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diff --git a/28166.txt b/28166.txt new file mode 100644 index 0000000..707d81a --- /dev/null +++ b/28166.txt @@ -0,0 +1,869 @@ +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. + +Creating the works from public domain print editions means that no +one owns a United States copyright in these works, so the Foundation +(and you!) can copy and distribute it in the United States without +permission and without paying copyright royalties. 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