CUSTOM MARK III
CP SERIES OIL FIRED UNIT
300 East Mountain Avenue South Williamsport, PA 17701
INSTALLATION AND OPERATING INSTRUCTIONS
CUSTOM MARK III
CP SERIES OIL FIRED UNIT
The Custom Mark III CP Series Oil Fired Unit is a high quality heating unit that will provide many years of comfortable and economical heat if properly installed and given proper care. It is IMPORTANT therefore that these instructions should be followed carefully.
The unit is completely assembled at the factory except for the following parts which are packed in a separate carton and strapped to the skids inside the shipping carton:
1 - 3/4" x Close Steel Nipple 1 - 3/4" x 3/4" x 1/2" Tee 1 - Fig. 105 Tridicator 1 - 3/4" No. 10-402-05 ASME Relief Valve 1 - 3/4" No. 600-19 Boiler Drain 1 - T87F-2055 Thermostat
The jacket extension for 128CPO is shipped in separate carton.
DAMAGE IN TRANSIT
Upon receipt of shipment of this material, inspect all cartons for external damage. If external damage is noted, open the carton and inspect for damage to equipment. Mark the number of cartons received in this condition on the delivering carrier's waybill, and request the services of their inspector.
If, upon opening a carton, concealed damage is discovered, open the entire shipment and note all equipment so damaged. Contact the delivering carrier and request inspection of the damaged equipment. Do not destroy the carton. The inspector from the freight company will need this to determine reason for damage.
Normally claims for any and all damages should be filed with the freight company within five working days after receipt of shipment.
All materials are sold F.O.B. Factory. It is the responsibility of the consignee to file claim with the delivering carrier for material received in a damaged condition.
BEFORE REMOVING SHIPPING CARTON, LOCATE UNIT IN ITS FINAL POSITION
The carton is plainly marked so as to indicate which is the outlet burner end of the unit which is also the end where the return and flue are located. Clearance should be provided in both the front and rear of the unit for cleaning. Where possible it is good practice to locate the unit so its sides are parallel to the chimney flue. In all instances locate unit as near chimney flue as possible in order to avoid use of a long flue pipe.
Once the packaged unit is in its proper place, cut all around the carton on the scored line as shown on carton. The entire carton may then be lifted from the skids.
If it is found necessary to move the unit a little more to place it in the exact location ready for piping, do so before removing skids.
DO NOT PUSH AGAINST ANY PART OF JACKET OR OIL BURNER WHEN MOVING UNIT. TO MOVE UNIT, PUSH AGAINST SKIDS, FLUE BOX OR SMOKE BOX. PUSHING AGAINST JACKET WILL RESULT IN DAMAGE.
The skids are specially designed for easy removal. It is necessary, however, to follow these instructions carefully.
A. After unit is in proper place, remove the two cross pieces from skids by pulling out all scaffolding (double headed) nails.
B. By inserting pinch bar or 2" x 4" underneath the smoke box (rear of unit), tilt one side of unit just high enough to lift lugs out of holes in skid, then knock skid out from underneath unit. Then do the same thing on the other side of unit. THE UNIT IS NOT BOLTED TO THE SKIDS. The 3/4" lugs welded to the unit simply fit into the 3/4" holes in the skids.
IMPORTANT DO NOT TILT UNIT BY PUSHING AGAINST JACKET IT IS NOT NECESSARY AND BY DOING SO THE JACKET WILL BE DAMAGED
In case floor is uneven, unit may easily be made level by inserting shims under the 4 shipping lugs. These lugs also keep the jacket 1/2" off the floor, protecting it from wet floors and dampness.
PIPING AND WIRING
Once the unit is in its proper location with the packing carton, skids and packing material removed, it is ready for piping and connection from Room Thermostat and 110 V. 60 Cy. A.C. Current.
The controls furnished are for a one zone Forced Water System consisting of T87F Room Thermostat, L8124A-1007 Triple Acting Aquastat and Circulator Relay, C554A-1018 Cadmium Photocell, R8184G-1005 Burner Relay and V4046A-1009 Oil Valve. Description and complete wiring diagram will be found packed with each control.
SPECIAL CONTROL SYSTEMS
For special control systems such as multiple installations, zone controlled, unit heater, radiant panel, etc., write to factory for wiring diagrams.
CHIMNEY AND BREECHING REQUIREMENTS
The CP boiler should be connected to a vertical vent system that will prevent: (1) positive pressure in the flue, (2) backward flow of flue gas through the unit when the burner stops, and (3) condensation in the flue.
Use double-walled or insulated pipe for sections of the flue in cold areas. All outside vents, except for short extensions, must be insulated to avoid condensation in the flue. Several types of prefabricated chimneys are available providing double-walled or insulated pipe, some with ceramic and others with metallic liners.
While the unit is equipped with an induced draft fan, proper size vent must be provided to remove the gases of combustion. It is recommended that a 4" to 5" increaser be used for venting the 87CPO and 108CPO and a 4" to 6" increaser be used for the 128CPO. For abnormal runs (exceeding 10 ft.), consult factory.
Vent and breeching must be gas tight by sealing with asbestos or thermo-setting pressure sensitive tape.
It is recommended that a draft regulator be installed in chimney flue just below the flue pipe opening, if the unit is attached to an extremely high chimney; an unlined chimney; or a chimney which is constructed on the exterior of the house.
CONTROLS AND TRIM
Controls are installed in place at the Factory. Attach thermo-altimeter in 1/2" tapping in top front of boiler. Install 3/4" x close nipple in 3/4" top connection with 3/4" x 3/4" x 1/2" Tee. 3/4" Tee opening for installation of the relief valve and 1/2" opening for expansion tank.
Controls are all in place and wired at the factory except connection to circulator.
REGULATING OIL PRESSURE
Standard nozzles furnished with the burner will produce the stamped rated capacity when used with Commercial Standard No. 2 Fuel Oil, and operated with a pressure of 100 lbs. per square inch. The standard setting of the fuel unit is 100 lbs. Due to difference in tank elevations, the pressure should be adjusted at the time of start up.
Care should be employed when attaching the oil lines to the fuel unit. Overtightening or twisting will twist the pump-motor mounting plate and put a stress on the motor bearings.
START UP PROCEDURE
1. Make certain that correct voltage has been supplied to motor and control circuit.
2. Insure that outside air openings are provided in the boiler room for ventilation, and for admission of air for combustion. The free area of such openings should not be less than 7 square inch opening per 100,000 Btuh burner input, or more as required by local codes.
3. Check to see that flue, wiring and water level are in order.
4. Start burner fan motor to prime pump. If pump does not pick up oil within a few minutes, prime the pump with lubricating oil. Do not allow pump to run more than a few minutes without additional lubrication.
5. Check oil pressure and adjust if necessary. (See REGULATING OIL PRESSURE).
6. Set air shutters. (See ADJUSTING BURNER) Refer to Figure 1.
7. Generously lubricate the front motor bearing with SAE #20 oil.
ADJUSTING BURNER (See Figure 1)
Positioning of the nozzle in relation to the face of the cone and the electrodes in relation to the nozzle are very important, also the face of the cone in relation to the face of the choke ring must be set according to the chart for each rate.
If the air shutter openings are too large the oil may not ignite.
1. This setting will vary somewhat depending upon the grade of oil being used or if No. 1 is used instead of No. 2.
2. The approximate burner air setting may be determined by observing the fire through the observation port on the front of the boiler. If the flame is smoky, the air shutter should be opened until the fire burns clean, without any trace of smoke. The flame should be bright yellow in color with the tips of the flame turning orange. If the flame is too white, reduce the amount of air admitted; and, if too red or smoky increase the air.
3. Final adjustments should be made using a flue gas analyzer to measure the CO_2 content of the flue gas and a Bacharach model smoke meter or equivalent to determine the amount of smoke (not to exceed a "TRACE").
For checking efficiency only the stack temperature and CO_2 may be taken immediately after the fan and refer to the standard efficiency charts for the results. Readings of 5 to 8% taken after the fan correspond to 10 to 12% taken in the rear uptake of the boiler.
The reduction in CO_2 reading in the flue is caused by the air being drawn in around the motor shaft for cooling purposes. The motor cooling air is at ambient temperature and, therefore, does not add energy to or subtract energy from the flue gas analysis, it only adds volume to the flue gas. Therefore, applying this data to standard efficiency charts will give a true indication of flue gas loss.
- NOTE Final adjustment should be made after the burner has been firing continuously for at least 10 minutes, as the fan pulls less air when the flue gases are hot. -
A. CHECK LIMIT CONTROL
Run the burner long enough to bring the water temperature up to at least 190 degrees then turn the limit control setting until the burner stops.
- NOTE The Minimum limit setting for any hot water boiler should be 140 degrees F. in order to prevent corrosion of the flues on the fire side. The burner should be run with the primary control thermostat terminals jumpered and the burner controlled directly from an aquastat keeping the boiler hot all the time, thus eliminating the sweating of the flues on the fire side caused by starting from a cold start. -
The proper tension on the fuel unit belt drive is set at the factory. However, the belt should be checked periodically to see that the setting is maintained. To check setting, first, remove the belt guard and then, using fingers, compress the belt at a point midway between the sheaves. The proper setting at this point measured between the outer edges of the belt, should be between 1-3/4" and 1-7/8". If adjustment is necessary loosen the two mounting bolts, and move the fuel unit up or down to give the necessary belt setting. Then re-tighten the mounting bolts securely and replace the belt guard.
PERFORMANCE CHECK LIST
QUESTION: What Causes Unit To Soot Up?
1. Nozzles 2. Flame Impingement 3. Firing Head 4. Leaks 5. Improper Burner Settings 6. Lack of Normal Maintenance 7. Poor Ignition 8. Retention Ring Cokes
Definitions of Answers:
A. Dirty B. Wrong type of nozzle, or manufacturing defect
2. Flame Impingement
A. High CO_2 B. Diffuser and choke ring clearance not uniform C. Dirty nozzle, or poor patterns D. Leaks
3. Firing Head
A. Diffuser and choke ring clearance not uniform B. Diffuser and choke ring face dimension out of tolerance. (See A Dimension, Figure 1) C. Dirty fuel systems
A. Induced fan gasket, or burner gasket improperly sealed B. Front cover assembly improperly installed or sealed
5. Improper Burner Settings
A. Unit not checked out completely by the serviceman B. Flame pattern erratic (Not concentric). Burner set up by CO2 only (Burner should be set up by CO2, smoke and visual observation.)
6. Lack of Normal Maintenance
A. Self explanatory (Recognition of the advantages of preventive maintenance).
7. Poor Ignition
A. No delay in oil valve, unit flutters on start up. B. Electrodes out of position C. Too much combustion air (Air shutter open too wide)
8. Retention Ring Cokes
A. Defective nozzle B. Cone, choke and nozzle out of adjustment (See Figure 1) C. Fluttering starts
DOMESTIC HOT WATER
In order to obtain the rated capacity of the instantaneous domestic hot water coil limit control should be set to maintain 200 deg. F boiler water temperature.
Flow regulator and tempering valve should be installed on all instantaneous domestic hot water coil systems.
The burner is adjusted at the factory before shipment but in case of improper operation at some future date Figure 1 will show proper setting. In all cases the flame retention ring should be concentric with the choke.
+ + + -+ + -+ MODEL NOZZLE CHOKE RING "A" I. D. NO. DELAVAN SIZE NO. & DIAMETER DIM. VANES + + + -+ + -+ 87CPO 1.25 GPH 70 deg. A 142640-002 2-5/8 D FLUSH 2-25/32 108CPO 1.65 GPH 60 deg. A 142641 2-31/32 D -3/16" 2-25/32 128CPO 2.00 GPH 70 deg. A 142641-003 2-31/32 D +1/4" 2-29/32 + + + -+ + -+