Bock Water heaters 32PPC, 51EC, 50ES, 32E, 50ESC User Manual

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TO THE INSTALLER: Please attach these in-

structions next to the w

ater heater.

TO THE CONSUMER: Read these and all com-

ponent instructions. Please keep for future reference. Please remember to return the registration card.

Waranty, registration card & parts list included.

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

BOCK RESIDENTIAL OIL-FIRED

WATER HEATERS

Model numbers: 20e, 20pp, 32E, 32EC, 32PP, 32PPC, 33E, 33PP, 40E, 40PP, 50ES, 50ESC, 51E, 51EC, 51PP, 51PPC, 71E, 120E

WARNING:

Improper installation, adjustment, alteration, service or maintenance can cause serious injury or property damage. Refer to this manual. For assistance or additional information, consult a qualified installer or service agency.

WARNING:

If the information in these instructions is not followed exactly, fire or explosion may result and can cause property damage, personal injury or death.

WARNING:

Follow minimum combustible clearance as noted on water heater label. Do not install on combustible flooring (see Figure 2, Page 3). Install in accordance with all local codes. In the absence of local codes, refer to NFPA 31 or ANSI Z21.10.1.

CAUTION:

The recommended temperature for normal residen-

The dial on the aquastat does not

tial use is 120 always reflect the outcoming water temperature, which could occasionally exceed 120 tion in outcoming temperature could be based on factors including but not limited to usage patterns and type of installation. Test your water at the tap nearest to the water heater. (See page 5 for measuring the outcoming water temperature).

The varia

ARNING:

Hotter water increases the risk of scald injury. Before changing the temperature setting, read the instruction manual. Temperatures at which injury occurs vary with the individual’s age and length of exposure.

The slower reaction times of children, elderly and physically or mentally impaired persons increases the scalding hazard to them. It is recommended lower water temperatures be used where these situations exist.

Households with small children or invalids may require a temperature setting less than 120°F to prevent accidental contact with hot water

To lower water temperature use point-of-use temperature limiting devices.

WARNING:

Flammable vapors may be drawn to this water heat

from other areas of the structure by air currents.

Do not store or use any flammable liquids in the vicinity of this heater.

WARNING:

Water heater blankets may restrict air flow to the heater and cause fire, asphyxiation, personal injury or death.

Bock Water Heaters, Inc.

110 South Dickinson Street • P.O. Box 8632 • Madison, WI 53708-8632

Phone: 608/257-2225 • Fax: 608/257-5304 • www.bockwaterheaters.com

CONSUMER RESPONSIBILITIES

THIS MANUAL HAS BEEN PREPARED TO ACQUAINT YOU WITH THE INSTALLATION, OPERATION, AND MAINTENANCE OF YOUR WATER HEATER AND T

O PROVIDE IMPORTANT SAFETY INFORMATION.

FAILURE TO FOLLOW THESE INSTRUCTIONS OR ALL APPLICABLE BUILDING CODES AND REGULATIONS VOIDS

HE WARRANTY ON THIS

T WATER HEATER.

MULTIPLE BURNER INSTALLATION

Read all instructions thoroughly before attempting installation or operation of the water heater. Keep these and all component instructions for future reference.

The manufacturer of this water heater will not be liable for any damages caused by failure to comply with the installation and operating instructions outlined on the following pages. These instructions are a guide for the correct installation of the water heater.

If the installer lacks the necessary skills or has difficulty following the directions, do not proceed but get help from a qualified person for that part of the installation that is not understood.

Local plumbing and electrical codes must be followed in the installation of this water heater. In the absence of a local code use the UNIFORM PLUMBING CODE and the NFPA Code. Local codes may supersede instructions in this installation manual.

When two or more burners are used, each unit should have a separate supply line to the fuel pump to prevent nuisance lockouts caused by one or both pumps starving for oil. If this is not possible, the use of a priority control is recommended.

Check new equipment to see if all components are in good condition. The water heater and oil burner may be shipped as separate units. The aquastat and immersion well may be packed with the oil burner

SELECT THE RIGHT LOCATION

Check for exhaust fans in the heater room or adjacent areas which draw combustion air away from

heater

MUST HAVE COMBUSTION AIR TO OPERATE.

THE HEA

TER

The new water heater requires fuel (#I or #2 heating oil), electricity and should be close to the chimney and water supply. Locate the heater near a floor drain if pos sible for easy maintenance and protection if trouble should occur

. Allow ample

space around the heater for servicing (see combustible clearance warning, page

1). Adequate air for combustion must be available. NOTE: Locate the heater so it is not subject to physical damage by moving vehicles or possible flooding.

FIGURE 1

TER HEA

WHEN THE W BINED APPLIANCE CONTACT THE LOCAL DISTRIBUTOR OR THE FACTORY FOR INSTALLATION INSTRUCTIONS ON “SYSTEM PLUS”.

DO NOT INSTALL THE WATER HEATER ON COMBUSTIBLE FLOORING (see Figure 2).

contact Bock Water Heaters with questions concerning proper flooring materials.

Minimum clearance to combustible construction is: SIDES 6"; BACK 6"; FRONT 24". The installation of this water heater must conform with local codes and ordinances. In the absence of local codes, the installation must comply with the National Fire Protection Association (NFP

TER IS USED IN A

APPLICATION, PLEASE

Refer to NFP

A 31) Code.

COM-

31 or

– 2 –

CONNECT WATER PIPING

Connect the water piping, being careful not to apply heat to the heater nipples. Install dielectric unions and shut off valves on both hot and cold water l

ines.

Hot water outlet (“HOT”) is on tank top. Cold water inlet is on right front bottom of 33E and 40E. On all other models, cold water inlet is on tank top.

The 40E and all “C” models (example: 32EC, 51PPC) have a 1” NPT tapping located on the front left side of the tank. This is an alternate outlet for use with combined appliance applications. If this fitting is not used, plug it with a fitting suitable for potable water.

A 1” NPT fitting is also located behind the drain valve on the 40E and all “C” models. This is for use as an alternate inlet or a combined appliance return. Your heater is shipped with a reducer in this location to mount the drain valve.

NOTE: INDEX MARK ON INLET BUSING MUST

OINT TOWARD ARROW ON DECAL. HOLD

USHING OR NIPPLE WHEN TIGHTENING

INLET FITTINGS. ROTATING BUSHING COULD DRASTI-

ALLY REDUCE PERFORMANCE.

INDEX MARK

INLET BUSHING

The 33E and 40E models are equipped with a brass inlet bushing installed in the tank. Heat-

equipped with this bushing are marked next

ers to the inlet by the decal shown on the left. The purpose of this bushing is to help keep the tank bottom free of sediment by aiding tank flushing. This bushing must be located as shown on the decal to function properly. Do not allow the bushing to rotate out of position when tightening the inlet fittings. In installations requiring high flow rates, contact the factory.

The drain valve fitting may be used as an alternate cold water inlet on heaters equipped with a dip tube, as shown in Figure 3. By plumbing a “T” into the drain fitting, the cold water inlet can be relocated to this point. The dip tube

must be

removed and its fitting plugged. Figure 3 also shows a copper loop heat trap installed on the hot water outlet to reduce standby losses.

FIGURE 2

must

be removed and its fitting plugged. Figure 3 also shows a copper loop heat trap installed on the hot water outlet to reduce standby losses.

Note: When converting to this configuration on an existing heater inspect the heater and make certain it does not have scale buildup on the

bottom of the tank. Scale can restrict the flow of water into the tank.

CAUTION!!

damage can occur from either the manual lifting of the lever or the normal operation of the

valve if it is not piped to a proper drain. If

T&P the valve fails to flow water or reseat, call a plumber

Scalding injury and/or water

, visually

FIGURE 3

– 3 –

Inspect the incoming water line for check valves or water pressure reducing v

alves. Any type of check valve may cause pressure to build up in the heater and cause tank failure. If the heater is installed in a closed system or if backflow prev

enters and pressure regulators are installed, add an expansion tank. Do not try to heat hard water. Install a water softener if the heater is being used in a hard water area (water hardness more than 7 grains).

An approved temperature and pressure (T&P) relief valve is factory installed in the opening provided in the upper right hand side of the heater. Pipe the T&P to within 6" of the floor or to a floor drain with a free flowing drain pipe. Do not install a check valve in the cold water line.

CONNECT TO CHIMNEY

MOUNT THE OIL BURNER

Using “L” or “A” type venting, connect the heater to the chimney. Use the same size smoke pipe as the heater flue pipe (on models 20e, 20pp, 32E, 32PP and 33E, you may use 4" with a reducer if needed).

WARNING:

120E, do not reduce the smoke pipe diameter. Run a separate smoke pipe from the water heater to the chimney wherever possible.

If it is necessary to tee into an existing smoke pipe, be sure the connector being teed into is large enough to accommodate the products of combustion of all units attached to it. When teeing into another connector, run in at 45° angle (see Figure

1). Install a draft regulator control only if necessary. Overfire draft should not be positive. Stack draft should be -.02” W.C. minimum to -.05” W should be a minimum of 11%. If a draft control is installed on the chimney, another one on the heater is not needed.

The oil burner is equipped with a primary relay well is packed with the burner. The thermostat is factory set at 120°F for residential use (see caution on page 1 regarding temperature variations). Install the immersion well with the aquastat and check the bulb length (see “Burner & Controls” section, page 10).

Remove the cardboard core from the burner opening. Mount the burner on stud bolts and place the gasket (supplied) between the burner flange and the heater. Secure the burner to the heater with 1/4 -20 nuts (supplied). Open the inspection door on the heater and check the burner tube with a mirror before firing to be sure the opening is not blocked (see Maintenance and Service sections on pages 6 and 7 for troubleshooting).

On Models 40E, 5OES, 50ESC, 51E, 51EC, 51PP, 51PPC. 71E and

.C. maximum; CO2

. An aquastat with immersion

CONNECT THE ELECTRICITY

CONNECT THE OIL LINE

WARNING!! WHEN YOU INSTALL THE BYPASS PLUG YOU MUST RUN A TWO-LINE SYSTEM.

– 4 –

All wiring must comply with applicable codes and ordinances. The primary relay is wired to the burner at the factory. Install the aquastat well in the 3/4" tapping at the front of the heater. Be sure the sensing bulb is inserted all the way into the well. For Honeywell aquastats, tighten the screw on top of the aquastat to secure the control to the well. For Carlin EZ-Temp aquastats, refer to the pre-packaged installation guide for proper set-up procedure. Refer to drawings for correct models. Connect the power supply to the aquastat and run through a fused disconnect switch (attached to heater in field). See Figure 1.

Gravity System: The oil burner is normally equipped with a single-stage pump equipped for one line (gravity) flow. Use 1/2" O.D. soft copper tubing and attach with flared fittings. DO NOT off valve and oil filter in the oil line. Follow the pump manufacturer’s instructions (attached to the pump).

Lift System: The burner should be ordered with a 2-stage pump. Run a 2-line system (suction and return lines). Install the bypass plug according to the

USE COMPRESSION FITTINGS. Install the shut

instructions attached to pump (plug is in a bag with an instruction sheet).

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