The Project Gutenberg EBook of Installation and Operation Instructions For Custom Mark III CP Series Oil Fired Unit, by Anonymous This eBook is for the use of anyone anywhere at no cost and with almost no restrictions whatsoever. You may copy it, give it away or re-use it under the terms of the Project Gutenberg License included with this eBook or online at www.gutenberg.org Title: Installation and Operation Instructions For Custom Mark III CP Series Oil Fired Unit Author: Anonymous Release Date: February 25, 2009 [EBook #28166] Language: English Character set encoding: ASCII *** START OF THIS PROJECT GUTENBERG EBOOK OIL FIRED UNIT *** Produced by Gerard Arthus, Diane Monico, and the Online Distributed Proofreading Team at http://www.pgdp.net INSTALLATION AND Operation Instructions FOR CUSTOM MARK III CP SERIES OIL FIRED UNIT MANUFACTURED BY AXEMAN-ANDERSON COMPANY 300 East Mountain Avenue South Williamsport, PA 17701 CPO2O--8410--5C INSTALLATION AND OPERATING INSTRUCTIONS CUSTOM MARK III CP SERIES OIL FIRED UNIT _GENERAL_ The Custom Mark III CP Series Oil Fired Unit is a high quality heating unit that will provide many years of comfortable and economical heat if properly installed and given proper care. It is _IMPORTANT_ therefore that these instructions should be followed carefully. _SHIPMENT_ The unit is completely assembled at the factory except for the following parts which are packed in a separate carton and strapped to the skids inside the shipping carton: 1 - 3/4" x Close Steel Nipple 1 - 3/4" x 3/4" x 1/2" Tee 1 - Fig. 105 Tridicator 1 - 3/4" No. 10-402-05 ASME Relief Valve 1 - 3/4" No. 600-19 Boiler Drain 1 - T87F-2055 Thermostat The jacket extension for 128CPO is shipped in separate carton. _DAMAGE IN TRANSIT_ Upon receipt of shipment of this material, inspect all cartons for external damage. If external damage is noted, open the carton and inspect for damage to equipment. Mark the number of cartons received in this condition on the delivering carrier's waybill, and request the services of their inspector. If, upon opening a carton, concealed damage is discovered, open the entire shipment and note all equipment so damaged. Contact the delivering carrier and request inspection of the damaged equipment. Do not destroy the carton. The inspector from the freight company will need this to determine reason for damage. Normally claims for any and all damages should be filed with the freight company within five working days after receipt of shipment. All materials are sold F.O.B. Factory. It is the responsibility of the consignee to file claim with the delivering carrier for material received in a damaged condition. _LOCATING UNIT_ _BEFORE REMOVING SHIPPING CARTON, LOCATE UNIT IN ITS FINAL POSITION_ The carton is plainly marked so as to indicate which is the outlet burner end of the unit which is also the end where the return and flue are located. Clearance should be provided in both the front and rear of the unit for cleaning. Where possible it is good practice to locate the unit so its sides are parallel to the chimney flue. In all instances locate unit as near chimney flue as possible in order to avoid use of a long flue pipe. _REMOVING CARTON_ Once the packaged unit is in its proper place, cut all around the carton on the scored line as shown on carton. The entire carton may then be lifted from the skids. If it is found necessary to move the unit a little more to place it in the exact location ready for piping, do so before removing skids. DO NOT PUSH AGAINST ANY PART OF JACKET OR OIL BURNER WHEN MOVING UNIT. TO MOVE UNIT, PUSH AGAINST _SKIDS, FLUE BOX OR SMOKE BOX_. PUSHING AGAINST JACKET WILL RESULT IN DAMAGE. _REMOVING SKIDS_ The skids are specially designed for easy removal. It is necessary, however, to follow these instructions carefully. A. After unit is in proper place, remove the two cross pieces from skids by pulling out all scaffolding (double headed) nails. B. By inserting pinch bar or 2" x 4" underneath the smoke box (rear of unit), tilt one side of unit just high enough to lift lugs out of holes in skid, then knock skid out from underneath unit. Then do the same thing on the other side of unit. _THE UNIT IS NOT BOLTED TO THE SKIDS._ The 3/4" lugs welded to the unit simply fit into the 3/4" holes in the skids. +----------------------------------------------+ | | | IMPORTANT | | | | DO NOT TILT UNIT BY PUSHING AGAINST JACKET | | | | IT IS NOT NECESSARY | | | | AND BY DOING SO THE JACKET WILL BE DAMAGED | | | +----------------------------------------------+ _LEVELING UNIT_ In case floor is uneven, unit may easily be made level by inserting shims under the 4 shipping lugs. These lugs also keep the jacket 1/2" off the floor, protecting it from wet floors and dampness. _PIPING AND WIRING_ Once the unit is in its proper location with the packing carton, skids and packing material removed, it is ready for piping and connection from Room Thermostat and 110 V. 60 Cy. A.C. Current. _CONTROL SYSTEM_ The controls furnished are for a one zone Forced Water System consisting of T87F Room Thermostat, L8124A-1007 Triple Acting Aquastat and Circulator Relay, C554A-1018 Cadmium Photocell, R8184G-1005 Burner Relay and V4046A-1009 Oil Valve. Description and complete wiring diagram will be found packed with each control. _SPECIAL CONTROL SYSTEMS_ For special control systems such as multiple installations, zone controlled, unit heater, radiant panel, etc., write to factory for wiring diagrams. _CHIMNEY AND BREECHING REQUIREMENTS_ The CP boiler should be connected to a vertical vent system that will prevent: (1) positive pressure in the flue, (2) backward flow of flue gas through the unit when the burner stops, and (3) condensation in the flue. Use double-walled or insulated pipe for sections of the flue in cold areas. All outside vents, except for short extensions, must be insulated to avoid condensation in the flue. Several types of prefabricated chimneys are available providing double-walled or insulated pipe, some with ceramic and others with metallic liners. While the unit is equipped with an induced draft fan, proper size vent must be provided to remove the gases of combustion. It is recommended that a 4" to 5" increaser be used for venting the 87CPO and 108CPO and a 4" to 6" increaser be used for the 128CPO. For abnormal runs (exceeding 10 ft.), consult factory. Vent and breeching must be gas tight by sealing with asbestos or thermo-setting pressure sensitive tape. _DRAFT REGULATOR_ It is recommended that a draft regulator be installed in chimney flue _just below the flue pipe opening_, if the unit is attached to an extremely high chimney; an unlined chimney; or a chimney which is constructed on the exterior of the house. _CONTROLS AND TRIM_ Controls are installed in place at the Factory. Attach thermo-altimeter in 1/2" tapping in top front of boiler. Install 3/4" x close nipple in 3/4" top connection with 3/4" x 3/4" x 1/2" Tee. 3/4" Tee opening for installation of the relief valve and 1/2" opening for expansion tank. _WIRING_ Controls are all in place and wired at the factory except connection to circulator. _REGULATING OIL PRESSURE_ Standard nozzles furnished with the burner will produce the stamped rated capacity when used with Commercial Standard No. 2 Fuel Oil, and operated with a pressure of 100 lbs. per square inch. The standard setting of the fuel unit is 100 lbs. Due to difference in tank elevations, the pressure should be adjusted at the time of start up. _FUEL LINES_ Care should be employed when attaching the oil lines to the fuel unit. Overtightening or twisting will twist the pump-motor mounting plate and put a stress on the motor bearings. _START UP PROCEDURE_ General: 1. Make certain that correct voltage has been supplied to motor and control circuit. 2. Insure that outside air openings are provided in the boiler room for ventilation, and for admission of air for combustion. The free area of such openings should not be less than 7 square inch opening per 100,000 Btuh burner input, or more as required by local codes. 3. Check to see that flue, wiring and water level are in order. 4. Start burner fan motor to prime pump. If pump does not pick up oil within a few minutes, prime the pump with lubricating oil. Do not allow pump to run more than a few minutes without additional lubrication. 5. Check oil pressure and adjust if necessary. (See REGULATING OIL PRESSURE). 6. Set air shutters. (See ADJUSTING BURNER) Refer to Figure 1. 7. Generously lubricate the front motor bearing with SAE #20 oil. _ADJUSTING BURNER_ (See Figure 1) Positioning of the nozzle in relation to the face of the cone and the electrodes in relation to the nozzle are very important, also the face of the cone in relation to the face of the choke ring must be set according to the chart for each rate. If the air shutter openings are too large the oil may not ignite. 1. This setting will vary somewhat depending upon the grade of oil being used or if No. 1 is used instead of No. 2. 2. The approximate burner air setting may be determined by observing the fire through the observation port on the front of the boiler. If the flame is smoky, the air shutter should be opened until the fire burns clean, without any trace of smoke. The flame should be bright yellow in color with the tips of the flame turning orange. If the flame is too white, reduce the amount of air admitted; and, if too red or smoky increase the air. 3. Final adjustments should be made using a flue gas analyzer to measure the CO_2 content of the flue gas and a Bacharach model smoke meter or equivalent to determine the amount of smoke (not to exceed a "TRACE"). For checking efficiency only the stack temperature and CO_2 may be taken immediately after the fan and refer to the standard efficiency charts for the results. Readings of 5 to 8% taken after the fan correspond to 10 to 12% taken in the rear uptake of the boiler. The reduction in CO_2 reading in the flue is caused by the air being drawn in around the motor shaft for cooling purposes. The motor cooling air is at ambient temperature and, therefore, does not add energy to or subtract energy from the flue gas analysis, it only adds volume to the flue gas. Therefore, applying this data to standard efficiency charts will give a true indication of flue gas loss. +---------------------------------------------+ | | | NOTE | | | | Final adjustment should be made after | | the burner has been firing continuously | | for at least 10 minutes, as the fan pulls | | less air when the flue gases are hot. | | | +---------------------------------------------+ A. CHECK LIMIT CONTROL Run the burner long enough to bring the water temperature up to at least 190 degrees then turn the limit control setting until the burner stops. +---------------------------------------------------+ | | | NOTE | | | | The Minimum limit setting for any hot water | | boiler should be 140 degrees F. in order to | | prevent corrosion of the flues on the fire | | side. The burner should be run with the primary | | control thermostat terminals jumpered and the | | burner controlled directly from an aquastat | | keeping the boiler hot all the time, thus | | eliminating the sweating of the flues on the | | fire side caused by starting from a cold start. | | | +---------------------------------------------------+ _BELT ADJUSTMENT_ The proper tension on the fuel unit belt drive is set at the factory. However, the belt should be checked periodically to see that the setting is maintained. To check setting, first, remove the belt guard and then, using fingers, compress the belt at a point midway between the sheaves. The proper setting at this point measured between the outer edges of the belt, should be between 1-3/4" and 1-7/8". If adjustment is necessary loosen the two mounting bolts, and move the fuel unit up or down to give the necessary belt setting. Then re-tighten the mounting bolts securely and replace the belt guard. _PERFORMANCE CHECK LIST_ _QUESTION: What Causes Unit To Soot Up?_ _Answers_: 1. Nozzles 2. Flame Impingement 3. Firing Head 4. Leaks 5. Improper Burner Settings 6. Lack of Normal Maintenance 7. Poor Ignition 8. Retention Ring Cokes _Definitions of Answers_: 1. Nozzles A. Dirty B. Wrong type of nozzle, or manufacturing defect 2. Flame Impingement A. High CO_2 B. Diffuser and choke ring clearance not uniform C. Dirty nozzle, or poor patterns D. Leaks 3. Firing Head A. Diffuser and choke ring clearance not uniform B. Diffuser and choke ring face dimension out of tolerance. (See A Dimension, Figure 1) C. Dirty fuel systems 4. Leaks A. Induced fan gasket, or burner gasket improperly sealed B. Front cover assembly improperly installed or sealed 5. Improper Burner Settings A. Unit not checked out completely by the serviceman B. Flame pattern erratic (Not concentric). Burner set up by CO_2 only (Burner should be set up by CO_2, smoke and visual observation.) 6. Lack of Normal Maintenance A. Self explanatory (Recognition of the advantages of preventive maintenance). 7. Poor Ignition A. No delay in oil valve, unit flutters on start up. B. Electrodes out of position C. Too much combustion air (Air shutter open too wide) 8. Retention Ring Cokes A. Defective nozzle B. Cone, choke and nozzle out of adjustment (See Figure 1) C. Fluttering starts _DOMESTIC HOT WATER_ In order to obtain the rated capacity of the instantaneous domestic hot water coil limit control should be set to maintain 200 deg. F boiler water temperature. Flow regulator and tempering valve should be installed on all instantaneous domestic hot water coil systems. _BURNER SETTING_ The burner is adjusted at the factory before shipment but in case of improper operation at some future date Figure 1 will show proper setting. In all cases the flame retention ring should be concentric with the choke. [Illustration: FIGURE 1] +--------+----------------+-----------------------+--------+---------+ | MODEL | NOZZLE | CHOKE RING | "A" | I. D. | | NO. | DELAVAN SIZE | NO. & DIAMETER | DIM. | VANES | +--------+----------------+-----------------------+--------+---------+ | 87CPO | 1.25 GPH 70 deg. A | 142640-002 2-5/8 D | FLUSH | 2-25/32 | | 108CPO | 1.65 GPH 60 deg. A | 142641 2-31/32 D | -3/16" | 2-25/32 | | 128CPO | 2.00 GPH 70 deg. A | 142641-003 2-31/32 D | +1/4" | 2-29/32 | +--------+----------------+-----------------------+--------+---------+ [Illustration: (parts listed counter-clockwise from left side) Tubes 37CP19 08CP19 728CP19 4CP25 40624 144539 134955 144538 131798 131651 140734 142743 R8184G V4046A-16 1R111B-1BP 140611 141741 144691 141740 MM1163 141646-G03 140606] End of the Project Gutenberg EBook of Installation and Operation Instructions For Custom Mark III CP Series Oil Fired Unit, by Anonymous *** END OF THIS PROJECT GUTENBERG EBOOK OIL FIRED UNIT *** ***** This file should be named 28166.txt or 28166.zip ***** This and all associated files of various formats will be found in: http://www.gutenberg.org/2/8/1/6/28166/ Produced by Gerard Arthus, Diane Monico, and the Online Distributed Proofreading Team at http://www.pgdp.net Updated editions will replace the previous one--the old editions will be renamed. 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