LAARS MAX 165 User Manual
Installation, Operation and Maintenance Instructions Document 1106D
Installation,
Operation and
Maintenance
Instructions for
MAX
Residential
Oil-Fired Boiler
Models MAX 75 (DV)
MAX 100 (DV)
MAX 120 (DV)
MAX 140 (DV)
MAX 165 (DV)
FOR YOUR SAFETY : This product must be installed and serviced by a professional service technician,
qualified in boiler installation and maintenance. Improper installation and/or operation could create
carbon monoxide gas in flue gases which could cause serious injury, property damage, or death.
Improper installation and/or operation will void the warranty.
W ARNING
If the information in this manual is not followed exactly , a fire or explosion may result causing
property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other appliance.
Installation and service must be performed by a qualified installer , service agency , or fuel oil
supplier.
READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE
70-196D
Page 2
LAARS Heating Systems
TABLE OF CONTENTS
SECTION 1.
General Information
1A. Introduction...................................................3
SECTION 2.
Technical Specifications
2A. Boiler Outputs ............................................... 5
SECTION 3.
Installation
3A. Freight Claims............................................... 6
3B. Regulations ...................................................6
3C. Sizing the System ......................................... 6
3D. Location ........................................................6
3E. Clearance ..................................................... 6
3F. Combustion Air (other than direct vent) ......... 6
3G. Ventilation Air (conventional chimney
and direct vent) ............................................. 7
3H. Chimney Connection ..................................... 7
3I. Direct Vent Balanced Flue System................ 8
3J. Installation of Balanced Flue System ............ 9
3K. Boiler Piping..................................................9
3L. Freeze Protection ......................................... 9
3M. Indirect Hot Water Tank.............................. 10
3N. Burner Controls ........................................... 10
3O. Fuel System................................................ 10
3P. Gravity Head System .................................. 10
3Q. Suction Lift System ..................................... 10
3R. Oil Filter ...................................................... 10
3S. Wiring .........................................................10
SECTION 4.
Operation
4A. Preliminary Burner Settings......................... 19
4B. Burner Adjustments..................................... 19
4C. Sequence of Operation ............................... 19
SECTION 5.
Maintenance and Service
5A. Boiler .......................................................... 22
5B. Oil Burners.................................................. 22
5C. Oil Filter ...................................................... 22
5D. Cold Oil ....................................................... 22
SECTION 6.
Homeowner Information
6A. Living With Your Boiler ................................ 22
6B. General Information .................................... 23
SECTION 7.
Part Numbers
................................................................... 23
MAX Oil-Fired Boiler
SECTION 1.
General Information
1A. Introduction
The MAX Boiler has been constructed to meet
the stringent requirements of the ASME Boiler Codes
and designed to provide a rapid response to hot water
and heating demands at a very high thermal efficiency.
This is a low mass boiler. To take advantage of
this feature, and prevent short cycling, always select
the lowest firing rate satisfactory for the load
requirement.
The boiler is supplied either for connection to a
conventional chimney or comes complete with a
balanced flue system for direct venting through the
wall.
With the balanced flue system, air for
combustion is drawn from outside through a terminal
and ducted directly to the burner, making the boiler
virtually room sealed. Flue gases are discharged
through the same terminal so that wind pressures are
applied equally to inlet and outlet, making it a true
balanced flue system. A silencer is also incorporated
in the terminal to reduce the flue gas discharge noise.
This is a particularly useful feature if the terminal is
located near a bedroom window or adjacent to
neighboring properties.
The boiler is constructed with two concentric
water jackets, the inner one forming the furnace tube
and the outer the flue gas annulus. Flue gas retarders
fitted around the annulus are specifically designed to
extract the maximum heat from the gases with
minimum pressure loss.
Page 3
The simple annular design also makes it possible
to keep the water content to a minimum (only 3.2 gals.
[12L] for the MAX (DV) 75, 100, 120 and 5.1 gals.
[19L] for the MAX (DV) 140, 165). Because of this
low mass, water is rapidly heated to the temperature
demands. Another benefit of the low thermal mass is
the insignificant level of standby loss when the burner
shuts down.
To achieve the best possible heat transfer, the
boiler is designed on the “Series Flow” principle
whereby the return water is preheated by first passing
through the outer water annulus before coming into
contact with the furnace tube. This arrangement also
provides a counter flow of flue gases and water so that
the coolest gases come into contact with the coolest
water for the most efficient heat transfer.
Heavily insulated doors at front and back of
boiler, provide easy access for cleaning and
inspection, with the burner being swung on the front
door either left or right as required.
Accurate sensing of temperature and pressure is
assured by grouping all controls and safety devices on
a common supply manifold.
The use of the latest flame retention head burner
allows the boiler to operate under a slight positive
pressure which ensures stable combustion under
virtually all operating conditions.
MAX (DV) GPH Nozzle Pump Input AFUE Heating Water Shipping
Model Rate Size Pressure MBTH/hr Rating Capacity Content Weight
75 0.72 0.65 140 101 87.0 85,900 3.0 12 324 147
100 1.00 0.85 140 140 86.5 121,200 3.2 12 324 147
120 1.20 1.00 140 168 86.0 141,600 3.2 12 324 147
140 1.40 1.20 150 196 85.6 166,000 5.1 19 431 196
165 1.65 1.35 150 231 85.0 192,400 5.1 19 431 196
GPH P.S.I. % BTU/h gal. L lbs. kg
Table 1. Boiler Specifications.
Page 4
LAARS Heating Systems
(127mm)
Side Front
Figure 1. Boiler Dimensions (refer to Table 2).
Table 2. Boiler Dimensions.
MAX Oil-Fired Boiler
Page 5
Auto Air Vent
Honeywell L4006E High Limit Aquastat
(Manual Reset)
1¼" Supply
¾" Relief Valve
Honeywell L8148 Aquastat
Temperature / Pressure Gauge
1¼" Return
Flue Gas
Sampling Plug
Figure 2. Controls Layout.
SECTION 2.
Technical Specifications
2A. Boiler Outputs
Boiler constructed and hydrostatically tested in
accordance with ASME Boiler code Section IV.
Beckett / Carlin / Riello (model varies) Oil
Burner complete with flame retention head,
Honeywell control and cad. cell. or equivalent
(A post purge timer and oil solenoid valve is
fitted to direct vent burners)
Honeywell L8148A Aquastat Relay.
Honeywell L4006E High Limit Aquastat
(manual reset - direct vent boilers only)
Temperature and pressure gauge.
Pressure relief valve 3/4"
Automatic air vent
Air eliminator built into supply manifold
Boiler drain valve 1/2"
• 2500-004: 15-foot vent kit contains 15-feet of 5"
stainless steel pipe (for vent) and 15-feet of 4"
aluminum (for ducted air), with clamps, adapters,
heatshield and silicone.
•
2500-009: Direct vent terminal (Univent
terminal) to be used with either 10-foot or 15foot vent kits, for all MAX DV boiler sizes.
In addition, the following vent terminal extensions
can be used to bring the terminal above grade level to
meet code requirements:
•
2500-010: Vent terminal extension for 75, 100 and
120
•
2500-011: Vent terminal extension for 140 and 165
Balanced Flue System Kits
(direct vent boilers only)
For direct venting, vent pipe kits and vent
terminals are available.
•
2500-002: 10-foot vent kit contains 10-feet of 5"
stainless steel pipe (for vent) and 10-feet of 4"
aluminum (for ducted air), with clamps, adapters,
heatshield and silicone.
Page 6
LAARS Heating Systems
SECTION 3.
Installation
3A. Freight Claims
The boiler and it's components should be
inspected for damage upon arrival and any claim filed
immediately against the carrier by the consignee. The
carrier is responsible for taking prompt action on all
claims.
3B. Regulations
THE BOILER INSTALLATION MUST BE
CARRIED OUT BY A QUALIFIED INSTALLER
IN ACCORDANCE WITH THE REGULATIONS
OF AUTHORITIES HAVING JURISDICTION
AND CSA STANDARD B139 or ANSI / NFPA 31
Installation of Oil Burning Equipment - latest edition,
the
National Electrical Code ANSI / NFPA 70 - latest
edition and local codes and authorities having
jurisdiction. Such applicable requirements take
precedence over the general requirements contained
herein.
The installer must also be properly licensed and
experienced in all the codes and ordinances.
WARNING
In the interest of safety, gasoline or other flammable
fluids or vapors must not be stored or used in the
vicinity of the boiler.
3C. Sizing the System
Over sizing the boiler will cause short cycling
and reduce its operational efficiency, so it is
recommended that a building heat loss calculation is
made to ensure that the correct size boiler is used
(see Table 1).
3D. Location
The boiler should be mounted on a solid level
floor and located as close as possible to the chimney
or the position chosen for the direct vent terminal.
The boiler can be mounted on a combustible floor due
to its wet base construction, however, a check should
be made to ensure the floor is capable of supporting
the installed weight of the boiler including its water
content.
A closet may be used to enclose the boiler,
providing the enclosure is properly vented to ensure
the controls do not become overheated (see
Ventilation Air section). The boiler must also have the
correct amount of air available for combustion when
using a conventional chimney (see Combustion Air
section).
When installed,
necessary use metal shims under the base to level the
the boiler must be level. If
unit particularly front to back otherwise air could be
trapped inside the boiler.
3E. Clearance
Adequate clearance should be allowed around
the boiler for cleaning and servicing. The following
minimum clearances are recommended:
Front - 24" (610mm) (for hinging door)
Rear - 6" (152mm)
Sides - 6" (152mm)
Clearance from combustible materials should be in
accordance with local and national codes. Guidance is
given in the National Fire Protection Bulletin NFPA,
Installation of Oil Burning Equipment. All other
applicable codes should also be followed.
3F. Combustion Air
(other than direct vent)
WARNING
As an additional measure of safety, Laars strongly
recommends installation of suitable Carbon
Monoxide detectors in the vicinity of this appliance
and in any adjacent occupied spaces.
AVERTISSEMENT
Laars recommande fortement, comme mesure de
sécurité supplémentaire, l'installation de détecteurs
de monoxyde de carbone adaptés dans le voisinage
de l'appareil et dans chacune des pièces habitées
adjacentes.
Chimney Vent: For boilers installed in
basements, infiltration may be adequate to provide
combustion air. For buildings of exceptionally tight
construction, the boiler must be installed in an
unconfined space, or in an area which directly
communicates with an unconfined space. An
unconfined space is a space whose volume is 50 cubic
ft. (1.4m3) or more per 1,000 BTU (293kW) of the
aggregate input of all appliances in that space. Two
openings to the space, one 6" (152mm) from the floor
and one 6" (152mm) from the ceiling of the enclosure
must be provided. Each opening must have at least
168 square inches (1084 sq.cm) of free area.
Chimney Vent with outside air duct connected
directly to burner: In an installation of exceptionally
tight construction, intake air may be ducted directly to
the burner from the outdoors. On an AF2 burner
remove the black air intake shroud to connect the 4"
(102mm) aluminium duct (up to 15 equivalent ft.
[4.6m] maximum). Terminate the duct on the outside
of the building with a suitable protective cover. This
cover must be located at least 16" (406mm) above
grade or above an anticipated snow line.
MAX Oil-Fired Boiler
Page 7
On Carlin EZ-1 burners install model # 97406
combustion air intake system.
3G. Ventilation Air
(conventional chimney and
direct vent)
Where the boiler is installed in a basement there
is normally sufficient air infiltration to provide
adequate ventilation.
Where the boiler is installed in a closet or
otherwise confined space ventilation must be provided
to keep the controls from overheating. This is
accomplished by providing two openings to the space,
one 6" (152mm) from the floor and one 6" (152mm)
from the ceiling.
3H. Chimney Connection
Caution
An oil-fired unit shall be connected to a vent having
sufficient draft at all times to ensure sfe and proper
operation of the unit.
The chimney must be inspected and thoroughly
cleaned before connecting boiler. Most local codes
require the chimney to be lined when using an oil fired
boiler in order to protect the bricks and mortar from the
condensation produced by modern high efficient boilers.
The chimney must terminate at least 3 ft. (0.9m)
above the point where it passes through the roof and
be in a position free from down draft.
The boiler should be connected to the chimney
with the shortest possible run of 5 in. flue pipe and be
located above the chimney base to allow a drop leg for
scale accumulation to avoid blocking flue pipe
entrance.
Horizontal runs should be pitched up towards
chimney at approximately 1/4 inch per foot.
Install balanced damper on chimneys higher than
20 feet (6.1m).
Install "Blocked Vent Switch" provided in
accordance with attached instructions. Follow all
Warnings, Cautions and Maintenance Instructions for
safe, trouble free operation.
IMPORTANT: Max 75-140 may condense
when vented into an outside chimney. To minimize
potential for condensing, install either thermostatic
union or recirc bypass, shown in Figures 12 and 13.
As the boiler and flue pipe are under slight
positive pressure on start-up, it is necessary to seal all
pipe joints with high temperature tape or silicone
sealant to avoid any flue gas leakage into room.
5" diameter flue pipe secure both ends of
pipe with clamps and
seal with silicone
Oil Burner
Burner Intake Air
& Adaptor
Balanced Flue T erminal
10" max.
Flange Fix to Wall
Ð
Ï
6½"
Gas Flue Discharge
Air Intake Screen
4" pipe adapter
4" diameter air pipe - secure
both ends
with clamps
Figure 3. Direct Vent Balanced Flue System.
Page 8
³
Minimum 1.5
(0.5)
LAARS Heating Systems
3
³
4
(1.2)
(0.9)
³
³
7
(2.1)
Figure 4. Terminal Locations - Minimum Distances.
1
(0.3)
3I. Direct Vent Balanced Flue System
With this system flue gases are vented directly
through the wall and fresh air for combustion is drawn
in through the same terminal, thus ensuring wind
pressures are equal to the intake and flue gas
discharge to create a balanced flue condition.
The terminal also incorporates a silencer to
reduce the flue gas discharge noise and a specially
designed end cap which throws the flue gases clear of
the wall to avoid surface discoloration.
NOTE: If the burner is not correctly adjusted it
is possible that surface discoloration may occur. Laars
will not accept any responsibility for such
discoloration.
The position chosen for the Balanced Flue
Terminal must conform to the following guidelines:
1. The terminal shall not be less than 3 ft. (0.9m)
above or 10 ft. (3m) horizontally from any forced
air inlet into the building.
1.5
(0.5)
1
(0.3)
Gravity Air Inlet
1 (0.3)
4
(1.2)
3
(0.9)
Forced Air Inlet
Dimensions shown in feet (m).
2. The terminal shall not be less than 4 ft. (1.2m)
below, 4 ft. (1.2m) horizontally or 1 ft. (0.3m)
above any door, window, or gravity air inlet into
the building.
3. The terminal shall not be less than 3 ft. (0.9m)
from an inside corner of an L shaped building.
4. The terminal shall not be less than 7 ft. (2.1m)
above grade when located adjacent to public
walkways.
5. The terminal shall not be less than 2 ft. (0.6m)
from an adjacent building.
6. IMPORTANT: The terminal shall be located at
a height not liable to blockage from leaves, snow
or other debris,
at least one foot (0.3m) above
grade level.
7. The terminal shall be positioned so that flue gases
are not directed where they can jeopardize people,
overheat combustible structures, or enter buildings.
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