Page 1
--/*,
AUAIIABLEWTIH
RITT,|,O OR AERO
BURNIRS
Page 2
The
Efficient
qnd
Dependqble
Cqst
lrcn
Oil
Boiler
Molibu is more thon
"iusf
onother" compoct, cost
iron
oil boiler:
Molibu combines
the
bed ouolitv
feotures of exi$ino boilers in o
reosonobly
priced pockoqe.
And it
offers Slon/Fin[ super
heot
tronsfer section deiign wfi'ich
vinuolly
eliminotes soot-clogging ond
imoroves heot tronster.
In
size, oppeoronce ond
level-of-quietness, the Molibu
rivols
qor
fired
units,'mokinq
it ideol for instollotion in
ployroom
or
finisled
bosement. And siice it oerforms well even with o conventionol
burner, Molibu is the
perfect
boiler
for replocement work.
Molibu comes out of
the
crote
fully
pre-wired
ond reody for hook-
up.
lt feotures mony little iouches ihot simplify
the life
of
the
controctor ond servicemon.
All
quipmeni
isfront-mounted for
eosy instollotion, eosy service ond eosy occess
to tonkless heoter.
Outstqnding
Feotures:
Inoenious flue
possoqe
confisurotion
reduces overoqe droft los by ouer
ld%.youget
sufficie"nt
heot ironsfer euen
when
chi'iney conditions ore
poor
(reploceme-nt
iobs
or
when
house is enlorged|.
Molibu
performs
well euen wiih virtuolly ony conventionol
burner. Perfect for
new instolloilons or
replocement
work.
Burner tube
is lorge
enough
for
oll
stondord bronds ond models,
Feoiures oir-eliminotor cost
into front section, eliminoting
the need for
o
seporote device.
Enoineered
for
speedv
instollotion ond
mointenonce.
Corton
is
only
25"wide
--
iorr.r
througll normol doorwoys.
All models ore fully ossetbled ond
pre-
wired.
Burner'ri flonge-mounted to .nrrr.
proper positioning.
Designed for eosy
mointenonce. Burner, conhols, circulotor ond
tonkless
heoter
ore
locoted in front
for
eosy occess.
Decorotor
iockel
hos
\
interchongeoble side ponels
to simplify replocement
in'cose
of domoge.
\/
Choice of
Aero
burner,
or odvonced technology
Riello
bumer.
Relioble, high-
efficienry
Riello burners ensure o
minimum of",oll bo,kr ond reduce
"
moinienonce controct costs.
Page 3
RATINGS-MM SERIES
WITH AERO BURNERS
ModEl
Number Burner Cap. +
ml/s USGPH
Gross
Oulput
Watts BTUH
Hol Water
Chlmney
Size
Chimney
Helght
mm ft.
Boller
Water
Content
L U.S.
gals
Welght
of
'P'
Boiler
kg
lbs
Net
Oulput
WAttS BTUH
Net Rating
Water
m2 Sq.
ft.
Rectangular
mm
In.
Inside
Diameter
mm
in
MM-
85
MM-100
MM-120
MM-150
0.89
0.85
1.05 1.00
'1.26
1.20
1.58
1.50
30500 104,000
34000'116,000
41
000
139,000
52 000 178.000
26 500 90,400
29 600
100,900
35 400
120,900
45400 154,800
56.0
63.5
74.9
95.9
603
684
806
r0s2
2ogx203 8x8
203x203
8xB
203x203 8x8
203x20g
8xB
152
6
152 6
152
6
152 6
4600 15
4600
15
4600 15
4600
15
23.
2.
23.
23.
o.
o.
6.
o.
1A4
405
184
405
184
405
184
405
.AddsutfX,.P''|orpac|€gedwaterboi|er,orsUfiX..XP,,forpac|€gedMterbo
Nelntingstorba$bmrdndiatjonarebasdonapipingandpick-Upal|owanceof1'15(hottate0'S|af
For debils ot
nozle size and
pump pressure,
referto Bum€r
Manual.
'
Add suffx
"PT'
for
paclaged
water boiler wih
b
--Atcombustoncdditioio|1uo',ho/oco,.tTank|esSheabrratingsbasedoninhrmitbntdraw.chimney|ri0htforal|MSed6mde|S|sm
Ne,t
ratings for baseboard
for dehjls
of node size
and
pump
pressure,
refer
to Bumer
ilanual
Dimensions
12 mm
(112"1
TAPPING
FOR AIR VENT
12 mm
('ll2")&
19 mm
(3/4")
TANKLESS COIL
CONNECTIONS
ON
M SERIES ONLY
38
mm
(1-1/2")
SUPPLY-MM
SERIES
52
MM
i2')
SUPPLY_M
SERIES
OPTIONAL
EXTENDED JACKET
Equipment
PACKAGED
WATER
BOILER
(sutfix
P) includes
pre-
assembled
heat exchanger
with built-in
air eliminator,
combustion
chamber
and
base,
insulated
flush
iacket;
oil
burner
with
nozzle,
primary
relay and cadmium
sulfide
flame
detector;
draft
regulator; altitude,
pressure
and
temperature
oauqe;
pressure
ieliet valve
(ASME);
flue brush;
dual
iqudsrit
fiigh
limit/circulator
relay),32
mm
(1-1l4")
circulator*,
drain cock,
24
volt thermostat.
PACKAGED
WATER
BOILER
(sufiix
XP) Same as
P boiler
above,
but without
circulator
and
thermostat.
PACKAGED
WATER
BOILER
WITH
TANKLESS
HEATER
(suffix
PT)
includes all equipment
listed
for model
f
plus
tbnkbss
heater,3-way
combination
control
(high
limit,
circulator
relay
and
low limit
with adiustable
ditferential)
instead
of
2-way combination
control.
PACKAGED
WATER
BOILER
WITH
TANKLESS
HEATER
(sutfix
XPT)
Same as
PT boiler
above,
but without
circulator
and thermostat.
PACKAGED
STEAM
BOILER
(suffix
PZl includes
pre-
assembled
heat
exchanger,
combustion
chamber
and base,
insulated
flush
jacket;
oil burner
with
nozzle, cadmium
sulfide
flame detector,
primary
burner
convol, steam
pressure
limit control
with
siphon
pressure
gauge,
low water
cut-off,
water
level sight
glass
with
fittings, steam
pressure
relief
valve
(ASME),
drain
cock, draft
regulator, 24
volt
thermostat,
flue brush,
Steam
trim
packaged
separately
to
prevent
damage.
PACKAGED
STEAM
BOILER
WITH
TANKLESS
HEATER
(sufiix
PZT)
includes
all equipment
listed
for model
PZ'
plus
tankless
heater
and low
limit control.
OPTIONAL
EOUIPMENT
Extended
jacket
(covers
burner,
control
&
circulator),
two-stage
fuel
pump.
32
mm
(1-1l4")
/
RETUFN
\-,
L____SZ__
I l-.ul.li--
^
:l
|
'---
,
6------------------------'..---------l
l--432
mm
(17')
*l
I
r_--l
tDimensions
shown
are
for Aero burner"
SIDE
VIEW
'
Cartons
tor all models
are 635
mm
(25")
wide,
1067 mm
(42")
high.
STEAM
BOILER
DIMENSIONS
Front
view: Low water cut-off
extends
191 mm
(7-
1/2") beyond
left side
of flush
iackel.
sids
viewl
Reter to
"8"
above.
No
extended
iacket
available
for
sleam
models.
U
RATINGS-M
SERIES
WITH
AERO BURNERS
Model
Numbel Burner
Cap.
ml/s USGPH
Gross
Output
Watls BTUH
Hot
water
Steam
Chimney
Size
Tankless
Heater Cap.
1
Us
USGPN
'PZ'Boiler+
Water
Content
L
U.S.oals
Weighl
ol'PZ
Boll6r
kg
lbs.
Net
Output
Watts
BTUH
Net
Rating
Water
m2 Sq.
ft.
Net
Output
Watts BTUH
Net
Rating
Steam
m2 Sq.
tl
Rectangular
mm
in.
lnside
Diameter
mm tn.
M-100
M-120
M-150
1.00
1.20
1.50
1.05
1.26
1 .58
34000
116,000
39 000
132,000
48 000 165.000
29 600 100,900
33 600
1 14,800
42 100 143,500
62.5 673
71.1 765
88.9
957
25 500 87,000
29 000 99,000
36
300 123.800
33.7
363
38.4
413
48.0
516
2O3x2O3
8x8
203x203
8x8
203x203
8x8
178
7
178
7
178 7
0.19
3
0.22
3-112
0.25
4
21.6 5.7
21.6
5.7
25.4 6.7
152 335
168 370
191
420
.-
S
@
E
N
{
@
Boiler
Model
Flush Jacket
Deplh
mm
tn.
"B"
Depth Inc,
Burner
mm
tn.
"c"
Extend Jacket
Diametel
mm tn.
"D"
Flue Collal
Depth
+
mm
in-
Ovemll
Carton
mm in.
M-100
M-120
M-150
MM-85
MM-100
MM-120
MM-150
445
445
521
445
445
445
445
17'v2
17
112
201t2
17 1t2
17 112
17 112
17 112
711
711
747
2A
2A
31
28
2A
2A
28
71'l
711
711
711
476
876
953
876
476
476
876
341t2
341t2
37 112
34112
34't12
34'v2
34112
174
174
174
7
6
6
6
6
152
152
152
152
1016
1016
1016
't016
10t6
1016
101 6
40
40
40
40
40
40
40
Page 4
RATINGS-MM SERIES
WITH RIELLO
BURNERS
Model
Number Burner Cap.
+
ml,'s USGPH
Gross
' '
OulPut
Watts BTUH
Hol Water
Chimney Size
Chimney
Height
mm ft.
Boiler
Water
Contenl
L US
gals
Weighl
ol'P'
Boiler
kg lbs
Nel
Oulput
Watts
BTUH
Net Rating
Water
m?
sq.
tt
Rectangular
mm in.
lnside
Diameter
mm in.
MM-85
irM-100
Mt\,t-120
MM-150
MM.200
MM-250
MM-275
MM-300
0.89 0.85
1 .05 1.00
1 .31 1.25
1.58 1.50
2.10
2.OO
2.63 2.50
2.89 2.75
3.16 3.00
30 800 105,200
34
700 1 18,300
44
000
149,900
s2 800
179,900
70
800 241,500
66 900 296,200
94 600 322,700
103 900 354,300
27 000 91,500
30 200
102,900
38
200 130,300
45 900 156,400
61 600 210,000
75 500 257,600
82
200 280,600
90 300 308,100
56.7 610
63.7
686
80.7 869
96.9
1043
130.1 1400
1
59.5 1717
1 73.8 1871
190.8
2054
203 x 203
2O3
x2O3
203 x 305
203 x 305
203 x 305
203 x 305
203 x
305
203 x
305
8x
8x
8x
8x
8x
8x
8x
8x
2
152 6
152 6
178 7
203 I
203 I
203 8
203 8
203 8
4600 15
4600 15
4900 16
5200
17
5500 18
5500
18
5500 18
5500
18
23.1 6.
23.1 6.
23.1 6.
23.1 6.
26.9 7.
31.0 8.i
34.8 9.i
34.8 9.:
184 405
184 405
184 405
184 405
206
455
236 520
259 570
259 570
'Add
sufx
"P"
tor
packaged
Mter boiler,0rsufx
For
dehils 0f nOzle
size
and
pump pressure,
refert0
Eurner
lvlanual.
RATINGS-M
SERIES
WITH RIELLO
BURNERS
''AtcombUstioncond|tiono|121h!1hokco,'tTanklessheaterratingsbas€donint€rmitbmdmw
For
deuils ol
nozle
size
and
pump
pressure,
referto Bumer lvlanual.
Dimensions
12
mm 1112"\
TAPPING
FOR
AIR VENT
12 mm
(112")
&
'19
mm
(3/4")
TANKLESS
COIL
CONNECTIONS
ON M SERIES ONLY
32
mm
(l-1/4')
RETURN
NOTE:
It is recommendsd that
the draft rsgulator
bs
installed a minimum
of
457 mm ( 18") from
the boiler.
.-ffi
FRONT VIEW
'Dimensions
shown are
for Riello burner
Aero Dimensions i 267 mm
(1
0112"
\
'
Cartons
lor all models are 635 mm
(25")
wide, 1067 mm
(42")
high.
STEAM
EOILER DIMENSIONS
Front
view:
Low water cul'off exlends
191 mm
17
-
1/2")
beyond
lelt
side ot f lush
jacket.
Side view:
Fefer to
"B"
above.
No
extended
iacket
available lor steam models.
l*____
c
--------------------------*
SIDE
VIEW
Boilel
Model
Flush
Jackol
Depth
mm in.
"8"
Depth inc.
Eumer
mm tn.
"c"
Extend Jackel
Dlameter
mm tn.
"D"
Flue Collar
Depth +
mm tn.
Overall
Carton
mm
in
M.100
M.120
M-150
M-200
M-250
MM-85
MM-100
MM-120
MM-150
MM-200
MM-250
MM-275
MM-300
445
445
521
610
445
445
445
445
521
610
699
aoo
17 1tZ
17 1t2
201t2
24
27 1t2
17 1t2
17 1t2
17
1t2
17
'i2
m1t2
24
27 ilz
27 112
71t
28
71't
2o
787
31
876
341t2
965 38
711 I
711
28
711 28
711
28
787
3l
876
341t2
965 38
965 38
476
341t2
876 341t2
953 37 1t2
1054
41
112
1130
441t2
876 341t2
876 *1t2
876 34112
876
U1l2
953 37 1t2
1054 41 1t2
1 130
44
1t2
1 130
44112
178 7
17A ?
174 7
203 8
203
I
152 6
152
0
152
6
152
6
17A 7
203 I
203
I
203 8
1016
1016
1016
1 194
1
194
1016
1016
1016
1016
1016
1'194
1 194
1 194
40
q
47
47
40
4Q
40
40
N
47
47
47
Equipment
PACKAGED
WATER
BOILER
(sutfix
P) includes
pre-
assembled
heat exchanger
with built-in
air eliminator,
combustion
chamber
and base,
insulated flush
iacket;
oil
burner
with
nozzle,
primary
relay and cadmium
sulfide
flame
detector;
dratt
regulator; altitude,
pressure
and
temperature
gauge;
pressure
reliel
valve
(ASME);
flue brush; dual
aquastat
(high
limiVcirculator
relay),32 mm
(1"1/4")
circulator*,
drain cock,
24 volt thermostat.
{
,
PACKAGED WATER BOILER
(suffix
XP) Same
as
P boiler
\F'l
above, but
without circulator and thermostat.
PACKAGED
WATER BOILER WITH TANKLESS HEATER
(suttix
PT)
includes all equipment
listed for model
f
plus
tankless heater,3-way combination
control
(high
limit,
circulator
relay
and
low limit with adjustable difierential)
instead of
2-way
combination
control.
PACKAGED WATER
BOILER WITH TANKLESS HEATER
(sutfix
XPT) Same as PT boiler above, but
without
circulator
and thermostat.
PACKAGED
STEAM BOILER
(suffix
PZ) includes
pre-
assembled
heat exchanger,
combustion
chamber and base,
insulated
flush
jacket;
oil burner
with
nozzle, cadmium
sulfide
flame detector,
primary
burner control,
steam
pressure
limit control with siphon
pressure gauge,
low water
cut-off,
water level
sight
glass
with fittings, steam
pressure
relief valve
(ASME),
drain
cock, draft
regulator, 24
volt
thermostat,
flue brusJr. Steam
trim
packaged
separately
to
prevent
damage.
!
PACKAGED STEAM
BOILER
WITH TANKLESS HEATER
(sutfix
PZT) includes all equipment
listed for model PZ,
plus
tankless heater and
low limit control.
'
Excepton MM-250, MM-275, MM-30o
A thermic
three-way
mixing valve should be
installed
on all residential oil
installations.
Valves are
available
from
SlanUFin.
lE
T'*ANT,F, N
LTD,LTE
E,
*,*;'iffi
.,**
;;",ffi
)ffi
E N GI
N EE RED FOF EXCETTEA'CE
Model
Number
Burner Cap.
ml/s
USGPH
Gross
' '
Output
Watts BTUH
Hot Water Sleam
Chimney Size
Tankless
Healer Cap.
t
l/s
USGPM
'PZ'Boiler
+
Water
Content
L US
gals
Weight
ot'PZ'
Boiler
kg lbs.
Net
Output
WAttS BTUH
Net
Rating
Water
m,
Sq.
ft
Net
Output
WAttS BTUH
Net Rating
Sieam
m, Sq.
tl
Rectangular
mm in
Inside
Diameter
mm tn.
M-100
M-l20
M-150
M-200
M-250
1.00
1.20
'1.40
2,00
2.40
1.26
1 .47
2.10
2.52
34500
117,600
41
800
142,740
49
300
168,200
69 000 235,400
83 700 285,400
30 000
102,300
36400
124,100
42
900
146,300
60 000 204,700
72800 244,200
63.4
76.8
90.6
126.8
153.7
682
827
'1365
25 900 88,200
31 400 107,000
37000 126,200
51 800 176,600
62 800
214,100
34.2 368
41.4 446
48.9
526
68.4
736
82.9 492
203x203 8xg
203x203
Ex8
20gx20g 8xB
209x203 8x8
203x305 8x12
178 7
178
7
178
7
203 I
203 I
0.19 3
0.22 3-112
0.25
4
0.32 5
0.38 6
21.6
5.7
21.6 5.7
25.4 6.7
28.4 7.5
31.8 8.4
1s2 335
168
370
191 420
220
485
247 545
OPTIONAL
EXTENDED JACKET
Page 5
Page 6
IMPORTANT-REFER TO STANDARD CSA 81391976, INSTALLA'rION CODE FOR OIL BURNING
EQUIPMENT, FOR RECOMMENDED INSTALLA-
TION PRACTICE.
CONTENTS Page
Tapp~ngs and Openlngs
2
Ratlngs and Data
2
lnstallatlon lnstructlons
Locat ~on
3
Air
Supply
3
Chlmney
Requirements
and Dlmenslons
3
Electrical
Supply
3
Fuel
011
Supply
3
Flow Control Valve
3
Mlnlrnum Clearances
3
Aquastat Sett~ngs
3
Pressure Control Sett~ngs
3
Operat~ng lnstructlons
4
Cleanlng lnstruct~ons
4
Cleanlng and Fllllng New Water Boller
4
Steam Controls lnstallat~on
6
Cleanlng and Fllllng New Steam Bo~ler
6
Wlrlng Dlagrams
S Dlagram
8
P Dlagram
8
PT D~agram
9
PZ Dlagram
9
PZT Dlagram 10
Care and
Malntenance
Extended Shutdown 11
Provldlng Protect~on from Freez~ng 11
011
Burner 11
General
Maintenance
11
MALIBU SERIES, BOILER-BURNER UNIT
IS
APPROVED FOR USE WlTH FUEL OIL NOT
HEAVIER THAN No.
2
(FURNACE) OIL.
THlS SYSTEM MUST BE
INSTALLED IN ACCORDANCE
WlTH APPLICABLE LAWS,
REGULATIONS AND ORDINANCES
WHICH ALWAYS TAKE
PRECEDENCE OVER THESE
INSTRUCTIONS.
THlS MANUAL MUST BE
LEFT WlTH OWNER AND
SHOULD BE HUNG ON
OR ADJACENT TO THE
BOILER FOR REFERENCE.
Page 7
BOILER TAPPINGS AND OPENINGS
TOP VlEW
BACK
VlEW
(3)
2"
on M SERIES
1
lh"
on
MM
SERIES
-*o
op]
/
FRONT VlEW
(5)
I/?
"
(1)
1"
on steam boilers only
(7)
1
lh"
return
MM
SERIES
M
SERIES
Slwm
Tankkrr
..
--
- - -
-
(1) N/
A
1"
wash out tapplng
N/A
(2)
3/4"
relief valve tapping
3/4"
relief valve tapplng
3/4"
reliel valve tapping
(3)
1.1 /2"
supply tapping
2"
supply tapptng
2"
supply tapplng
(4)
1 /a"
air vent tapping
1 /a"
air vent tapping
1
/8"
alr vent tapping
(5)
1 /2"
pressure temp gauge tapping
1 /2"
low water cut off tapplng
112"
pressure temp gauge tapping
(6)
1 /2"
aquastat gauge tapping
1/2"
low water cut off tapping
1 /2"
aquastat gauge tapping
(7)
1-1/4"
return tapping
1-1 /4"
retum tapping
1-1 /4"
return tapping
(8)
1 /2"
tapping
LWCO
tapping
1 /2"
tapping
el
N/
A
112"
tankless heater tapping
1
/2"
tankless heater tapping
M
Serles
Ratings
Add
S~II
5
lor basmc oor~er w~tn burner sull\r P 10, Dm'haged water m,ler suttl.
PT
10, packaged eater bolter *,In Iankless neale, ruf4
.
p7
tor
Pachaged ,learn Dotter sufh.
Plr
lor pachagd steam holler w~tn ~anh~ess neater
+
Tanhless nearer olfngs based on ~nle<miIlenl arm*
Cn mney ne,ght tor a11 M Serves mode1.i 8s 4800 mm
i
I
5 11
I
Chtmnel l
D
3 178mm
17
1
lo! M IOO
M
120
and M 150 XUmm 18 1 lor
M
XC
a-il
U
2%
Oromm
I
B
R Oulpul
Walls BTUH
34000 116000
38000 l32OOO
48 OOO I65 000
64000 220000
81000 278000
MM
Series
Ratings
1
Ooilmr
. .
Rmctangular
.-
I
-
(rres Can Gals
i-
--
4600 15 IS
I5
'
Id
'6
21
17
21
6
18
32
7
I
18
32
7
!
_--I_-__j
Add sullja S tot Ddsoc molmr
wain
ot,rner sulla. P lor packaged *ale, Dote,
Net ol'ngl lor DdsebO.rd fmdlml~u" are based on a Dotng and ~i~h
UP
alloeance
01
1
15
in,,!
*aler
at30
'
1J3 tsteami Slant
Fin
Snouid be Lonsutle<r Delore
select~ng a m~ler lor onslallmtaon harfng unusual D,PI"Q and
pick
up
CeQu .ements
.
Lqnl
041
ll
COl
WI
I Il413aa ETu~gal
I
2
no1
watmr
n.1
1.0 R bulput
Wall8 BTun
29600 100900
33600 l14B00
42 I00 I43
500
56
100 191 300
7OBM) 241700
n.1 Rmllng
Walmr
rn2
Sp
11
625 673
71
I
765
88
9 957
1184 1275
1497
1611
Page 8
INSTALLATION INSTRUCTIONS
MALIBU OIL FIRED CAST IRON BOILER
MODELS
M-100 THROUGH M.250.
LOCATION: Mount the baler near tho ch~mney to keep the
flue
plpec js short as poss~ble. Bo~ler must be mounted
on a level
Il?ur,dat~on Install on non-combust~ble floor
only
3.
Remove obstructions.
4
Replace worn sections of metal stacks.
5.
Seal bad masonry jolnts.
6
Repa~r damaged linings
AIR SUPPLY:
C.
Where more than one appliance vents into a common chimney, the area of the common flue should
A.
Enclosed boiler room having normal tight
construe-
at least equal the area of the largest flue plus 50%
tlon requlres two unobstructed openings for passage
of the
add~tional flue areas.
of air into the boiler room.
D. Ch~mney height shall extend at least 3 feet above
1.
Air drawn vertically from outdoors; One openlng
on floor and one opening on ceiling each w~th a
where
~t
passes through the roof of a building, and
minimum
free air passage area of 1 square Inch
at least 2 feet above any r~dge within 10 feet of the
per
4000
Btuh of total system ~nput.
Ch~mney.
2.
Air drawn
horizontally
from outdoors through an
outslde wall; One louvred openlng near the floor
(below burner air ~nlet) and one louvred opening
near the ceiling (above the highest draft
regula
tor or draft hood rellef open~ngs), each opening
with a minimum free air passage area of 1
square inch per
2000
Btuh of total system input.
3.
Alr drawn from Inside the bu~ldlng; One opening
near the floor (below burner air inlet) and one
openlng near the
celling (above the highest draft
regulator or draft hood relief
open~ngs), each
openlng with a
mlnlmum free air passage area of
1 square inch per
1000 Btuh of total system
input
B.
If
boilers are installed adjacent to other fuel burning
equipment, the area of free openings must
be
appropriately increased to accommodate the addi.
tional load
E.
Vent connector
lnto chimney must be same size as
breeching outlet.
F.
Vent connector should be
Inserted into, but not
beyond
Inside of chimney liner.
Q.
CAUTION-UNIT SHALL BE CONNECTED TO A
FLUE HAVING SUFFICIENT DRAFT AT ALL TIMES,
TO ASSURE SAFE PROPER OPERATION OF THE
UNIT.
ELECTRICAL SUPPLY: Electrical
wlring and equ~pment
should be installed in accordance with CSA Standard
C22.1,
and Canadian
Electrical
Code, part 1 and any
local codes having
jur~sdiction
FUEL OIL SUPPLY:
011
piping should be a minimum of
tube A manual shut-off valve must be installed as
close as
posslble to the oil storage tank. An oil filter of
C. Unless properly controlled,
avo~d the use of forced
capaclty larger than the fir~ng rate of the burner should
ventilation, since it can create an undesirable pres-
be
Installed
011
plplng should be protected
:rcv
k~nk~ng
sure differentla1 between boiler room and air source.
or other damage
'For further details refer to C.G.A. Standard
B 149.1
Installation Code For Gas.
FLUE CONNECTION: Connect flue
p3pe between top of
the boiler and chimney.
Horizontal
sectlons of the flue
pipe must
be
pltched upward to the ch~mney at least
'/r"
per foot. The breech~ng should not exceed 10 ft. of how
zontal length The flue pipe should be cemented lnto the
thimble
uslng asbestos shorts
The
thlmble should be
flush with the
lns~de surface of the flue l~ner and the
flue pipe should not extend beyond
th~s polnt Install
the draft regulator
In the flue p~pe. as shown In the
separate
~nstructlons sheet lnslde the draft regulator
carton
CHIMNEY
REOUIREMENTS 6 DIMENSIONS: Refer to
data on page
2
of
this
manual
A.
A vitreous tile lined ch~mney of the slze shown on
Page
2
is recommended Local codes apply.
B.
Check ch~mney cond~tron
Exist~ng ch~mneys and stacks may have deter lorat.
ed; without repalrs the11 use would be hazardous
Before
connecting
to an oid ch~mney or stack
1 Clean
11
2.
Inspect
~t
thorodgh!y
If the oil tank
IS
~nstalled above or on level with the
burner, a one pipe
s~ngle stage o~l system may be used.
If the
011
tank
IS
~nslalled below the burner, a two pipe
s~ngle stage
011
system may have to be used. If the total
lift is more than
8
feet, a two plpe, two stage fuel system
must be used.
If
a boosler pump
IS
used care should be taken to see
that the pressure orr the
Inlet s~de of the burner fuel un~t
does not exceed 8 P S I
G
FLOW CONTROL VALVE: When domest~c hot water
tankless healer
IS
used a flow control valve should be
Installed In the supplv plplng as shown In the ~llustrat~on
MINIMUM CLEARANCES: Above
30"
Front
24"
Rear
18"
S~des
18"
Flue Plpe 18 inches
AOUASTAT SETTINGS:
Low
ltrnlt
should be set at least
20" below
Ihe
htgh llmlt sett~ng
PRESSURE CONTROL SETTING: Recommended h~gh
l1m11 sett~ng 1s
10
P
S I G
The h~gh l~m~t sett~ng should
never exceed
15
P
S
I
G
3
Page 9
THE INSTALLATlON SHALL BE IN ACCORDANCE
WITH THE REGULATIONS OF AUTHORITIES HAVINQ
JURISDICTION. REFERENCE IS MADE TO C.S.A.
STANDARD
B
139 - 1976 INSTALLATION CODE FOR
OIL BURNING EQUIPMENT, FOR RECOMMENDED
INSTALLATION PRACTICE.
OPERATING INSTRUCTIONS.
1.
Make sure boller and system are filled with water,
and all air is vented from the system. Steam boilers
should be filled to the normal water level before
firing.
2.
Depending
on burner model, remove plug or loosen
set screw in plug at bottom of oil pump, and bleed
air from oil supply
Ilne. (See separate instructions
furnished
w~th burner). Then tlghten plug.
3.
With burner
operating,
close burner air bands until
smoky flame is
obtained.
Then slowly open bands
until clean flame is produced.
4.
For maximum efflclency and freedom from soot,
combustion should be adjusted for
C02 of at least
10% with not more than No. 2 smoke.
5.
Insert draft gauge through observation door; adjust
draft regulator
untll
-
.01"
to - .02" W.C. is obtain.
ed
over fire.
8.
Recheck smoke spot and adjust if necessary.
IMPORTANT:
Overflre draft must be maintained at
-
.01" to .02" W.C. or performance will not be satisfactory.
To maintain rated output,
boller should be cleaned and
readjusted once a year, preferably in the fall.
NOZZLE REPLACEMENT: See burner instruction
book-
let, available from Dealer for proper type and size.
CLEANING INSTRUCTIONS: Remove jacket top cover.
Remove nuts
holdlng flue collector brackets. Lift flue
collector to expose flue passages. Insert brush between
row of pins at 80" angle, working from tip downward.
Repeat for each of the
flve channels between pins. To
cover complete surface of heat exchanger, repeat same
process in opposite direction. (See diagram).
CLEANING AND FILLING
A NEW WATER BOILER
1.
BEFORE FILLING WATER BOILER.
A. Check burner to be
certaln
~t
IS
ready for firing.
DO NO
FIRE Into an empty bo~ler
B.
Be prepared to heal raw water to at least 180°F.
as soon as
11
IS
Introduced Into the boiler. This
procedure
wlll remove
dissolved,
corrosive
gases.
C. Prov~de dra~rl Ilne, w~th valve, from boiler. Use a
bottom tapping.
L~ne and drain must be suitable
for handling caustic solution.
2.
CLEANING WATER BOILER SYSTEMt
A. Prepare a boll-out solution of SODIUM HYDROX-
IDE (caustic soda) or TRI-SODIUM PHOSPHATE.
NOTE. Use caution
In handling chemicals.
Caustlc soda
IS
harmful to skin,eyes,andclothing
1. Proportions: 1 Ib. of either chemical per
50
gallons of system water.
2. Stir chemical in water until dissovled, and
pour into the boiler through a top tapping.
Replace plug.
B.
Fill the entire system with water.
C. Start the burner,
uslng start-up procedure.
D.
Clrculate the water through the entire system
E. Vent the system, including the radiation
F. Allow boiler water to reach operating tempera-
ture,
if
possible
G.
Continue to circulate the water for a few hours.
H. Shut off the burner
I. With CAUTION,
draln the boiler solution to a
safe location.
DO NOT LEAVE SOLUTION IN
SYSTEM OVER 2 HOURS.
J.
Wash the water s~de of the boiler thoroughly
using a
hlgh pressure water stream. Fill and
drain the
boller several times.
3.
T
REATIN& WATER FOR CORROSION
CONT
ROLt
(This is not Scale Control)
A. Prepare a solution of SODIUM CHROMATE.
Proportions:
6
oz. per
50
gallons of system water.
B.
Stir chemical into water until dissovled, and pour
into the boiler through a top tapping. Replace
Plug.
4.
FlLLlNQ AND VENTING THE WATER BOILER.
A. Refill the system
w~th fresh water
B.
Bring water temperature to at least 180'F.
promptly
C.
Circulate water through entlre system
D. Vent the system,
~nclud~ng the rad~ation.
E. The boller is now ready to be put into service or
on standby
F.
If
brand-name airxontrol devices are used, vent.
ing instructions
furnoshed with the devices
should be followed.
t
Water content of boller 1s Ilsled on Page2; Table showing volume of water In standard plpe and tube is on Page
II
4
Page 10
WATER BOILER
BLEEDING
SCRNV
OIL
INLET
PRESSURE
ADJUSTMENT
SCREW
5
Page 11
STEAM CONTROLS INSTALLATION
INSTRUCTIONS
1.
Assemble above components exactly as shown in
the assembly drawing. Two
'ji
inch tappings are in
the front casting for this assembly. For convenience
holes are pre punched
In the jacket, start assembl-
ing in the following steps
. . .
Place the bottom sectlon of the water glass in the
low water cut off.
Uslng
'/2
x
2"
nipple.
Install above sub-assembly in lower tapping uslng
the fittings
provided.
See low water cut off sheet for final assembly.
Install steam siphon and Hlgh Pressure limit along
with pressure gauge as shown in the assembly
drawing.
CLEANING AND FILLING
A
NEW STEAM BOILER
1.
BEFORE FILLING STEAM BOILER.
A.
Check burner to be certain it is ready for firing.
DO NOT
FIRE into an empty boiler.
B. Be prepared to heat raw water to at least 180°F.
as soon as ~t is introduced into the boller. This
procedure will remove dissolved,
corrosive gases.
C. Provide drain line, with valve, from boiler. Use a
bottom tapplng. Line and drain must be suitable
for handling
caustlc solution.
2.
CLEAN STEAM BOILER SYSTEM.t
A. Fill the boiler to water line indicated on the boiler.
B. Follow start-up procedure for burner and operate
the boiler with steam
In the entire system for
2
or 3 days to bring oil and dirt fror,i the system to
the boiler. While system
1s in operation, maintain
the proper water level in the boiler by slowly
adding water to the boiler.
C. Shut down burner, cool down boiler, and drain
system.
D. SPECIAL NOTE REGARDING STEAM BOILERS:
To
slmpllfy cleanlng and blowdown procedures
on
Mallbu Steam Bollers, there is a 1" wash-
out
tapplng on the rear of the boiler. Sediment
should be flushed from the boiler on a regular
basls. uslng
this
tapplng
E.
Procedure to dissolve oil and grease in boiler:
1
Fill
boller to proper water Ilne.
2.
Prepare a boil-out solutlon of SODIUM HY.
DROXIDE (caustic soda) and TRI-SODIUM
PHOSPHATE:
NOTE:
Use caution in handling
chemicals.
Caustic soda is harmful to skin, eyes
and clothing.
a.1 Proportions: 1 Ib. of each chemical per
50
gallons of system water.
b.) Stir chemicals into water untll dissolved,
and pour into the boiler through a top
tapping. Replace plug.
3.
Start the burner; boil the water for at least
5
hours; shut off the burner.
F.
With CAUTION, drain the boller solution to a
safe location. DO NOT LEAVE SOLUTION IN
SYSTEM OVER
2
HOURS.
G.
Flush the boiler thoroughly.
3.
TREATING WATER FOR CORROSION CONTROLt
(This is not scale control).
A. Prepare a solution of SODIUM CHROMATE.
Proportions: 1 Ib. per
50
gallons of boiler water.
8.
Stir chemical in water until dissolved, and pour
into boiler through a top tapping. Replace plug.
4.
FILLING AND VENTING THE STEAM BOILER.
A. Refill the boiler to the indicated water
llna
B. Bring water to boiling temperature, promptly.
C. The boiler is now ready to
be
put into service or
on standby.
Water content of
boller 1s l~sted on Page
2,
Table showing volume of water in standard plpe and tube is on Page
11
6
Page 12
"M"
SERIES
STEAM
BOILER
PRESSURE RELIEF VALVE
7
/
__
.---___
-
OUTL-ET
PRESSURE GAUGE
-.-
n
/'
PRESSURETROL
STEAM
SIPHON
LOW WATER
-
CUT-OFF
INLET
WATER LEVEL GAUGE
DOMESTIC HOT WATER
TAPPINGS, PZT MODEL
WATER LEVEL
29'/2"
OFF FLOOR
PRIMARY CONTROL
ELECTRIC HOOK-UP
OIL BURNER
Page 13
I.
.
LIMIT CONTROL
-
1
CIRCULATOR WIRED THROUGH
L4062A SEPARATE FUSED DISCONNECT
I
LOW
FOR CONSTANT CIRCULATOR
LIMIT
c
LIMIT OPERATION
I
-
~1
CIRCULATOR
OPERATING
d
L2
CONTROL FUSE-D
DISCONNECT
BLACK
L1
WHITE
L2
JUNCTION BOX
LIMIT CONTROL
\
\
CIRCULATOR
FBI84
THERMOSTAT
(
REUY
\
BUCK
-
I
yx
BLACK
\
1
L1
WHITE
I
I
WHITE
L2
ORANGE
CAD CELL
FLAME DETECTOR
TRANSFSFMER
'P'
WIRING DIAGRAM
r---------
7
Page 14
'PZ WIRING DIAGRAM
1
L1
L2
12
w
k
BURNER
I
/"
MOTOR
3
WHITE
!
JUNCTION BOX
'PP WIRING DIAGRAM
C2 C1
I
P
Y
ok
2s
'
-\
CI'RCULATOR
W
Y
0
4
m
Page 15
LIMIT CONTROL LOW WATER
PAW CUT-OFF
0
LOW LIMIT
L4006A
0
..
24V.
THERMOSTAT
JLlNCTlON BOX
BUCK
7-
I
X
1
I
L1
q
m184
WHITE
I
I
RELAY
Y
I
L2
b
F
I
?
F
I
CAD
CELL
FLAME DETECTOR
TRANSFORMER
'PZP
WIRING DIAGRAM
---------
1
Page 16
CARE
AND MAINTENANCE
B BOILER CONTROLS check contacts, settlr:gs
correct
functioning
1.
DCTENDED SHUTDOWN, OR REMOVAL OF BOILER
FROM SERVICE
C. PIPING, Check plplng and
accessories
for leaks
A. Flush sludge from bottom of
bo~ler While the
D. CHIMNEY or STUB VENT and
BREECHING.
boiler is still hot
(180"
to
200°F.)
drain water
check for
obstruct~ons and leaks.
from the bottom of the boiler until it runs clear.
E.
COMBUSTION AIR TO BURNER: check for con-
B.
Provide corrosion protection to water (this is not
scale control):
1.
For steam boilers, maintain a SODIUM CHROMATE solution strength of
1
Ib. per
50
gallons
of water; and
ref111 to the top of the gauge
glass.
2.
For water boilers, ma~ntain a SODIUM CHROMATE
solut~on strength
of
6
oz. per
50
gallons
of water; and refill to normal fill-pressure with
system vented.
3.
Raise water temperature to at least
lSO°F.
for
one hour to release dissolved gases.
4.
Shut down burner by disconnecting the main
switch.
C. Clean
boller heatlng surfaces thoroughly, down
to clean metal.
1.
Remove top, flue collector and burner, to
facilitate cleaning soot and scale from heating surfaces. (a wire brush and vacuum
cleaner may be helpful).
2.
Protect fire side surfaces from corrosion by
swabbing with neutral mineral
011.
3.
Reseal top, flue collector (with furnace putty).
D.
If
boiler room
IS
damp, provlde ventilation
2
PROVIDING PROTECTION FROM FREEZING.
A.
Water should be drained from the system and
boiler, insofar as possible.
B. To any
remaining
water in system and boiler,
add sufficient
anti-freeze
solutlon to protect from
freez~ng.
C. Before again f~lllng system for boller operation,
all
antl.freeze must be flushed and drained from
the system
D.
The use of
anti-freeze
solutions in the system
water that
IS
circulated
through the boiler (d~rect
heating of ant~.freeze
solutions)
is
not sanct~on-
ed
by the ASME Low Pressure Boiler Code.
3.
OIL BURNER
Should be inspected and cleaned annually, and
following
any perlod of Improper operation Clean
between vanes of the blower. and clean drawer
assembly Recheck
cornbustlon, as outl~ned on
Page
4.
4.
GENERAL MAINTENANCE
These
operations
are recommended to be perform
ed at regular
intervals
tlnued POSITIVE supply of air as requlred Alr
needs are gredtest In cold weather, when lnlets
may have been closed, In
disregard
to thelr
Importance
F
WATER SYSTEM check
1.
System to be full of water, and pressure to remain stable (between
12
ps~ and
25
ps~)
2
Alr control system nolse and air blndlng In
rad~atlon should not occur
3
Water llnes
slightest
leaks should be cor-
rected
4
Low water cutoff, for operatlon (see ~nstructlons furnlshed wlth unlt)
G
STEAM SYSTEM check
1
Low water cutoff, for operatlon (see lnstruc
tlons furnlshed wtth unlt)
2
Any unusual water condltlons Obtaln water
analys~s, and treat water
H BOILER ROOM AIR SUPPLY air vents should be
open and free of
obstruct~on Also see Page3
Trble Showing Volume of Water In
Strndrrd Plpe and Tube
A. BOILER HEATING
SYRFACES: clean off all coat-
ings found. Reseal covers
11
SLANTIFIN LTDILTEE,
6450
Northam Dr., Mississauga.
On!.
i4V
1
h3
(4!6j
677-8400
No
i
inchesb~n FI / Inches Lln Ft
-;_____
-
1
I
-
I
-
1
-
0430 00075
40
1
06221 00157 05451 00121
-
I
-
0666 00181
40 0824 o 0277
1
o
785 00251
40
,
1
049 0 0449
40
1
380 0 0779
40
,
1610'0106
1
025 i 0 0429
1 265
1
0 0653
1505 00924
40
;
2067 1 0174 i 1985 0161
40 2 469 0 249
'
2 465 , 0 248
40
I
3ObA 0384 2945 0354
40 3548 0514
/
3425 10479
40 4026 0661 390510622
40
1
5 047 1 04
1
4 875 0 970
40
6 065
1
1 50
;
5 845 / 1 39
30 8071 266 7 725
/
2 43
30 110 136 4
19
9 625 ' 3 78
30
i1209Gi96
1
11 565 1 5 46
Page 17
BURNER
S,ERVICE
AND
INSTALLATION
MANUAL
Malibu
M
SERIES
MM
SERIES
These
burners are approved for
use with Group 1 or
2
Controls,
for burning fuel oil not heavier
than No.
2
(furnace) oil.
The
installation of a burner shall
be
in accordance with the regula
tions of authorities having jurisdiction. Reference is being made
to
C.S.A
Standard 8139 - 1976,
"Installation Code for Oil Burning
Equipment".
L
5iitEnLlMlTm
6450
Northam
Drive.
Mtsstssauga.
Ontario.
L4V
1H9
A
1416) 677-8400
b
PRINfED IN CANADA
EFFECTIVE OCT.
1993
OllR
AREA
CODE
BECMS
(905)
4
Page 18
BURNER DIMENSIONS
Page 19
1 - DESCRIPTION OF OIL BURNER
These
011
burners are normally llange mounted.
A rear hinged transformer is standard
eaulpment. By
removlng one screw on the front slde of the houslng.
the transformer may be swung up and the electrode
aasembly easlly removed through the openlng. High
tenslon leads are sprlng bus bars; no screw connection.
The
Junctlon
box
Is an Integral part of the burner
housing.
If
primary
control Is mounted on burner a 4' x 4'
fleld junctlon
box
is supplied mounted.
11
-
DESCRIPTION & REMOVAL OF ELECTRODE
ASSEMBLY
Remove screw
8. Fig.
3,
and rotate transformer on its
hinge. After opening the tubing
connection
at the side
of the blower
hous~ng, remove the clmp nut,
E,
and
dlsengage the oil-line. Remove the firing assembly by
rotatlng
it
'/a
turn in a clockwise dlrection and then
pulling It outward and upward. Refer to
Flg. II for firing
aasembly adjustments. To reinstall the flrlng assembly,
insert It with the bend of the tubing In the vertical plane
and rotate It
%
turn counterclockwise so the bend ce
incldes with the outlet in the housing. Make sure the
bus bars are
posltloned so that they will contact the
transformer terminal nuts when the transformer is in its
normal position.
MM
SERIES - WITH
AERO BURNER
MOTOR H.P.: (F-AFC)
'A:
R.P.M.
60
CY
1725,
MOTOR H.P.: (HF-AFC)
'/a:
R.P.M.
60
CY
3450.
Ful
PUfW
1725rpm
1725rpm
1725rpm
3450rpm
3450rpm
Fm
524-3 16
524-316
524-316
524-316
524-316
Fuel pump standard slnglestage. optional 2.stags
Stalk
DkC
3"
3"
3"
3%"
3%"
m
3"
3"
3"
3"
3"
Bdkr
Mo61
lor^
MI20
MlSO
M200
M250
Nozzle
%=-
3"
3"
3"
3"
3"
3"
3"
Bdk
Mo61
MM
85
MM120
MM150
MM200
MM2SO
MM275
MM300
S&m
1
.OO
1.20
1.50
2.00
2.50
Stalk
DhC
3"
3"
3"
3%"
3Ym"
3
11.
"
3%"
Burm
Mo61
FAFC2
FAFW
FAFW
HFAFW
HFAFC3
Ful
Pump
1725rpm
1725rpm
1725rpm
3450rpm
3450rpm
3450rpm
3450rpm
Fm
524-3 16
524-316
524-316
524-316
524.3 16
524-316
524.316
&nwc
Mo61
FAFC2
FAFC3
FAFW
HFAFC3
HFAFC3
HFAFW
HFAFC5
End
Con
AFC2
AFW
AFG4
AFG3
AFG3
ma
60.
60'
60.
60.
60.
bd
Gun
AFC2
AFC3
AFG4
AFC3
AFC3
AFG4
AFCS
TUP,
AR or
0
AR or
0
AR or
0
AR or
0
AR or
0
Node
fYP@
ARO~O~
I
ARO~O(
I
AR~~O(
AR
or
0
/
~~or~i
I
ARorQl
AR or
0
S&m
.85
1.20
1.50
2.00
2.50
2
75
3.00
ma
60'
60'
60.
60.
60.
60.
60.
Page 20
ELECTRODE
SrnNO
MODELS
FAFC AND HFAFC
Flg.
II
Ill
-
PROPER INSTALLATION OF BURNER
1.
TO INSTALL NOZZLE, see
II
-
Oescrlptlm
6
W
moval
of
Electrode Assembly. Remove the plastlc cover
on the
nozzle and Install the nonle. If
:t
Is necessary to
change the
nonle size, slmply Install a nonle of the
deslred slze - no adjustments need be made.
Check
to
sea that the electrods settlngs
are
comt.
(See
Flg.
11).
Reinstall
the electrode assembly. Tighten the clmp nut
and
also the flare nut. 'Rotate the trmsfomr to Its
orlglnal posltlon
and
tlghten the
subw.
Notc
Use
~~oper
nonle wrench.
2
After referring to the lnstructlons attached to the oll
pump. connect the oil Ilne(s) to the oll pump.
3.
Install the primary control and thermostat In clccord-
ance wlth instructlons supplied.
'Look at blast tube from front end and check
nozzle for
being In centre on end wne ogenlng.
If
It
Is not, adjust
knurled nut and lnslde nut on oll pips.
IV
-
CONTROLS AND WIRING
For spaciflc control wlring Instructions, refer to wlring
dlagrsm packed with the controls. All controls should
be
Installed
and
regulated In
eccordence
wlth the control
manufacturor's instructlons.
The wlrlng of the controls on the burner and the internal
wlrlng In the control panel have been completed and
tested st the factory and should not
be
altered except In
accordance with the control manufacturer's Instructlons
for regulating ignition, time and safety lockout.
Wlrlng at the bumer shall be done In approved 3-wlre
flexible condult or rlgld condult. All wlring except that
specifically
lndlcated for low voltage should
be
com-
pleted in accordance with the
Canadlan Electrical Code,
Part
I,
and local authorlties having jurisdicatlon.
All
wiring must conform to CaMdlan Standards
Associa
tlon, local, and Canadlan Electrical Codes.
Do
not, In
any
cme, use less than number
14
A.W.G. wire for line
voltage wiring. The burner should
be
wlred with lines
dlrectly from the power supply cabinet
and
not from any
lightlng circuil.
It
Is to
be
protected
by
a
15
ampere fuse.
Page 21
V - AIR SUPPLY
VII - ADJUSTMENT OF BURNER FOR
BEST EFFICIENCY
Boller should
be
provided with adequate fresh air for
combustion.
If
the furnace or boller Is Installed in a utility
toom or closet,
grilles
should
be
placed near the celllng
and the flwr to provlde ventilation as well as alr for
combuatlon. One square
Inch mlnlmum free area per
1,000 B.T.U. per hour input or
135
square Inches for
each gallon per hour Input are requlred In each
grllle.
Outdoor
connections
should
be
screened and provlded
wlth louvers.
VI
-
TEST
PROCEDURE
1.
The burner shall
be
operated and the fuel rate adjust-
ed to that requlred for the
partlcular installatlon.
2
Draft shall
be
adlusted to amount recommended.
3.
Combustion alr adjustments are to be made to glve
the hlghest C02. Set alr for smoke spot.
If
the mlnlmum
requlred percentage of C02 cannot
be
obtalned In the
breechlng, It will be permlsslble to take COZ over the
flre, which wlll be acceptable. A considerable
difference
between the two C02 readings Indicates a leak of air
Into the flue passes or flre box of the boiler.
4.
Stack temperature shall
be
recorded after 10 mlnutes
of operation.
1.
Set the room thermostat
10
degrees higher than the
temperature
on
the thermometer. Adjust the Iimlt COntrd
to
180
degrees.
See
that the manual reset button of the
integral thermal
overtoed switch on the oll burner motor
Is pushed In. Open ail valves and
oll Ilnes. Open the fire
door or observation door of the furnace or
boller. To
purge the alr from the oil line and
oll pump loosen the
plug In the gauge port of the pump (see oil pump
Instructlons). Close the burner swltch and allow the
burner to run untll there are no
air bubbles In the oll
issuing from the gauge port of the pump. Then tlghten
the plug in the pump.
2
To obtain best efficiency and performance, adjust the
draft regulator alternately wlth the bumer alr band ad-
justment untll a
10 to 12% C02 flue gas analysla Is
obtalned wlth
-.02" W.C. over-flre draft. To approach
thls C02 readlng, close the burner alr supply
adlustment untll a smoky flame Is obtalned, and then open It
only enough so that a clean flame is apparent
Immedl.
ately after the flredwr or observatlon dwr Is opened.
Use
Instruments
for proper adlustment of burner.
(Smoke anaylser
K
draft tester).
3.
Check the safety controls for proper operation
as
described in the control manufacturefs instructions.
4.
Be sure to leave the installatlon in a clean and tldy
condition.
5.
Advise the home owner how to start and stop the oll
burner.
6.
Return in two or three weeks and recheck burner
odiustment and operation. Repeat steps one through six.
Page 22
Vlll- CARE OF HEATING SYSTEMS, FLUE AND
CHIMNEY
HEATING SYSTEMS: Ditferent heating units present
different problems in care and cleaning.
Before install*
tlon and durlng tree sewlce period heatlng units should
be thoroughly checked for leakage and air seal.
FLUES: The flue passages should
be
thoroughly clean-
ed
and resealed to prevent heat loss and poor heat
absorption.
Wlre brushes wlth suitable handles and
vacuum cleaners make good cleaning tools.
me
tlue pipe should have no
obstructions
caused by
hand dampers or foreign matter.
CAUTION: Oil burning equipment shall
be
connected to
tlues havlng
sufficlent dratt at all times to assure safe
and proper
operatlon of the burner.
IX - INSTRUCTIONS FOR REMOVAL AND
REPLACING BURNER PARTS
MOTOR, FAN AND FLEXIBLE
COUPLING
(Refer
to
Flg.
Ill)
Loosen set screw
F.
Remove the two screws A1 and
A2.
The motor
may
now be removed from the housing, wlth
the fan and coupling attached to Its shaft.
TO
remove
the coupling, loosen set screw and pull rubber
coupllng
away from shalt. To remove the fan from the motor
shaft, loosen set screw C.
PUMP
Loosen screws
Dl
and D2. Open pipe and tubing con.
nectlons loosen set screw and remove pump.
TRANSFORMER
Remove screw
B and rotate transformer on its hlnge.
AIR
1
ADJUSTMENT
BAND
FIG.
Ill
Page 23
X
OIL
TANK
OIL GAUGE
-
FILL PIPE
FUEL TANK
TANK SLOPES DOWNWARD
LOOP
OIL LINES
'Anti-Syphon valve on installations with tank above burner level
'Check valve on installations with tank below burner
lwel
1.
The oil tank should
be
installed in accordance with
local regulations and those of the Canadian Standards
Assoclatlon.
Galvanized
tanks and piplng are not recom.
mended.
2
Gravity supply tanks located inside buildings shall
not exceed
250
gallons individual capacity, or
500
gal-
lons aggregate capacity (in one building). Inside tanks
larger than the above must
be
installed In an enclosure
or casing constructed of reinforced concrete at least
6"
thick, or of brick at least
8"
thick. bonded to the floor.
The space between the enclosure and the tank shall
be
completely filled with well-tamped earth or sand.
Instead of an enclosure. the tank may
be
encased In
reinforced concrete at least
6"
thick applied dtrectly to
the tank.
3.
Underground oil supply tanks should
be
located so
that the top of the tank is below the level of all piping to
which the tank is connected, so that oil cannot
be
dis-
charged through a broken pipe or connection by syphon.
Ing. The tank shall be buried so as to
be
covered by not
less than two feet of earth, or one foot of earth on top of
which is placed a slab of reinforced concrete not less
than
4
inches thlck. A well-tamped earth foundation
shall be provided beneath the concrete slab, which shall
extend at least one foot beyond the tank in all
directions. The tank shall be set on a lirm foundation and
sand shall
be
packed around
II.
When necessary. to
prevent floating.
11
shall be securely anchored or
weighted.
Page 24
4.
Proper allowance shall
be
made tor expanslon, con-
traction.
Jarr~ng and vlbratlon. Wlth the exceptlon of tlll
llnes and test wells, plpe llnes shall
be
provlded wlth
double
swlng joints, which wlll permlt the tank to settle
without
stralnlng the pipe :onnectlons. Tanks shall be
equipped with an open vent or an approved
automatlcal.
ly operated vent, whlch wlll permlt
discharge
to the
open
alr. Vent plpe and vent openlng shall be large
enough to prevent abnormal pressure In the tank
durlng
fllllng,
1
%"
plpe slze belng the mlnlmum. The vent er(d
flll
plpes should drain to the tank, and the lower end of
the vent plpe shall not
be
cross-connected wlth the
1111
plpe. The outer end of vent pipe shall be provlded wlth
a
weather-proof hood whlch should
be
hlgh enough above
the ground to prevent Its
belng obstructed wlth snow or
Ice. The vent plpe shall not
be
closer than two feet,
either vertically or
horlzontally, from any wlndow or
other bulldlng opening.
5.
The storage tank shall be fllled only through a 2"
flll
pipe termlnatlng outside of the
building,
no closer than
flve feet from any bulldlng opening at the same or lower
level. A
metal cover deslgned to prevent
tampering
sha!l
be provlded.
6.
Complete plplng of suction and return lines to and
from burner wlth
%"
or
'/a"
copper servlce pipe and
flttlngs for
same.
Lay plpe in 6 wlde by 12
deep
trench.
The suctlon plpe should not come closer than
3"
to
4"
from bottom of tank. None ot'the other plpes should
come lnslde of tank. A
speclal suctlon llne flttlng Is
used to let suctlon pipe through. Make a hole, large
enough to permit entry of both plpes, through wail
where plpes are to enter basement, 12 below ground.
The copper pipes should be
lald in one piece from tank
to burner, wlthout traps, being sure to leave a
sufflclent
coil of pipe Inside basement to reach to burner Install*
tlon. (CAUTION:
Be
sure to
flll
in around plpes wlth
cement to make basement wall
waterlight).
7.
All plping shall be approved copper tublng, at least
36''
0.0.
(Ya"
0.0.
copper tublng Is preferred) havlng
r
wall
thickness
not less than
0.049"
shall
be
used In
connectlng the burner to the tank. The plplag shall
be
protected from posslble Injury. and shall
be
rlgldly
fastened In place In a
workmanlike
manner. Where
practlcable, it should be burled underground, or In a
concrete floor, or placed In a metal-covered plpe trench.
Do
not cover the piping untll the burner has been InStalled and operated so that any leaks may be corrected.
Pipe joints and
connections
shall be made tight, and
unions and tubing fittings of an approved type only shall
be
used. Use only pipe thread compound resistant to oU.
A
filter shall
be
installed in the oil supply llne
to the burner.
To
detennine the proper fuel line size, refer to the fuel
unit instructions shipped wlth the oil burner.
XI
-
DRAFT
REGULATOR, SETTING
A draft regulator of approved deslgn Is recommended,
the
same
nomlnal slze
as
the flue plpe, and
an
ad)uetable
type to eecure the proper adjustment of flue gas. It
should
be
placed between chlrnney and stack control
(If
used) In a poeltlon such that the lnrushlng alr through
the draft regulator wlll not
cool the thermal element of
the stack control.
Adlust draft to 0.04-0.05 W.C. at the breech and 0.01-
0.02 W.C. over the flre or as lndlcated on the furnace
boller rat lng plate.
XI1 - CHIMNEY SIZE AND INSPEC11ON
1.
Startlng wlth mlnimum gallonage, the mlnlmum slze
recommended Is
7"
flue pipe wlth
8"
x
8"
lnslde chlm
ney.
2
A chlmney flue shall extend at least 3 feet above the
hlghest polnt at whlch the chlmney comes in contact
wlth the roof. and not less than 2 feet above the hlghest
roof surface or structure
wlthln 10 feet horlzontally of
the chlrnney.
3.
Any .ccumulatlon of soot or debris in chimney
offmet8 should
be
removed.
4.
Any obstructlons such u a protruding Joint or a
plece of broken tlle wedged In the chimney should be
removed.
b
No other apgllance connectlon should be made to
the same flue plpe.
8.
The flue pipe should have an upward pltch toward the
chlrnney of at least
'/a
Inch per foot of length. It should
flt tlghtly and should not project Into the chlrnney.
7.
Any leakage between tiles, around cleanout doors. or
around the vent plpe should be sealed.
8.
C.S.A. Listed shut-off valve shall be installed In the
oil supply line in an accessible location close to the
lank.
Page 25
6450
NORTHAM
DRIVE
MlSSlSSAUGA
ONTARIO
L4V
1H9
TELFPHONE
Iwji
677-8400
"A
Commitment to Excellence"
"DOvouO 9 I'Excellence"
Replacement Instructions
February,
1992
Malibu Combustion Chamber
FURNISHED:
1.
One plece fiber chamber.
2.
Chamber slde clips.
3
Front ~nsulation piece.
4.
Furnace cement.
5.
Base front burner mounting plate
(M-250
only).
PART NUMBERS
1
INSTRUCTIONS:
(Refer to sketches, Page
2)
BOILER SIZE
UU85
to
I50
U
100,120
UUZOO,
MI
50
UUZSO U200
UU275,300
A250
I
1
Turn off all switches to boller and burner Draln
system, or turn off valves and maintain system
water and drain boilers only
2 Remove smoke
plpe, flue cover and jacket Dls-
mount
011
burner and set aslde Cover against dirt
and damage
NOTE
Boiler flues should be clear+
ed down to base metal before
ref~rlng It may be
most convenient to do so now before the old
chamber
IS
removed
3
Remove nuts from the two hold-down bolts at front
of
baselcast~ng jolnt Loosen rear nuts
4.
Raise front of casting block approximately two ~r+
ches.
NOTE:
Use jacks or
2"
x
6"
props under
su~~lv and return main ~l~ina to ra!se boiler front.
5 Remove base front (burner
mountlng plate) Re
move old chamber and
~nsulation and discard Re
move
all chunks of old cement from cast,ng and
base top Clean out base
Inside
6
Sllde new chambe; Into posltlon, fully to the rear
and
bottomed-~n base Add front ~nsulatlon piece
an3
reinstall
base front plate (new plate on M-250)
7
Recheck blocks holdtng castlng In posltlon Guard
agalns:
accidents
Apply furnace cement to the
entlre top edge of the chamber and base top
flanges Apply
Itberally Insert s~de cllps on M-250
only (refer to sketches, Page 4) and press down
Apply more cement over top surface of
cllps
NOTE
Cl~p wlde flange must be ~ns~de of chamber
~e~ekdlng upon the prping and boiler placement,
8
Carefully lower castlng onto base Add front hold-
11
may be necessary to d~sconnect maln plptng
down nuts and t~ghten all four nuts, front and back
Make sure
castlng
IS
fully supported against move-
9
Remove all furnace cement squeezed out of joint,
ment Base cannot support castlng durlng cham-
~nslde and out Flll any voids ~n the jornt from out-
ber replacement
s~de JOlnt must be cornp~e~ely fllled with furnace
It
may be necessary to ~nsert a safety block across
cement
the front (see sketch, Page 4) to hold base front
down Block must allow
lnsert~on of cl~ps on M-250
only (see Paraaraoh
9
below)
FURNACE CEMENT
400131
400131
400131
400131
FRONT INSUL.
400053
400053
400053
400055
CHAMBER
400026
400027
400021r
400029
INSTALL INSTR.
401129
401 129
401 129
401 129
SIDE CLIPS
401183
401 16r4
401 145
401 186
Page 26
10.
Inspect chamber through burner opening. Cham
ber must be undamaged; clips must be in place. All
excess cement must be removed.
11.
Reinstall burner, flue cover and smoke pipe Use
furnace cement to seal all flue joints. Reinstall
jacket. Refill system with water.
12.
Fire the boiler.
immediately
adjust burner air and
draft regulator to get
overfire draft
of
-.01
to
-.02
with 0 to
#I
smoke with smoke tester. The
chamber must be cured for at least one hour of
firing, during which organic binders in the
chamber produce slightly
higher than normal
stack temperature and smoke. After curing.
reset for normal service as
outl~ned in Malibu in
stallation manual.
NOTE
The ins~de flange of the steel s~de cl~ps w~ll,
after
many hours of
firing,
become brittle and warped
and
WIII
gradually ox~d~ze and d~sappear Thls
IS
nor-
mal They are no longer required
RAISE
CASTING FRONT AND INSERT CLIPS.
See instructions for clean~ng, installing chamber, adding furnace cement.
L
OOSE
N
HOLD-DOWN
NUTS
RAISETASTING
FRONT
/
EL:"',:,
FRONT
ADD
SAFETY
CHOCK
NUTS.
REMOVE
FRONT
PLATE
-
REMOVE
OLD
CHAMBER
ADD
NEW
CHAMBER.
FRONT
INSULATION, AND
FRONT
PLATE
INSERT
CLIPS
BOTH
SIDES
CLIP
DEEP
FLANGE
INSIDE
CHAMBER
SIDE
FRONT
TOP
VIEW
LOWER
CASTING
CHECK
JOINT,
CLEAN
INSIDE,
AND
ADD
CEMENT
AS
NEEDED
TIGHTEN
HOLD-DOWN
NUTS.
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