
CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
!
WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not
avoided, WILL result in death or serious injury
!
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
Become familiar with symbols identifying
potential hazards.
2. Safety Symbols
WARNING
Fire, burn, asphyxiation hazard. Do not use
gasoline, crank case oil, or any oil containing
gasoline. Failure to follow these instructions could
result in death or serious injury.
!

5PN 28141 REV. K [10/30/2018]
5. Locating the Unit - [See Table 1]
• Locate furnace so ue connection to chimney is short,
direct and consists of as few elbows as possible.
• Centralize furnace location with respect to supply and
return air ductwork. Central location minimizes trunk
duct sizing.
• All models may be installed on combustible oors.
6. Furnace Used In Conjunction With Air
Conditioning
• Install furnace in parallel with or upstream from
evaporator coil to avoid condensation in heat
exchanger.
• When installed in parallel, prevent chilled air from
entering furnace by use of dampers or air controlling.
• 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 specically 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
drain pan and top of heat exchanger as specied by
coil manufacturer.
Table 1: Minimum Installation Clearances
Location Clearance to Combustibles (Inches)
BCL-S and BFL BCL High Capacity
Top 1 3
Bottom 0 0
S/A Plenum 1 3
Rear 6* 24
Side 1 6* 6
Side 2 24 18***
Front 24 24
Flue Pipe 9** 9**
Enclosure Standard Standard
* 24" Required Service Clearance
** 18" in USA
*** 18" Required on one side only for service to rear

6PN 28141 REV. K [10/30/2018]
Manufacturer recommends over re draft of -0.02 in. w.c.
See Figure 2.
Flue pipe must not pass through any oor or ceiling,
may pass through a wall where suitable re protection
provisions have been installed.
• Refer to CAN/CSA B-139 for rules governing the
installation of oil burning equipment.
• United States, refer to NFPA 31 for regulations
governing the installation of oil burning equipment.
See Appendix A for burner set-up.
Over-re draft access port.
7. Combustion Air
WARNING
Asphyxiation hazard. Failure to provide adequate
combustion and ventilation air could result in death
or serious injury.
!
Comply with CSA B139 (Canada) and NFPA 31 (U.S.)
Standards for the Installation of Oil Burning Equipment
and applicable provisions of local building codes to provide
combustion and ventilation air.
8. Chimney 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 ue collar on the furnace.
• Flue pipe should connect to chimney so the ue pipe
extends into, and terminates ush with the inside
surface of chimney liner. Seal the joint between pipe
and lining.
• Chimney outlet should be at least two feet above
highest point of peaked roof.
• All unused chimney openings should be closed.
• Chimneys must conform to local, provincial or state
codes, or in the absence of local regulations, to the
requirements of the National Building Code.
NOTICE
This furnace is approved for use with Type L vent or
equivalent. Maximum vent temperature for Type L
vent is 575°F (300°C).
WARNING
Asphyxiation hazard. Chimney vented versions of
furnace must be connected to ue having sucient
draft at all times. Failure to follow these instructions
could result in death or serious injury.
!
Figure 2 - Check Over-Fire Draft

7PN 28141 REV. K [10/30/2018]
9. Barometric Damper Control
Barometric damper control, also known as draft regulator,
is used on conventional chimney venting only. Control
automatically maintains constant negative pressure.
Ensures proper pressures are not exceeded. If chimney
does not develop sucient draft, draft control does not
function properly.
• Install draft regulator in same room or enclosure as
furnace. Draft regulator should not interfere with
combustion air supplied to the burner.
• Locate control near furnace ue outlet.
• Install per instructions supplied with regulator.
• Set over re draft, measured at oil burner mounting
plate over-re draft access port, to -0.02 in. w.c. See
Figure 2 page 6.
10. Optional Side Wall Venting
Certain BCL-S and BFL furnace models are manufactured
as sidewall vented units. Refer to Direct Venting Instructions,
P/N 240006979 included with Vent Kit for details.
Sidewall Venting (Direct Venting
burners; Beckett AFII.
Refer to Appendix A, Table A2.
11a. Models with Electronic Fan Timer Control
and Snap-Disc Limit Control (See Figure 3)
Electronic Fan 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 ow of cold air when blower comes on.
• United Technologies 1158-120 has an adjustable fan
o time of 2, 3, 4 or 6 minutes as displayed in Chart
1. Fan o delay time starts when burner motor is de-
energized at end of call for heat. Blower shutdown
is delayed to remove any residual heat from heat
exchanger.
• Electronic fan timer board works in conjunction with
snap disc limit controls, performing a safety function,
and breaks power to oil burner primary control,
shutting o burner if furnace over-heats.
• Limit control is thermally operated and automatically
resets. Limit control is factory installed, pre-set and
is not adjustable.
• If limit control opens with United Technologies
1158-120 electronic fan control, circulating fan will
energize. When limit closes, fan o timer begins.
At the end of fan o time cycle burner is energized,
initiating normal burner cycle.
FIGURE 3: UNITED TECHNOLOGIES 1158-120 FAN TIMER BOARD

8PN 28141 REV. K [10/30/2018]
Chart 1- United Technologies 1158-120
Dip Switch Position Blower Delay Times
1 2 3 4 On Seconds O Minutes
O O 30
On O 60
O On 90
On On 120
O O 2
On O 3
O On 4
On On 6
11b. Models with Mechanical Fan And Limit
Control
Furnace equipped with White Rodgers 5D51 fan and limit
control. Temperature sensitive fan switch is actuated by a
helical bi-metal sensing element enclosed in a metal guard,
and controls the circulating air blower. This provides a delay
between burner ignition and blower start up to eliminate
excessive ow of cold air when blower comes on.
Blower shutdown is also delayed to remove any residual
heat from heat exchanger and improve annual eciency
of the furnace. Fan on settings of 110º F to 130º F (43º C
to 55º C) and fan o settings of 90º F to 100º F (32º C to
37ºC) will usually be satisfactory.
Limit switch performs safety function and breaks power
to oil burner primary control, which shuts o the burner if
furnace over-heats. Limit control is thermally operated and
automatically resets.
Limit control is factory installed, pre-set. Limit control
incorporates a limit stop which prevents the limit switch
from being set above the factory setting. Do not tamper
with or attempt to adjust limit stop. The limit control should
be set at or below the factory setting. DO NOT SET LIMIT
CONTROL ABOVE FACTORY SETTINGS.
Model Factory Limit Control Setting
BCL-S 230°F
BFL 190°F
BCL High Capacity 200°F
Limit control and fan control are incorporated in same
housing and are operated by the same thermal element.
12. Electrical Connections
• Furnace is listed by Canadian Standards Association
under NRTL (North American) Standard.
• Canada, all eld wiring shall conform to CAN/CSA
C22.1 Canadian Electrical Code, Part 1, and by local
codes, where they prevail.
• United States, all eld 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 circuit breaker is close
to the furnace, or furnace is located between circuit
breaker and entry to furnace room.
• Clearly mark service switch. Install in accessible area
between furnace and furnace room entry. Locate so
as to reduce possibility it can be mistaken as light
switch or similar device.
• Power requirement is: 120 VAC, 1 Ø, 60 Hz.
Factory Equipped Blower Amps
1/3 and 1/2 HP 12
3/4 HP Belt Drive
and 1 HP Direct Drive 15
1 HP Belt Drive 20
• Accessories requiring 120 VAC power sources such
as electronic air cleaners and humidier transformers
may be powered from furnace circuit, or from
electronic fan timer board where provisions have
been made for such connections, but should have
their own controls.
• Do not use direct drive motor connections as a power
source, there is risk of damaging accessories.
• Thermostat wiring connections are shown in wiring
diagrams in Appendix B. Some micro-electronic
thermostats require additional controls and wiring.
Refer to thermostat manufacturer's instructions.
• Locate thermostat approximately 5 feet above oor,
on inside wall, and where thermostat is exposed to
average room temperatures. Avoid locations where
thermostat is exposed to cold drafts, heat from
nearby lamps and appliances, exposure to sunlight,
heat from inside wall stacks, etc.
• Adjust thermostat heat anticipator to amperage
draw of heating control circuit as measured at "R"
and "W" terminals of thermostat. Do not measure
current with thermostat connected to the circuit.
Measure amperage by connecting ammeter between
two wires which connect to thermostat "R" and "W"
terminals.

9PN 28141 REV. K [10/30/2018]
13. Humidier
• Humidier is optional accessory available through
most heating supplies outlets.
• Follow humidier manufacturer's installation
instructions
• Protect furnace heat exchanger from water or water
droplets from humidier.
• Do not use direct drive motor connections as source
of power for 120 VAC humidiers and humidier
transformers.
14. Piping Installation
• Install fuel system in accordance with requirements
of CAN/CSA B-139, and local regulations.
• United States installation shall conform to NFPA No.
31 and local codes and authorities.
• Use only approved fuel oil tanks, piping, ttings and
oil lter.
• Install oil lter as close to burner as possible.
• Refer to instructions and illustrations in oil burner and
oil pump instructions shipped with the furnace.
15. Oil Filter
Install oil lter between fuel oil storage tank and oil burner.
When using oil burner nozzle smaller than 0.65 U.S.
Gallons Per Hour, install additional 7 to 10 micron lter as
close as possible to oil burner.
16. Oil Burner Nozzles
Furnaces are certied for multiple ring rates. Furnace
may be red at ideal rate for wide range of structures by
manipulating oil burner, nozzle, ame retention head, and
temperature rise. Refer to Table A-1 thru A-3, and furnace
rating plate to determine proper combinations.
17. Oil Burner Adjustment
• Adjust burner air supply to maintain fuel to air ratio
to obtain ideal combustion conditions.
• Lack of air causes "soft" and "sooty" ames, resulting
in soot build-up throughout heat exchanger passages.
• Excess combustion air causes bright roaring re and high
stack temperatures resulting in poor fuel eciency.
• Furnaces operate most eciently with No. 1 smoke
spot on Bacharach Scale. Dust will eventually build
up on air moving components of oil burner assembly
resulting in decreased air supply with potential soot
build up in ue gas passageways of heat exchanger.
Soot behaves as insulator and impairs good heat
transfer. Stack temperature increases, and eciency
decreases. To avoid this problem, adjust the air
supply to provide no more than trace smoke spot on
Bacharach Scale.
• See Venting Instructions included in Vent Kits for set-
up details for sidewall vented furnaces.
19. Burner Primary (Safety) Control
Furnace is equipped with primary combustion control, also
referred to as burner relay or burner protector relay, which
uses a cad cell located in burner housing, to monitor and
control combustion.
Dust or combustion residuals can build up on lens of
cad cell impairing its response to ame. Check cad cell
for cleanliness and proper alignment if primary control
frequently shuts down combustion.
20. Combustion Chamber
Furnace is equipped with cerafelt combustion chamber, held
in place by a retaining bracket.
Check the alignment of the combustion chamber
and oil burner before ring. It is possible for the
combustion chamber to shift if subjected to rough
handling during transit.
Inspect combustion chamber for damage or carbon build
up whenever oil burner is removed for repairs or routine
maintenance.
NOTICE
Set up sidewall vented models to deliver zero (0)
smoke.
NOTICE
Before operating furnace check burner alignment
with combustion chamber. End cone of air tube must
be centred to accommodating ring of combustion
chamber. Adjust as necessary.
18. Burner Electrodes
Correct positioning of electrode tips with respect to each
other, fuel oil nozzle, and burners is essential for smooth
light ups and proper operation.
Refer to oil burner instructions provided with furnace and
Appendix A Section A.2 for electrode specications.
NOTICE
Do not tamper with furnace controls they are
sensitive. If problems persist, call your service
contractor.

10 PN 28141 REV. K [10/30/2018]
Belt Drive Blower Systems
WARNING
Improper installation could result in death or serious
injury. Belt drive components operate at high speeds
and may snag loose clothing resulting in injury or
death. Have a trained service professional preform
the following instructions. Failure to follow these
instructions could result in death or serious injury.
!
Belt drive blower systems can be modied for speed and
air delivery by adjusting variable speed motor pulley and
changing blower pulley.
• Adjust variable speed motor pulley by loosening 5/32
allen set screw in outer sheave. Turn outer sheave
clockwise to increase blower speed, counter clockwise
to reduce speed.
• Verify setscrew is tightened at one of the at spots,
failure to do so will convert the variable speed pulley
to a xed speed pulley by ruining the threads.
• Modify blower speed by changing the blower pulley.
Smaller blower pulley will cause the blower to turn
faster. Large pulley reduces blower speed.
• Large increases in the blower speed may increase
power requirements.
• Check amperage draw of the blower motor after
making changes. If amperage draw is greater than
the value listed on the motor rating plate, replace
with motor of higher horsepower.
• Deection of 3/4 of an inch to 1 inch fan belt tension
is necessary. Less deection places a strain on the
blower bearings and increases start up amperage
draw.
• More deection allows excess slippage and causes
premature motor pulley wear.
• Automotive belt dressings are not recommended.
• Bar soap will work as belt dressing to reduce belt
squeaks, etc. If using soap apply to the sides of belt
only.
If operating belt drive blower at speeds above 1100
RPM, replace sintered bronze blower bearings with roller
bearings.
Blower assembly in BCL (170-2/190/200/225) models with
1 HP blower is equipped with roller bearings.
21. Circulating Air Blower
• 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.
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
residential duct systems.
• Under-sized duct systems may require higher blower
speed to obtain system temperature rise.
• Some older duct systems were not designed to provide
static pressure. They typically feature special reducing
ttings at each branch run and lack block ends on the
trunk ducts. These systems may require modication
to provide some resistance to the airow to prevent
over-amping of direct drive blower motor. Selecting a
lower blower speed may correct this problem.
• Direct drive blower speeds are adjusted by changing
"hot" wires to motor winding connections. Refer to
wiring diagrams in Appendix B or wiring diagram label
axed to furnace.
• Do not move neutral wire (normally white wire)
to adjust blower speed.
• Single blower speed for both heating and cooling
modes may be used. Use a "piggy-back connector"
accommodating both wires on a single motor tap.
• It is also acceptable to connect selected motor speed
with a pigtail joined to both heating and cooling speed
wires with a wire nut.
• Safety precaution against accidental disconnection of
wires by vibration, secure wire nut and wires with few
wraps of electricians tape.
• Do not connect power leads between motor
speeds. Always connect neutral wire to motor's
designated neutral terminal.
• If joining blower speed wiring is done in furnace
junction box, tape o both ends of unused wire.
• Do not use blower speed wires as source of
power to accessories as electronic air cleaners
and humidier transformers. Unused motor
taps auto-generate suciently high voltages to
damage accessory equipment.
WARNING
Fire, burn, asphyxiation hazard. Do not start the
burner unless blower access door is secured in
place. Failure to follow these instructions could
result in death or serious injury.
!