State GPO 69-700 Service Manual
MODELS GPO 86-199 THRU GPO 69-700(A)
COMMERCIAL OIL FIRED WATER HEATER FOR HOT WATER SUPPLY
• Installation • Operation • Service • Maintenance
TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION
CAUTION
RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE
USING APPLIANCE.
500 Tennessee Waltz Parkway
Ashland City, TN 37015
www.statewaterheaters.com
Phone: 1.800.821.2017 • Fax: 1.800.433.2515
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND
PRINTED 1112 195092-003
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
1
FEATURES AND SPECIFICATIONS
TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION
RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE
USING APPLIANCE.
This is a typical oil-red heater for commercial water heating applications.
The principal components of the heater are shown and identied here.
The identication plate illustrations on page 3 interpret certain markings
into useful information. Use these references to identify the heater and
its components
FIGURE 1.
TABLE 1. NOMINAL MODEL DIMENSIONS
Model
GPO 86-199 GPO 86-245 GPO 84-315(A) GPO 75-385(A) GPO 75-455(A) GPO 69-700(A)
Dim. Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm
A 74 1/2 1,892 74 1/2 1,892 74 1/2 1,892 73 3/4 1,873 73 3/4 1,873 73 3/4 1,873
B 36 3/4 933 36 3/4 933 36 3/4 933 36 3/4 933 36 3/4 933 36 3/4 933
C 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705 27 3/4 705
D 2 51 2 51 2 51 2 51 2 51 2 51
E 3/4 NPT 3/4 NPT 3/4 NPT 3/4 NPT 3/4 NPT 3/4 NPT
F 8 203 8 203 8 203 8 203 8 203 10 254
G 26 5/8 676 26 5/8 676 26 5/8 676 24 3/4 629 24 3/4 629 30 3/16 767
H 74 1/2 1,892 74 1/2 1,892 74 1/2 1,892 73 3/4 1,873 73 3/4 1,873 79 3/16 2,011
J 1 1/2 NPT 1 1/2 NPT 1 1/2 NPT 1 1/2 NPT 1 1/2 NPT 1 1/2 NPT
K 1 1/2 NPT 1 1/2 NPT 1 1/2 NPT 1 1/2 NPT 1 1/2 NPT 1 1/2 NPT
L 22 3/4 578 22 3/4 578 22 3/4 578 23 7/16 595 23 7/16 595 28 7/8 733
Approx.
Shipping 553 251 554 252 554 252 624 283 700 318 739 335
Weight STD. Lbs Kg. Lbs. Kg. Lbs. Kg. Lbs. Kg. Lbs. Kg. Lbs. Kg.
Approx.
Shipping 657 298 742 337 747 339 822 373
Weight ASME --- --- --- --- Lbs. Kg. Lbs. Kg. Lbs. Kg. Lbs. Kg.
ALL DIMENSIONS IN INCHES/mm
*Model numbers followed by the sufx "A" indicates the optional A.S.M.E. tank construction.
TANK APPROX U.S Gallons/Hr. and Litres/Hr at TEMPERATURE RISE INDICATED
CAPACITY EFF. F° 40F° 50F° 60F° 70F° 80F° 90F° 100F° 110F° 120F° 130F° 140F°
Model Btuh KW U.S.Gal. Litres % C° 22.2C° 27.7C° 33.3C° 38.8C° 44.4C° 50C° 55.5C° 61.1C° 66.6C° 72.2C° 77.7C°
GPO 199,000 86 80 GPH 477 381 318 272 238 212 191 173 159 147 136
86-199 58 326 LPH 1804 1443 1203 1031 902 802 722 656 601 555 516
GPO 245,000 86 80 GPH 587 469 391 335 293 261 235 213 196 181 168
86-245 72 326 LPH 2221 1777 1481 1269 1111 987 889 808 740 683 635
GPO 315,000 84 80 GPH 754 604 503 431 377 335 302 274 251 232 216
84-315(A) 92 318 LPH 2856 2285 1904 1632 1428 1269 1142 1039 952 879 816
GPO 385,000 75 80 GPH 922 738 615 527 461 410 369 335 307 284 263
75-385(A) 113 284 LPH 3491 2793 2327 1995 1745 1551 1396 1269 1164 1074 997
GPO 455,000 75 80 GPH 1090 872 727 623 545 484 436 396 363 335 311
75-455(A) 133 284 LPH 4125 3300 2750 2357 2063 1833 1650 1500 1375 1269 1179
GPO 700,000 69 80 GPH 1677 1341 1118 958 838 745 671 610 559 516 479
69-700(A) 205 261 LPH 6347 5077 4231 3627 3173 2821 2539 2308 2116 1953 1813
* All tanks are tested at 320 psig working pressure.
** Based on No. 2 fuel oil with a heat content of 140,000 Btu's per gallon at 80% thermal efciency. Above 2,000 altitude, input
ratings should be reduced 4% for each 1000' above sea level.
TABLE 2. RECOVERY CAPACITIES, based on 80% efciency
2
TABLE OF CONTENTS
FEATURES AND SPECIFICATIONS ....................................................2
APPROVALS .........................................................................................3
IDENTIFICATION
Oil and Burner Nameplate Decal ................................................3
Oil Burner Specications .............................................................4
SAFETY .................................................................................................4
INSTALLATION
Required Ability ...........................................................................4
General .......................................................................................4
Uncrating .....................................................................................4
Leveling .......................................................................................4
Location.......................................................................................4-5
Clearances ..................................................................................5
Combustion and Ventilation Air ...................................................5
Chemical Vapor Corrosion ..........................................................5-6
Flue Gas Venting.........................................................................6
Vent Connector and Draft Regulator ...........................................6
Water Piping ................................................................................7
Closed Water System .................................................................7
Drain Valve and Access Panels ..................................................7
Fuel Systems ..............................................................................7-8
Burner Installation .......................................................................8-9
Fuel Pump ...................................................................................9
Wiring Diagrams..........................................................................9
OPERATION
General .......................................................................................9
Filling ...........................................................................................9
Start Up .......................................................................................9
Water Temperature Control ......................................................... 10
APPROVALS
The burner and controls are listed by Underwriters' Laboratories Inc.
Accordingly, the burner bears one of the UL labels indicating periodic
inspection of the production of this equipment.
All ASME tanks are built to the standards of Section IV of the American
Society of Mechanical Engineers code and are stamped with their symbol.
The National Board of Boiler and Pressure Vessel Inspectors papers are
furnished upon request. The NB number and HLW symbol (to the right)
are on the plate located just below cleanout on tank. (May be viewed by
removing cleanout cover on jacket).
High Limit Switch E.C.O. .............................................................10
Burner Certicate (Combustion Test) ..........................................10
Self-Cleaning Hydro-Cannon ......................................................10
Draining .......................................................................................11
MAINTENANCE
General .......................................................................................11
Relief Valves ...............................................................................11
Flushing.......................................................................................11
Sediment Removal ......................................................................11
Lime Scale Removal ...................................................................11-12
Circulating Pump .........................................................................13
Soot Removal..............................................................................13
Vent System ................................................................................13
Anode Rod Inspection .................................................................13
INSTALLATION DIAGRAMS ................................................................14-19
CHECKLIST AND SERVICE INFORMATION
Electrical Wiring Replacement ....................................................19
Not Enough or No Hot Water ......................................................19-20
Burner Starts - Won't Operate .....................................................20
Water Too Hot .............................................................................20
Water Heater Makes Sounds ......................................................20
Water Leakage is Suspected ......................................................20
Burner Won't Start .......................................................................20
Burner Starts But Fails To Run ....................................................20
Normal Start, But Locks Out On Safety ......................................21
Safety Primary Control ................................................................21
COMBUSTION TEST SPECIFICATIONS .............................................21
TROUBLESHOOTING ..........................................................................22
REPLACEMENT PARTS LIST ..............................................................23-24
IDENTIFICATION
The heater and burner rating plates or labels provide valuable information.
When ordering parts or inquiring about a unit, be sure to include all
information from the plates. See the picture on page 2 for approximate
location of the heater rating plate.
The heater model number is structured as follows:
OIL BURNER NAMEPLATE DECAL
The oil burner's nameplate decal (see page 2 for the approximate location
on the burner) contains a burner KBTU/H input which should exactly match
the model input appearing on the rst line of the heater's rating plate. The
oil burner series 940 or 941 indicates the burner equipped w/single or two
stage pump respectively, should match letter "O" or "T" of the heater model.
If these codes do not match, the oil burner may not be the correct model
for the heater model purchased, Contact your State dealer for further
information and replacement , if required.
A TYPICAL OIL BURNER NAMEPLATE DECAL
FIGURE 2.
3
OIL BURNER SPECIFICATIONS
The oil burner nameplate decal includes a series code which identies the
major features of the oil burner. The series number is the last three digits
of the burner code number.
Table 3 below describes the oil burner characteristics for each series
number. The burners are to be used with fuel oil not heavier than No. 2.
TABLE 3. SOME NOTABLE OIL BURNER FEATURES
R.W. Suntec Nozzle Type
State Becket Safety Oil Pump Oil
Burner Burner Timing Type Pump
Series Model + Mode Spray Spray
Number* Number Pattern Angle
A2VA
AFG 7118 Type B
940 15 Sec. Single - Solid 80°
SF Stage A2YA- Cone
B2VA
8216 Type B
941 AFG 15 Sec. Two- - Solid 80°
SF 15 Sec. Stage BY2A Cone
8916
* To provide the proper ring rate for each model heater, see SPECIFICATIONS:
there are burner models for each heater model in table 2. The Burner and heater
model numbers must match and the heater (or the burner) series number should
indicate the features specied for the installation.
+ All oil burners are UL dened as having "interrupted ignition" . . . meaning the
ignition is on during the ame establishing period only. Ignition is off when the
burner is off. Standard safety timing is 15 seconds.
7916
For installations where gravity feed of fuel oil from the storage tank to the
heater is practical, an oil burner with a single-stage oil pump can be used.
The 940 series of burners have single-stage pumps which are shipped
for installation of a supply line to the tank only. A return line back to the
storage tank can be installed, if required, by making a small modication
to the pump, see the oil burner installation manual.
For installations where gravity feed cannot be employed, (the storage tank
is located signicantly below, or remote from, the heater) an oil burner
with a two-stage oil pump should be used. The 941 series of burners have
two-stage pumps which are shipped for installation of a supply and return
line to the tank. However, in situations where the return line is not required
(low lift installations), the pump may be modied to operate without the
line, see the oil burner installation manual.
IMPORTANT
The oil-red water heater shipment consists of two packages, heater and
oil burner. Check to be certain the model number on the heater and oil
burner packages match. To assure matching equipment, see preceding
information.
GPO 86 GPO86 GPO 84 GPO 75 GPO 75 GPO 69
Model Heater 199 245 315/315A 385/385A 455/455A 700/700/A
Min. State
Firing Burner 1.42 1.75 2.25 2.75 3.25 5.0
Rate
In Non
GPH State 1.1 1.5 2.0 2.5 3.0 4.5
Burner
SAFETY
DANGER
BE SURE TO TURN OFF POWER WHEN WORKING ON OR NEAR THE
ELECTRICAL SYSTEM OF THE HEATER. NEVER TOUCH ELECTRICAL
COMPONENTS WITH WET HANDS OR WHEN STANDING IN WATER.
WHEN REPLACING FUSES ALWAYS USE THE CORRECT SIZE FUSE
FOR CIRCUIT.
If it is necessary to reset the safety primary control, depress red button
one time only. If burner does not operate after depressing red button
one time, call service agent.
INSTALLATION
REQUIRED ABILITY
INSTALLATION OF SERVICE OF THIS WATER HEATER REQUIRES
ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE
FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, OIL BURNER
AND ELECTRICAL WORK REQUIRED.
GENERAL
The installer should be guided by these instructions, local codes and the
following publications.
• Standard for the Installation of Oil Burning Equipment, NFPA
Standard No. 31, Available from National Fire Protection
Association, Batterymarch Park, MA 02269.
• Code for the Installation of Heat Producing Appliances,
Available from American Insurance Association, 85 John Street,
New York, NY 10038.
• The National Electrical Code, NFPA No. 70. Availability same as
NFPA Standard No. 31.
• In Canada - CAN/CSA-B139, Installation Code for Oil Burning
Equipment.
Do not test the burner or control system before the heater is lled with
water. Follow the START-UP procedure in this manual.
UNCRATING
Uncrate the heater by removing the outside mat and top locator. The
shipping pallet must be removed from the unit. It may be possible to
simply unbolt the base from the pallet and, with the help of two or more
persons, work the unit off the pallet. Some units will be too heavy and
wil l re q u i r e the use of jac k s or li f t i n g eq u i p m ent. S a f e l y re m ove th e pa l l e t
and move the unit into position. Be Careful When Moving This Heater.
It will tip over easily.
LEVELLING
Install the heater plumb to the ground. If it is necessary to adjust the
heater, use metal shims under the channel type skid base.
LOCATION
The water heater should not be installed where the combustion air is
contaminated, see COMBUSTION AND VENTILATING AIR. Temperature
in the location must be above 32°F (0°C) and free of combustible dusts
and ammable gases or vapors.
For the best installations, the water heater should be located:
1. On a level surface.
• Shim the channel type skid base as necessary If leveling is
required.
2. Near a oor drain.
• The heater should be located in an area where leakage of the tank
or connections will not result in damage to the area adjacent to the
heater or to lower oors of the structure.
• When such locations cannot be avoided, a suitable drain pan
should be installed under the heater.
• The pan should be at least two inches deep, have a minimum
length and width of at least two inches greater than the diameter
of the heater and should be piped to an adequate drain. The pan
must not restrict combustion air ow.
• The discharge opening of the relief valve should always be
piped to an open drain.
• Choose the point of major hot water usage, fuel supply and chimney.
4
• Try to make hot water and oil piping as short as possible.
• Insulate hot and cold water piping where heat loss and
condensation may be a problem.
CLEARANCES
The heater has minimum clearances to combustible material, on a noncombustible oor of: 6 inches (152 mm) from the sides and rear, 24
inches (610 mm) from the front, and 18 inches (457 mm) from the vent
connector. These clearances are, as shown in g. 3A to prevent possible
re hazard conditions.
At least 24" (610 mm) of top clearances are recommended for vertical
vent installation.
Allow sufcient room at rear of heater for servicing of T&P relief valve.
At least 24" (610 mm) should be provided at the front of the unit for
proper servicing.
Units which are to be installed on combustible ooring must be supported
by a full layer of hollow concrete blocks, g. 3, from 8" (203 mm) to
12" (305 mm) thick and extending 12" (305 mm) minimum beyond the
heater in all directions. The concrete blocks must provide an unbroken
concrete surface under the heater, with the hollows running continuous
and horizontally. A 3/16" (4.8 mm) steel plate must cover the concrete
blocks, see Fig. 3.
CHEMICAL VAPOR CORROSION
Water heater corrosion and component failure can be caused by
the heating and breakdown of airborne chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioning refrigerants,
swimming pool chemicals, calcium and sodium chlorides, waxes, and
process chemicals are typical compounds which are potentially corrosive.
These materials are corrosive at very low concentration levels with little
or no odor to reveal their presence.
Products of this sort should not be stored near the heater. Also, air which
is brought in contact with the water heater should not contain any of these
chemicals. If necessary, uncontaminated air should be obtained from
remote or outside sources.
UNCONFINED SPACES (Building Construction)
NOTE: An unconned space is dened as a space whose volume is not
less than 50 ft
all fuel burning appliances installed in that space. The unconned
space may be thought of as extending to all areas which cannot
be separated by a door or door(s). All other spaces not tting this
description, should be thought of as conned space.
1. In unconned spaces in buildings of conventional frame, brick or
stone construction, inltration will normally supply an adequate
amount of air for combustion and ventilation.
2. If the unconned space is within a building of tight construction, eg.
weather stripping, heavy insulation, caulking, vapor barrier, ect.,
air inltration may be insufcient to support proper combustion and
ventilation, air shall be obtained from outdoors or from spaces freely
communicating with the outdoors.
3
per 1000 BTUH (4.83m3 per kW) of total input of
PROPER INSTALLATION ON COMBUSTIBLE FLOORING
FIGURE 3.
NOTE: If electrical conduits run under the oor of the proposed heater
location, insulate the oor as recommended above.
PROPER INSTALLATION CLEARANCES FOR TWO DIFFERENT
VENTING SYSTEMS
FIGURE 3A.
* HOT WATER OUTLET LOCATION AT FRONT OF HEATER
• FACTORY FURNISHED HEATER MANIFOLD KITS (OPTIONAL)
ARE DESIGNED FOR 10" (254 mm) SPACING BETWEEN SIDES
OF ADJACENT UNITS.
COMBUSTION AND VENTILATION AIR
GENERAL
The water heater area should have sufcient air for satisfactory combustion
of oil, and proper venting and of safe ambient temperature.
When a heater is installed in an area where exhaust or ventilating fans may
create unsatisfactory combustion or venting, approved provisions must be
made to overcome the problem, see NFPA Standard No. 31, Chapter 1.
• Follow instructions under Part 2 of Confined Spaces (Room
Construction)
CONFINED SPACES (Room Construction)
1. All air from inside building (conventionally constructed buildings only):
The conned space shall be provided with two permanent openings,
one within 12" (305 mm) of the ceiling and one within 12" (305 mm) of
the oor, g. 4.
FIGURE 4.
• Each opening shall have a free area of not less than one square
inch per 1,000 Btu per hour (140 square inches per gallon of oil
consumed per hour) of the total input rating of all appliances in the
enclosure, freely communicating with the interior areas having in
turn adequate inltration from the outside. In all cases, each opening
shall not have a free area of less than 100 square inches.
2. All Air From Outdoors: The conned space shall be provided with two
permanent openings, one in or within 12" of the top of the enclosure
and one in or within 12" of the bottom. The openings shall communicate
directly, or by means of ducts, with outdoors or such spaces that freely
communicate with outdoors.
• If the appliance room is located against an outside wall and the air
openings communicate directly with the outdoors, each opening
shall have a free area of not less than one square inch per 4,000
Btu per hour (35 square inches per gallon of oil consumed per hour)
of the total input rating of all appliances in the enclosure.
5
• When communicating with outdoors by means of vertical ducts, each
opening shall have a free area of not less than one square inch per
4,000 Btu per hour (551 mm
2
/kW) (35 square inches per gallon of oil
consumed per hour) of total input rating of all appliances in the enclosure.
• If horizontal ducts are used, each opening shall have a free
area of not less than one square inch per 2,000 Btu per hour
(1,101 mm
2
/kW) (70 square inches per gallon of oil consumed per
hour) of total input of all appliances in the enclosure, g. 5.
FIGURE 5.
FLUE GAS VENTING
In the absence of any local codes, regulations, or vent pipe or chimney
manufacturer's recommendations, for oil red equipment, follow the
suggestions below for designing and installing a venting system.
For these water heaters, it is recommended that an adequate chimney be
used for venting the ue gases. Type B, double wall, vent pipe should be
used as the vent connector pipe. However, where no chimney is available,
vent pipe may be used to construct a vent.
Where an existing chimney or vent is to be used, be sure that the chimney
or vent has adequate capacity for the number and sizes of appliances
being vented through it. Inspect the chimney or vent and remove all soot
or other obstructions which will retard free draft.
VENT CONNECTOR AND DRAFT REGULATOR
The chimney or vent connector diameter should be the same size as the
heater ue outlet, see Table 4. A minimum rise of 1/4" per foot (21mm/M)
of horizontal connector length must be maintained between the heater
and chimney opening, g. 6. The connector length should be kept as
short as possible.
TABLE 4. SUGGESTED VENT CONNECTOR SIZES
Model Number Inches (mm)
GPO 86-199* 6 152.4
GPO 86-245 8 203
GPO 84-315/315A 8 203
GPO 75-385/385A 8 203
GPO 75-455/455A 8 203
GPO 69-700/700A 10 254
* These models are factory supplied with a ue reducer which should
be installed on the top cover.
Outlet Diameter
In venting systems where a continuous or intermittent back (positive) draft
is found to exist, the cause must be determined and corrected. In some
cases, a special vent cap may be required.
If the back draft cannot be corrected by normal methods or if a suitable
draft cannot be obtained, additional make up air must be provided to the
room to assure proper venting and combustion.
Note: A negative draft must be maintained in the vent piping.
The barometric draft regulator must be installed in the same room
as the heater, fig. 6. Locate the regulator as close as possible to
the heater and at least 18" (457.2 mm) from a combustible ceiling
or wall. A manually operated damper should not be placed in the
chimney connector.
PROPER VENT CONNECTOR INSTALLATION
FIGURE 6.
CHIMNEY
The oil-red water heater must be connected to a chimney built in
accordance with accepted building code practice or listed factory built type,
Table 5. The exit point of the chimney ue gas must be at least 3' (0.91
M) above the highest point where it passes through the roof of a building.
Also, it must be at least 2' (0.61 M) higher than any portion of a building
within 10' (3.05 M) of the chimney.
MULTIPLE HEATER FLUES
When two or more oil-red water heaters are connected to a single chimney
or vent there shall be sufcient draft available for safe combustion and
removal of combustion products to the outdoors from each heater. Refer
to local codes for connection details.
Only one oil-red water heater should be connected to any one type L
venting system.
A draft regulator shall be provided for each oil-red water heater in a
multiple heater system.
DANGER
INCORRECT INSTALLATION CAN CAUSE IMPROPER OPERATION,
FIRE, ASPHYXIATION, SERIOUS PERSONAL INJURY OR DEATH. NEVER
OPERATE THIS WATER HEATER UNLESS IT IS PROPERLY VENTED
TO THE OUTDOORS AND HAS ADEQUATE COMBUSTION AIR SUPPLY.
Oil Equivalent Output Square & Rectangle
Firing Heat Input Heat Stack Round Stack Minimum
Model Rate Rate Rate Dimension Diameter Height
Number (GPH) (LPH) Btuh kW Btuh kW Inches mm Inches mm Feet Metres
GPO 86 -199 1.42 5.38 199,000 58 159,200 47 8 1/2 X 8 1/2 216 x 216 9 228.6 20 6.1
GPO 86 -245 1.75 6.62 245,000 72 196,000 57 8 1/2 X 8 1/2 216 x 216 9 228.6 20 6.1
GPO 84-315 (A) 2.25 8.52 315,000 92 252,000 74 8 1/2 X 13 216 x 330 10 254 30 9.1
GPO 75 -385 (A) 2.75 10.41 385,000 113 308,000 90 8 1/2 X 13 216 x 330 10 254 30 9.1
GPO 75 -455 (A) 3.25 12.30 455,000 133 364,000 107 13 X 13 330 x 330 12 304.8 35 10.7
GPO 69 -700 (A) 5 18.93 700,000 205 560,000 164 13 X 18 330 x 457 14 355.6 40 12.2
TABLE 5. USUAL CHIMNEY SIZES FOR UNITS
6
GENERAL
WATER PIPING
Select the piping diagram for the type of system to be installed from pages
14 through 18. When a circulation pump is used in the system a plug
cock should be installed where indicated to regulate water ow through
the heater.
RELIEF VALVE
An CSA design-certied and A.S.M.E.-rated temperature and pressure
relief valve is installed in the water heater . The relief valve has a discharge
capacity exceeding the maximum heater input rating and a pressure rating
not exceeding the working pressure shown on the rating plate of the heater.
A temperature and pressure relief valve must also be installed on any potable
water storage tank. This relief valve should have a temperature rating of
210° F (98.9°C), a pressure rating not exceeding the lowest rated working
pressure of any system component, and a discharge capacity exceeding
the total input of the water heaters supplying water to the storage tank.
THE PURPOSE OF A RELIEF VALVE IS TO AVOID EXCESSIVE
PRESSURE OR TEMPERATURE INTO THE STEAM RANGE, WHICH
MAY CAUSE SCALDING AT FIXTURES, TANK EXPLOSION, SYSTEM
OR HEATER DAMAGE.
To avoid scalding or water damage, a drain line must be connected to a
relief valve to direct discharge to a safe location, A DRAIN LINE MUST
NOT BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND
IT MUST NOT CONTAIN ANY VALVES BETWEEN THE HEATER AND
THE RELIEF VALVE OR THE RELIEF VALVE AND THE DRAIN LINE
EXIT. IN ADDITION, THERE SHOULD NOT BE ANY RESTRICTIONS
IN A DRAIN LINE NOR SHOULD IT BE ROUTED THROUGH AREAS
WHERE FREEZING CONDITIONS MIGHT OCCUR. DO NOT THREAD
OR CAP THE DRAIN LINE EXIT. RESTRICTING OR BLOCKING A DRAIN
LINE WILL DEFEAT THE PURPOSE OF THE RELIEF VALVE AND MAY
CREATE AN UNSAFE CONDITION. Install a drain line with a downward
slope such that it naturally drains itself.
Your local code authority may have other specic relief valve requirements.
NOTE: These heaters are equipped with an automatic burner shutoff
system actuated by high water temperature.
CLOSED WATER SYSTEM
A closed system will exist if a back-ow preventer (check valve), pressure
reducing valve, or other similar device is installed in the cold water line
between the water heater and the street main (or well). Excessive pressure
may develop due to the thermal expansion of heated water causing
premature tank failure or intermittent relief valve operation. This type of
failure is not covered by the limited warranty. An expansion tank may be
necessary in the cold water supply to alleviate this situation, see installation
diagrams on pages 14-18. Contact the local plumbing authority.
TANK CLEANOUT PORT - FIGURE 8.
Models having ASME tank construction will have two cleanout ports. One port
will be located as indicated above and the other will be located directly opposite.
Occasionally, some water seepage will occur at a cleanout port. To correct
this situation, slightly tighten the cleanout cover bolts until the seepage
is eliminated. Do not over tighten the bolts or the cleanout gasket will be
damaged. Tighten each bolt gradually and alternate between opposed
bolts on the cleanout cover.
FUEL SYSTEMS
GENERAL
The Standard for the Installation of Oil Burning Equipment-NFPA No. 31,
local codes, and these instructions must be followed when installing the
tank, piping and burner. In addition, an oil pump installation sheet and oil
burner certicate are packed with the burner for use and completion by
the installer.
On fuel systems with high pressures, a Webster "OSV" oil safety valve
(Webster Electric CO., Racine, Wisc.) will be required to reduce the oil
pressure at the burner pump. See FUEL PUMP, page 9, for pressure
ratings of the burner's pump.
This manual and the completed oil burner certicate (CS75) are to be left
with the user for future reference.
Figure 9 shows a typical single stage one or two line fuel system. When
two or more tanks are connected to one burner, the supply line from each
tank should run to a header tted with an approved three-way valve.
Normally only one tank may be drawn at a time unless local codes permit
simultaneous feeding of two tanks on gravity type installations.
DRAIN VALVE AND ACCESS PANELS
The heaters are equipped with a 3/4" NPT drain valve mounted above and
to the left of the oil burner, see FEATURES, page 2.
An access panel is located above and to the left of the oil burner and
covers the ame observation port, g. 7. A plug is inserted into the ame
observation port and must be removed in order to look into the combustion
chamber. Always reinstall plug before replacing access panel.
COMBUSTION CHAMBER ACCESS PORT - FIGURE 7.
Another access panel is located above and to the right of the oil burner,
g. 8. This panel covers the cleanout opening in the tank which is sealed
by a gasket and cover.
A TYPICAL HEATER INSTALLATION - FIGURE 9.
Refer to pages 2, 3, and 4 in this manual for more information about burner
series numbers and characteristics for adaptability to the following systems.
SYSTEM TYPES
Single Stage, Supply Line Only: The bottom of the oil storage tank must
be above the level of the fuel unit, g. 10. The fuel oil will ow by gravity to
the burner. A single pipe joins the tank and fuel unit. Burner Series No. 940
is from this type of service as shipped (the bypass plug is not installed).
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If the tank(s) bottom is lower than the plug by more than 10 feet, a two
stage pump with a two line system must be used with maximum tubing
runs (which includes lift) as shown in Table 7.
A GRAVITY FEED, SUPPLY LINE ONLY, INSTALLATION
FIGURE 10.
If the bottom of the oil tank is at least 2 inches higher than the plug opening at
which the supply line connects to the fuel pump, a single-line gravity-feed system
with 3/8" O.D. tubing may be used with a maximum run length of 100 feet.
• A two stage pump may be used on one line, gravity feed installations.
The pump will function as a single stage unit when the by-pass plug
is not installed.
• Single Stage, Supply and Return Lines. This type of system,
g. 11, is self-priming. Burner Series No. 940 with by-pass plug eld
installed, is for this type of service.
If the tank bottom is no lower than 10 feet below the plug, a single stage
pump may be used but, it must be a two line system with maximum tubing
runs (which includes lift) as shown in Table 6.
Distance Max. Distance Max.
Tank Run length Tank Run Length
Bottom Ft. (M) Bottom Ft. (M)
Below Below
Pump 3/8" 1/2" Pump 3/8" 1/2"
Plug O.D. O.D. Plug O.D. O.D.
Ft. (M) Tubing Tubing Ft. (M) Tubing Tubing
1 (0.3) 74 (22.5) 100 (30.4) 9 (2.7) 51 (15.5) 100 (30.4)
2 (0.6) 71 (21.6) 100 (30.4) 10 (3.0) 48 (14.6) 100 (30.4)
3 (0.9) 69 (21.0) 100 (30.4) 11 (3.3) 45 (13.7) 100 (30.4)
4 (1.2) 66 (20.1) 100 (30.4) 12 (3.6) 42 (12.8) 100 (30.4)
5 (1.5) 63 (19.2) 100 (30.4) 13 (3.9) 39 (11.8) 100 (30.4)
6 (1.8) 60 (18.2) 100 (30.4) 14 (4.2) 37 (11.2) 100 (30.4)
7 (2.1) 57 (17.3) 100 (30.4) 15 (4.5) 34 (10.3) 100 (30.4)
8 (2.4) 54 (16.4) 100 (30.4)
TABLE 7.
MULTIPLE HEATER FUEL LINES
Where two or more heaters form a water heating system, each burner shall
have an entirely separate oil supply line from the tank to the burner.
BURNER INSTALLATION
GENERAL
An oil Burner Certicate is packed with the oil burner. Following the burner
manual installation the necessary tests shall be performed and the results
recorded on the certicate, see BURNER CERTIFICATE. The certicate and
this instruction manual must be left with the user for future reference. Check
to be certain the heater and burner model numbers are alike and the oil
pump characteristics are proper for the job. See IDENTIFICATION, page 3.
A SINGLE STAGE (LOW LIFT), SUPPLY AND RETURN
LINE INSTALLATION - FIGURE 11.
Distance Max. Distance Max.
Tank Run length Tank Run Length
Bottom Ft. (M) Bottom Ft. (M)
Below Below
Pump 3/8" 1/2" Pump 3/8" 1/2"
Plug O.D. O.D. Plug O.D. O.D.
Ft. (M) Tubing Tubing Ft. (M) Tubing Tubing
1 (0.3) 66 (20.1) 100 (30.4) 6 (1.8) 36 (10.9) 100 (30.4)
2 (0.6) 55 (16.7) 100 (30.4) 7 (2.1) 31 (9.4) 100 (30.4)
3 (0.9) 50 (15.2) 100 (30.4) 8 (2.4) 26 (7.9) 100 (30.4)
4 (1.2) 45 (13.7) 100 (30.4) 9 (2.7) 21 (6.4) 83 (25.2)
5 (1.5) 40 (12.1) 100 (30.4) 10 (3.0) 16 (4.8) 64 (19.5)
TABLE 6.
Two Stage, Supply and Return Lines: This system, g. 12, is required when
long lines and high lifts (requiring up to 20" of vacuum and 10' vertical lift) are
encountered. Burner Series No. 941 is used in this service. Bypass plug must
be installed.
BURNER
The burner assembly is mounted on the ange of the combustion chamber,
g. 13.
NOTE: Be certain combustion chamber opening is aligned with opening
in heater ange, g. 13, before placing burner into heater .
1. Place the ange gasket and combustion chamber seal over the burner tube.
2. Place the burner ange on the studs and into the heater ange opening.
A TWO STAGE (HIGH LIFT), SUPPLY AND RETURN
LINE INSTALLATION - FIGURE 12.
ASSEMBLY OF THE OIL BURNER TO THE HEATER
FIGURE 13.
3. Place the at washers and lock washers over the studs and fasten the
burner in place with the 3/8" - 16 nuts as shown.
Connect the oil line(s) and electrical wires to the burner as follows:
1. The oil pump manufacturer's instructions should be checked for
connection and bleeding information.
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