State Industries GPO 86-199 User Manual

MODELS GPO 86-199 THRU GPO 69-700(A)

COMMERCIAL OIL FIRED W ATER HEATER FOR HOT W ATER SUPPL Y

• Installation • Operation • Service • Maintenance

CAUTION

TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ THOUROUGHLY BEFORE USING APPLIANCE.

500 Lindahl Parkway

Ashland City, TN 37015

www.stateind.com

PLACE THESE INSTRUCTIONS ADJACENT TO HEA TER AND

PRINTED IN U.S.A. 0303 PART NO.195092-000

NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

FEATURES AND SPECIFICATIONS

TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHL Y BEFORE USING APPLIANCE.

This is a typical oil-fired heater for commercial water heating applications.

The principal components of the heater are shown and identified here. The identification plate illustrations on page 4 interpret certain markings into useful information. Use these reference to identify the heater and its components

FIGURE 1

T ABLE 1 NOMINAL MODEL DIMENSIONS

GPO 86-199 GPO 86-245 GPO 84-315(A) GPO 75-385(A) GPO 75-455(A) GPO 69-700(A)

Model

Dim. Inches mm Inches m m 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 9 33 36 3/4 933 36 3/4 93 3 36 3/4 933 C 27 3/4 705 27 3/4 705 27 3/4 7 05 27 3/4 705 27 3/4 70 5 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 6 76 26 5/8 676 24 3/4 6 29 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 57 8 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 suffix "A" indicates the optional A.S.M.E. tank construction.

T ABLE 2 RECOVERY CAPACITIES, based on 80% efficiency

TANK APPROX U.S Gallons/Hr. and Litres/Hr at TEMPERATURE RISE INDICATED

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) 1 13 284 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 efficiency. Above 2,000 altitude, input ratings should be reduced 4% for each 1000' above sea level.

CAPACITY EFF. F° 40F° 50F° 60F° 70F° 80F° 90F° 100F° 110F° 120F° 130F° 140F°

TABLE OF CONTENTS

FEATURES AND SPECIFICATIONS ................................................... 2

APPROVALS ....................................................................................... 3

IDENTIFICATION

Oil and Burner Nameplate Decal ...............................................3

Oil Burner Specifications............................................................ 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 ...................................................................................... 10

Filling .........................................................................................10

Start Up...................................................................................... 10

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.

High Limit Switch E.C.O............................................................. 10-11

Burner Certificate (Combustion T est) .........................................11

Draining .....................................................................................11

MAINTENANCE

General ...................................................................................... 11

Relief Valves ..............................................................................11

Flushing ..................................................................................... 12

Sediment Removal .................................................................... 12

Lime Scale Removal .................................................................. 12-13

Circulating Pump .......................................................................13

Soot Removal ............................................................................ 13

Vent System............................................................................... 13

Anode Rod Inspection................................................................ 13

INSTALLATION DIAGRAMS ............................................................... 14-19

CHECKLIST AND SERVICE INFORMA TION

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 SPECIFICA TIONS ............................................ 21

TROUBLESHOOTING ......................................................................... 22

REPLACEMENT PARTS LIST .............................................................23-24

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).

IDENTIFICATION

The heater and burner rating plates or labels provide valuable information to the installer and servicer. 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:

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.

OIL BURNER NAMEPLA TE 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 first line of the heater's rating plate. The oil burner series 940 or 941 indicates the burner equipped w/single or two

A TYPICAL OIL BURNER NAMEPLA TE DECAL

FIGURE 2

OIL BURNER SPECIFICATIONS

INSTALLATION

The oil burner nameplate decal includes a series code which identifies 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 Typ e Pump

Series Model + Mode Spray Spray

Number* Number Pattern Angle

A2VA

AFG 71 18 Type B

940 15 Sec. Single - Solid 80°

SF Stage A2YA- Cone

7916

B2VA

8216 Type B

941 AFG 15 Sec. Two- - Solid 80°

SF 15 Sec. Stage BY2A Cone

8916

* To provide the proper firing rate for each model heater , see SPECIFICATIONS:

there are burner models for each heater model in table 2.

+ All oil burners are UL defined as having "interrupted ignition" . . . meaning the

ignition is on during the flame establishing period only. Ignition is of f when the burner is off. Standard safety timing is 15 seconds.

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 modification to the pump, see the oil burner installation manual.

For installations where gravity feed cannot be employed, (the storage tank is located significantly 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 modified to operate without the line, see the oil burner installation manual.

IMPORTANT The oil-fired 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 W A TER. WHEN REPLACING FUSES AL W A YS 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 serviceman.

REQUIRED ABILITY

INSTALLATION OF SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENCED 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.

Standards 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 , ANSI/NFPA No. 70-1996. Availability same as NFPA Standard No. 31-1997.

• In Canada - CSA Standard No. B139, Installation Code for Oil Burning Equipment.

When other than a State burner is used, this instruction manual can be used as a general guide. The burner manufacturer's instructions will have to be consulted on specific questions of wiring, air adjustment, etc.

Do not test the burner or control system before the heater is filled 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 will require the use of jacks or lifting equipment. Safely remove the pallet 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 flammable 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 floor 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 floors 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 flow.

• 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.

• 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 floor 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 fig. 3A to prevent possible fire hazard conditions.

At least 24" (610 mm) of top clearances are recommended for vertical vent installation.

Allow sufficient 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 flooring must be supported

by a full layer of hollow concrete blocks, fig. 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.

PROPER INSTALLATION ON COMBUSTIBLE FLOORING

FIGURE 3

NOTE: If electrical conduits run under the floor of the proposed heater

location, insulate the floor as recommended above.

COMBUSTION AND VENTILA TION AIR

GENERAL

The water heater area should have sufficient 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.

CHEMICAL V APOR 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 unconfined space is defined as a space whose volume is not

less than 50 ft3 per 1000 BTUH (4.83m3 per kW) of total input of allfuel burningappliances installed in that space. The unconfined space may be thought of as extending to all areas which cannot be separated by a door or door(s). All other spaces not fitting this description, should be thought of as confined space.

1. In unconfined spaces in buildings of conventional frame, brick or stone construction, infiltration will normally supply an adequate amount of air for combustion and ventilation.

2. If the unconfined space is within a building of tight construction, eg. weather stripping, heavy insulation, caulking, vapor barrier, ect., air infiltration may be insufficient to support proper combustion and ventilation, air shall be obtained from outdoors or from spaces freely communicating with the outdoors.

• Follow the instructions under Part 2 of Confined Spaces (Room

Construction)

CONFINED SPACES (Room Construction)

1. All air from inside building (conventionally constructed buildings only):

The confined space shall be provided with the two permanent openings, one within 12" (305 mm) of the ceiling and one within 12" (305 mm) of the floor, fig. 4.

PROPER INSTALLATION CLEARANCES FOR TWO DIFFERENT

VENTING SYSTEMS

FIGURE 3A

* HOT WATER OUTLET LOCATION A T FRONT OF HEATER

• FACTORY FURNISHED HEATER MANIFOLD KITS (OPTIONAL) ARE DESIGNED FOR 10" (254 mm) SPACING BETWEEN SIDES OF ADJACENT UNITS.

REQUIRED AERA TION FOR APPLIANCE INST ALLA TION

IN A CONFINED SP ACE WITHIN A CONVENTIONALLY

CONSTRUCTED BUILDING

FIGURE 4

• 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

/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

/kW) (70 square inches per gallon of oil consumed per

hour) of total input of all appliances in the enclosure, fig. 5.

APPLIANCE AERA TION FROM OUTDOORS (OPTIONAL

FOR CONVENTIONAL BUILDINGS, MANDA TOR Y

FOR TIGHT BUILDINGS)

FIGURE 5

TABLE 4 SUGGESTED VENT CONNECTOR SIZES

Outlet Diameter

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 flue reducer which should

be installed on the top cover.

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, a blower type flue gas exhauster must be employed to assure venting and correct combustion.

Note: A negative draft must be maintained in the vent piping. Connections shall not be to a chimney , vent or venting system served by

a power exhauster unless the connection is made on the negative pressure side of the exhauster.

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.

FLUE GAS VENTING

In the absence of any local codes, regulations, or vent pipe or chimney manufacturer's recommendations, for oil fired 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 flue 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 REGULA T O R

The chimney or vent connector diameter should be the same size as the heater flue outlet, see T able 4. A minimum rise of 1/4" per foot (21mm/M) of horizontal connector length must be maintained between the heater and chimney opening, fig. 6. The connector length should be kept as short as possible.

TABLE 5 - USUAL CHIMNEY SIZES FOR UNITS

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

PROPER VENT CONNECTOR INST ALLATION

FIGURE 6

CHIMNEY

The oil-fired 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 flue 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-fired water heaters are connected to a single chimney or vent there shall be sufficient 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-fired water heater should be connected to any one type L venting system.

A draft regulator shall be provided for each oil-fired 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.

WATER PIPING

GENERAL

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 flow through the heater.

RELIEF VALVE

DRAIN V AL VE 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 flame observation port, fig. 7. A plug is inserted into the flame 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, fig. 8. This panel covers the cleanout opening in the tank which is sealed by a gasket and cover.

An A.G.A. design-certified 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 V AL VES BETWEEN THE HEA TER 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. Y our local code authority may have other specific 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-flow 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 develope 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. T o 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-NFP A 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 certificate 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 certificate (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 fitted 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.

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, fig. 10. The fuel oil will flow by gravity to the burner. A single pipe is run between the tank and fuel unit. Burner Series No. 940 is from this type of service as shipped (the bypass plug is not installed).

TABLE 6

Distance Max. Distance Max.

T an k 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)

Two Stage, Supply and Return Lines: This system, fig. 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.

A GRAVITY FEED, SUPPLY LINE ONLY, INSTALLA TION

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, fig. 11, is self-priming. Burner Series No. 940 with by-pass plug field 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.

A SINGLE STAGE (LOW LIFT), SUPPLY AND RETURN

LINE INSTALLATION - FIGURE 1 1

A TWO STAGE (HIGH LIFT), SUPPLY AND RETURN

LINE INSTALLATION - FIGURE 12

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.

TABLE 7

Distance Max. Distance Max.

T an k 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 (1 1.8) 100 (30.4) 6 (1.8) 60 (18.2) 100 (30.4) 14 (4.2) 37 (1 1.2) 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)

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 INST ALLA TION

GENERAL

An oil Burner Certificate is packed with the oil burner . Following the burner manual installation the necessary tests shall be performed and the results recorded on the certificate, see BURNER CERTIFICATE. The certificate 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 IDENTIFICA TION, page 3.

+ 16 hidden pages