PREFACE - EnviroSpec
Contents
1. 7 gph 3 gph at 200 psi B2VA 8416 3 gph Solenoid dumping fuel unit B2VA 8241 R H R H Boost pump 20 gph at 10 20 psi Model Number Special Features B2VA 8242 R H R H Also apply to 8 model numbers shown on fuel unit For example 8212 6 etc Viewed from shaft end MODEL 8200 7WO STAGE HIGH CAPACITY HIGH PRESSURE NOT PICTURED AND MODEL B 8800 7WO STEP TWO STAGE Two pipe installations up to 17 hg vacuum e Lift or gravity feed applications with 10 psi maximum inlet return pressure e Adjustable manual or automatic high low firing e High efficiency burner applica tions e Capacities to 23 gph e Pressure adjustable 100 to 200 psi low fire 200 300 psi high fire For no 2 fuel oil For other fuels consult factory e Two bolt flange mounting in any position except upside down SPECIFICATIONS ORDERING INFORMATION 3 5 16 Max G Strainer 2 7 8 Max Low Fire T Strainer Adjustment 100 200 pa Solenoi 3 8 Flexible Conduit Fitting Easy Flow Bleeder Valve Port Inlet Port Return amp Internal a ors 1 4 NPTF By Pass Port Solenoid Energized 1 4 NPTF Two Step Stage Models Flange Mount SPECIFICATIONS ORDERING INFORMATION Nozzle Strainer amp Rotation Port Nozzle Rating Location at 300 psi High Capacity Units B2VA 8243 B2TA 8245 B2TA 8248 High Capacity Units2. 3 All burner pumps being supplied by a boost pump should be installed single pipe even if they are two stage pumps MODELS AND SELECTIONS BOOST PUMP Pump Includes Rotation Delivery Item Pump from GPH 0 Model shaft RPM end Complete Boost BB 1020M B2VA 8241 5 R H 20 Pump Assembly BH 1030M H3BA E100B R H 30 Including Motor BH 1070M H6BA E100B R H 70 Boost Pump BB 1020R B2VA 8241 5 R H 20 Assembly Less BH 1030R 100 30 Motor BH 1070R H6BA E100B R H 70 Pressure Switch P N 128117 40VA amp 150 psi Max Adapter for 48N Motor P N 134462 Il 23 Boost pump assemblies are supplied with or without drive motors The pump has an internal valve regulator standard 10 20 psi range The valve regulates pressure and provides a check against loss of head during shut downs This eliminates the need for an external check valve Standard assemblies are capable of pushing oil to 35 feet vertical height For higher applications a simple spring change can meet your specific requirements To select the correct boost pump find the total firing rate of all the burners being supplied and select a GPH rating higher Example 1 We have four burners with the following nozzle capacities or firing rates 1 2 75 3 1 35 4 2 25 Total 5 15 required Select 1020 which will supply 20 Remember The firing rate
3. Tank Above Pump Single Stage Two Stage Single Stage Two Stage 3 8 1 2 5 8 L 12 75H L 17 75H L 12 75H L 17 75H 00860 L 12 75H 00860 L 17 75H 00860 L 12 75H 00860 L 17 75H 002180 L 12 75 002180 L 17 75H 00218Q L 12 75H 00218Q L 17 75H 000785Q 000785Q 000785Q 000785Q Tube Size 0 D inches 035 wall 3 8 1 2 5 8 uum Tank Below Pump Tank Above Pump V L 0086Q V L 00218Q V L 000785Q V L 0086Q V L 00218Q V L 0007850 75H 75H 75H Does not include valves filters etc in the line NOTES 1 Kinks or sharp bends in lines will increase vacuum 2 Return line pressure should not exceed 10 psi manufacturer or 3 psi NFPA 3 The installation instructions supplied with each Suntec fuel unit shows line lengths based on calculations from the above formula 4 Ifthe system configuration causes operation outside the recommended limits consider the following options a Reconfigure the system b Install a boost pump system c Contact the Suntec Factory Service Department ADD ONS AND MULTIPLE UNITS When adding or installing new fuel units to an existing system good practice is to have separate lines for each system If running separate lines is difficult impractical and or impossible it may be necessary to tie a n
4. B2TA 8850 2 8851 B2GA 8852 R H Also apply to 8 model numbers shown on fuel unit For example 8850 8 etc Viewed from shaft end At 130 psi 3At 150 psi M DE J SINGLE STAGE FUEL UNITS Single pipe gravity feed installations e Two pipe lift installations to 12 hg vacuum e Lift or gravity feed applications with 10 psi maximum inlet return pressure e Capacities to 60 gph e Six pressure options 10 to 300 psi e For no 4 and lighter fuel oils gasoline and JP fuels special e Hub and flange mounting in any position SPECIFICATIONS ORDERING INFORMATION pa Inlet Port 1 4 NPTF 315 32 gt Inlet Port Le 1 13 16 15 16 11 32 Spot Drill 000 2 Holes Pressure Adjustment Dashed Line 200 Mount R H Nozzle Port i 1 8 NPTF Easy Flow Bleeder Valve 1 4 NPTF Solid Line 400 Mount or Gauge Port 1 8 NPTF Hub Mount Maximum Firing Rate gph 1725 rpm 3450 rpm 100 psi 300 psi 100 psi 300 psi JJ2 3 JA2 7 2 10 J2 16 J3 i 20 24 26 30 33 40 46 55 60 Model Number Special Pressure Spring Choices A 20 40 psi C 150 300 psi E 10 20 psi B 75 200 psi D 40 80 psi Do not adjust J2 and 3450 rpm only models JA JB JJ to higher than 100 psi Requires C spring 100 300 psi range 5Requires C spring and hardened gear Typical Mod
5. faster bleed if desired Return line must terminate 3 4 above supply line inlet see Figure 4 Failure to do this may introduce air into the system and could result in loss of prime For additional information see Two Pipe Installation Section 111 3 of this manual TWO PIPE SYSTEM MODEL A AND B OUTSIDE TANK FUEL UNIT ABOVE BOTTOM OF TANK FILL AIR PIPE vent FIGURE 4 Always terminate return line as shown in Figure 4 Line lengths include both vertical and horizontal lengths ALL INSTALLATIONS SHOULD BE MADE IN ACCORDANCE WITH LOCAL AND NATIONAL CODES Il 10 MODEL SINGLE STAGE TWO STAGE 7WO PIP MAXIMUM LINE LENGTH H 3450 RPM 3 8 OD 1 2 OD 5 8 OD Tubing Tubing Tubing 10 GPH 16 10GPH 16 23 GPH 33 29 100 100 100 31 27 100 100 i 100 28 25 100 98 100 25 23 100 89 100 23 20 92 80 100 21 18 82 72 100 18 16 72 63 100 16 14 62 55 88 13 12 52 46 72 17 9 43 37 56 33 29 39 Lift H Figure 4 MODEL B TWO STAGE TWO STEP AND TWO STAGE HIGH PRESSURE 7WO P PE MAXIMUM LINE LENGTH H 3450 RPM 3 8 OD 1 2 OD 5 8 OD Tubing Tubing Tubing 10 GPH 16 10GPH 16 23 70 60 100 100 100 64 55 100 100 100 58 50 100 100 100 52 44 100 100 100 45 39 100 100 100 39 34 100 100 100 33 28 100
6. 100 i 100 27 23 100 91 100 21 18 81 70 100 57 49 100 Lift H Figure 4 Maximum firing rate not to exceed maximum nozzle capacity or strainer rating whichever is less A greater firing rate requires a suitable external strainer 11 11 SUNTEC ROTA ROLL FUEL UNITS MODEL J SINGLE STAGE AND MODEL H TWO STAGE INLET PORTS 1 4 NEW EASY FLOW AIR BLEED VALVE REGULATE E AND GAGE PORT PRESSURE PORT1 8 BY PASS PLUG INSERT FOR TWO PIPE RETURN SYSTEM PORT 1 4 GENERAL INFORMATION ALL SYSTEMS 1 Oil lines should not be smaller than 1 2 O D copper tubing See line sizing charts in this section or check line sizing on page 111 7 of this manual 2 Oillines must be airtight Check all connections and fittings Do not use teflon tape Do not use compression fittings 3 During initial start up or on a dry system prime the pump with clean lubricating oil or motor oil 4 Return line pressure must never exceed 10 PSI Higher pressures can damage the seal or cause leaks 5 Mounting Position J pumps can be mounted in any position H pumps can be mounted with the piston chamber regulating valve horizontal at either the top or bottom 12 ONE PIPE SYSTEM Do not install by pass plug Connect inlet line to pump inlet Start burner Open easy flow bleed valve one turn CCW Bleed unit until all air bubbles disappear Tighten easy
7. 16 BY PASS PLUG MODELB TWO STAGEFUEL INSERT FOR 2 PIPE SYSTEM UNIT HAS SAME PORTING USE 5 32 ALLEN WRENCH ARRANGEMENT AS MODEL A FIGURE 2 VACUUM CHECK A vacuum gage may be installed in either of the 1 4 inlet ports or in the 1 8 return port on single pipe installations whichever is most convenient The Model A pump should be used where the vacuum does not exceed 6 hg single pipe and 12 hg two pipe The Model B should be used where vacuum does not exceed 17 hg Remember running vacuum is the total of all pressure drops AP in the system from tank to inlet of pump PRESSURE CHECK f a pressure check is made use GAGE PORT NOZZLE PORT DO NOT USE EASY FLOW BLEED VALVE PORT FOR THE 7000 SERIES The easy flow bleed valve port contains pressure higher than operating pressure Setting pump pressure with gage in the easy flow bleed valve port results in WRONG operating pressure The 7400 is an exception see Figure 2 CUTOFF PRESSURE Average cutoff pressure for A and B fuel units is 80 psig To check cutoff pressure install pressure gage in nozzle port Run burner for short period of time Shut burner off Gage shows cutoff pressure Il 2 CAUTION Pressurized or gravity feed installations must not exceed 10 P S I on inlet line or return line at the pump A pressure greater than 10 P S I may cause damage to the shaft seal SOLENOID WIRING DISCONNECT POWER SUPPLY BEFORE WIRING TO PRE
8. DO NOT USE LESS THAN WITH UNDERWRITERS AND 3 8 0 0 TUBING LOCAL REGULATIONS INTAKE FUEL FILL AIR UNI AUX FILTER RETURN INSTALL AS SHOWN UNLESS PROHIBITED BY LOCAL REGULATIONS R FIGURE 3 Maximum recommended horizontal run for suction or return For conditions longer than the charts please contact factory Although there is a chart for 3 8 copper lines it is recommended that you not use less than 1 2 copper tubing On all installations running vacuum and return line pressure should be checked before leaving any installation 11 14 LIFT CONDITION MAXIMUM LINE LENGTH Lift H 3 8 O D Tubing 1725 RPM Figure 3 J J H H 6 2 3 0 48 37 100 90 42 32 100 83 36 28 92 76 30 28 84 70 18 76 63 68 56 60 52 43 35 5 LIFT CONDITION MAXIMUM LINE LENGTH H R Lift H 1 2 O D Tubing 1725 RPM Figure 3 mem rete 5 6 2 3 4 5 0 100 100 100 100 100 100 100 100 100 100 100 100 4 100 100 100 100 100 100 100 911100100 100 100 95 73 100 100 100 100 71 55 100 100 100 100 48 36 100 100 100 100 100 100 100 100 100 100 100 100 100 100 97 83 FIGUHE 3 Figure 3 continued on next page Il
9. Electrical connector Electrical connector 3753865 IV 18 WARRANTY AND RETURNED GOODS POLICY WARRANTY SUNTEC HEATING PRODUCTS MANUFACTURED BY SUNTEC INDUSTRIES INCORPORATED Suntec Heating Products are warranted to be free from defects in material and workmanship for the warranty period hereinafter defined when properly installed maintained and operated under normal use SUNTEC DISCLAIMS ANY LIABILITY FOR THE FAILURE OF PERFORMANCE OR MALFUNCTION OF THESE PRODUCTS RESULTING DIRECTLY OR INDIRECTLY FROM THE PRESENCE OF WATER RUST TEFLON TAPE OR CONTAMINATES IN THE SYSTEM Components not manufactured by Suntec are warranted only to the extent of and by the original warranty Effective with fuel units manufactured March 1 1987 and later the warranty period is A 3 years for residential units rated at 7 gph or less B 2 years for units rated over 7 gph C 1 year for waste oil units and D 1 year for solenoid valves and coils The warranty is limited to repair or replacement at Suntec s option either at its factory or a Suntec Approved Service Station transportation charges prepaid of products which shall be determined by Suntec or its Approved Service Station upon examination to be defective In the event in warranty products forwarded to a Service Station are tested and found not defective the Service Station is authorized to apply a nominal testing charge Service Stations will replace de
10. Il 27 FEEDER INES SUSPENDED FURNACES SHUT OFF VALVE 1 2 0 D TUBING AUXILIARY FILTER INLET LINE 1 1 4 PIPE 1 2 0 0 TUBING RETURN LINE i SUNTEC MAX LIFT H BOOST PUMP i amp MOTORSET APPROX 3 INCHES FIGURE 3 AUXILIARY TANK INSTALLATION AUXILIARY TANK Figure 3 illustrates a typical auxiliary tank installation It is a form of the loop system and subject to the same installation requirements In addition local ordinances governing auxiliary tanks should be complied with auxiliary tank doesn t need to be more than a few gallons in capacity Its advantages 1 Allows loop to be completed in close proximity to the main supply tank 2 Eliminates line surges and race conditions PRESSURIZED SYSTEM Figure 4 illustrates a pressurized system Although it is the least common installation it can be used where space and distance limitations preclude using loop system WHEN INSTALLING THIS SYSTEM 1 The pressure in the manifold must not exceed 10 psi when the boost pump is running and no burners are firing Il 28 MANIFOLD AIR BLEED MAX INTAKE PRESSURE HIGHEST POINT IN LINE AT BURNER 10 PSI PIPE CAP 0 30 PSI 1 2 0 D TUBING PRESSURE GAGE MANIFOLD LINE AUXILIARY SHUT OFF SUNTEC BOOST FILTER VALVE 1 2 0 0 TUBING INLET LINE PUMP amp MOTORSET RETURN LINE APPROX 3 INCHES FIGURE 4 PRESSURIZED SYSTEM INSTALLA
11. NEW INSTALLATIONS FOR NEW LINES NOTE The formulas in this section are set up to keep new installations within practical design limits for fuel pumps Viscosity used for calculations is 57 saybolt secs universal 8 04 centipoise 9 6 centistokes Calculated lengths do not include valves filters and an unusual number of 90 elbows Installations should avoid putting fuel oil where it is exposed to temperature extremes The pour point limit for 1 and 2 fuel oils not seasonally adjusted is 0 F and 20 F respectively GEARSET INLET LINE FLOW GALLONS PER HOUR Suntec Model No Flow at 1725 rpm Flow at 3450 rpm LENGTH OF RUN L The length of piping from tank to fuel unit is calculated using the following formulae which are based on flow properties for a given tubing size FIGUHE 9 L Horizontal run in feet from tank to fuel unit H Vertical distance in feet from bottom of tank to centerline of pump Q Gearset or line flow in gallons per hour gph V Vacuum in inches of mercury in hg EXISTING INSTALLATIONS The following formula can be used to determine what the vacuum should be on various line lengths of different size line tubing The resulting figures 7 may be used to determine if the configuration of an existing installation could cause system performance problems Tube Size O D inches 035 wall Tank Below Pump
12. UNIT AUX f FILTER i MAXIMUM ONE PIPE LIFT 8 FT i FIGURE 4 TWO PIPE SYSTEM REMOVE 1 16 BY PASS PLUG FROM PLASTIC BAG ATTACHED TO UNIT Remove 1 4 plug from return port Insert by pass plug see Figure 1 or 2 Attach return and inlet lines Start burner air bleeding is automatic Opening easy flow air bleed valve will allow a faster bleed if desired Return line must terminate 3 4 above supply line inlet see Figure 5 Failure to do this may introduce air into the system and could result in loss of prime For additional information see Two Pipe Installation Section page 111 3 of this manual Always terminate return line as shown in Figure 5 Line lengths include both vertical and horizontal lengths OUTSIDE TANK FUEL UNIT ABOVE BOTTOM OF TANK FILL FUEL UNIT PIPE AUX FILTER FIGURE 5 Il 4 SINGLE STAGE 7WO P PE MAXIMUM LINE LENGTH H R Lift H Figure 5 1725 RPM 3450 RPM 3 8 OD Tubing 1 2 OD Tubing 3 8 OD Tubing 1 2 OD Tubing 20400 R QUN Q 3 GPH 3 GPH 3 GPH 7 GPH 3 7 GPH 86 80 75 70 64 5 54 49 43 37 32 26 21 100 100 100 100 100 100 100 100 100 100 100 100 85 63 42 84 71 66 62 57 53 48 44 39 35 36 st 9r 27 22 78 73 68 63 57 52 47 42 26 2 1 100 100 10
13. boost pump and proceeding to furthest away System should be ready for normal service SERVICE 1 Check periodically for water accumulation 2 Change filter external as needed 3 4 Check pump strainer Periodically check for manifold pressure Il 31 TROUBLE SHOOTING PROBLEM SOLUTION Boost Pump doesn t run Check electrical connections and supply check for discharge and return line blockages Boost Pump runs but doesn t supply oil Measure inlet vacuum If too high check inlet line filter and valves Check to see that by pass plug is properly installed Check to see that inlet line has no air leaks Boost Pump supplies oil but burners do not fire Check capacity of boost pump to see that it exceeds total burner requirements Check to see that pressure rating of boost pump isn t exceeded by head requirements In system check to see if oil is passing through the stand pipe or riser Burner pump seals leaking Check inlet line pressure to burner pumps 1 32 PIPING Correct piping is critical to long term operation of any fuel oil system Improper line sizing will not only cause present and future service problems but can also cause premature failure of the components supplied by it SINGLE PIPE OR ONE LINE SYSTEM PRESSURE OPTIONAL PORT 1 8 NPTF 1 8 NPTF INLET PORT NOZZLE PORT 1 4 NPTF INLET OR SUCT
14. easyflow valve and bleed oil for 15 seconds after foam is gone in bleed hose Check intake line fittings for tightness Check all pump plugs for tightness Tighten or replace coupling Install fuel unit with correct rotation See form no 440100 Return unit to approved service station or Suntec factory for repair Check for water and dirt in tank IV 4 FUEL PUMP TROUBLESHOOTING GUIDE CAUSE REMEDY p _ _ _ ___ OIL LEAK Loose plugs or fittings Leak at pressure adj screw or nozzle plug Blown seal single pipe system Blown seal two pipe system i Dope with good quality thread sealer Retighten ets Washer may be damaged Replace the washer or o ring oes Check to see if by pass plug has been left in unit Replace fuel unit pose Check for kinked tubing or other obstructions in return line Replace fuel unit UM Replace fuel unit 29 Tighten cover screws replace damaged gasket NOISY OPERATION Bad coupling alignment Air in inlet line Tank hum on two pipe system and inside tank re Loosen fuel unit mounting screws slightly and shift fuel unit in different positions until noise is eliminated Retighten mounting screws iets Check all connections Use only good flare fittings is
15. firing rate not to exceed maximum nozzle capacity or strainer rating whichever is less A greater firing rate requires a suitable external strainer C5 CO C 4 C C5 C5 C C 11 19 WASTE OIL PUMPS Waste oil pumps are designed to supply oil up to 1500 centistokes to remote tanks or heaters Line sizing listed below is calculated for multi weight oils such as 10W 30W maintained at 329F minimum and straight weight oils such as 40W 50W 90W heavier gear lubes maintained at 50 F minimum Maximum Pump Delivery Operating Horsepower Monel Pesar Vacuum lt 1000CST gt 1000CST J3NBN A132B 20 40 psi 20In Hg 1 6 HP 1 4 HP A2RA 7736 30 psi 1 8 HP 1 8 HP 0 100 psi 1 7 HP 1 7 HP A2RA 7737 10 20 psi 1 8 HP 1 8 HP 10 20 psi 1 7 HP 1 7 HP A1RA 7738 100 150 psi 1 8 HP 1 8 HP 20 In Hg for fuels more viscous than 2 fuel oil 10 In Hg for 2 fuel oil and lighter Use alternate nozzle port INLET OR SUPPLY LINES Pump Model Inlet Line Inlet Line Number Size I D L Maximum J3NBN A132B 3 4 in 20 ft J3NBN A132B 60 ft A2RA 7736 7737 7738 1 2 in 20 ft A2RA 7736 7737 7738 3 4 in 90 ft Waste oil pumps are designed for one pipe or single line installation Do not install the by pass plug Do not use teflon tape Use J I C flare or pipe fittings only Do not exceed 10 psi manufacturer or 3 psi NFPA when supply
16. flow bleed valve Figures 1 and 2 show typical one pipe installations J and H pumps are not recommended for lifts H above two feet or 2 inches mercury inlet vacuum with the exception of the J2XXF pump For additional information see Single Pipe Installation Section page 111 1 of this manual Figures 1 and 2 are typical one pipe systems INSTALL IN ACCORDANCE WITH LOCAL AND UNDERWRITERS REGULATIONS SHUT OFF VALVE LINE FILTER FIGURE 7 NOTE J MODELS NOT RECOMMENDED FOR LIFT ABOVE TWO FEET SINGLE PIPE EXCEPTION J2 F MODELS WHICH INCLUDE THE NEW BLEED CHECK VALVE FUEL LINE UNIT FILTER INLET FIGURE 2 Il 13 L Line Length in Feet H Head in Feet Q Firing Rate in GPH 3 8 Line L 2 75H 1 2 Line L 2 75H 0086 00218 If tank is above pump change to Fittings valves and filters will reduce total length allowed TWO PIPE SYSTEM Install by pass plug inside the return port of the pump using an allen wrench and making sure it is tight See illustration at the beginning of this section On a connected two pipe the fuel pump is selfpriming Model J can be used two pipe to 12 inch mercury vacuum Model H can be used to 17 inch mercury vacuum For additional information see Two Pipe Section page 111 3 of this manual Figures and 4 are illustrations of typical two pipe installations INSIDE OR OUTSIDE TANK FUEL UNIT ABOVE BOTTOM OF TANK INSTALL IN ACCORDANCE
17. in the circuit Operation is simple Pressure developed by the oil burner fuel unit closes the low voltage switch connected to the fuel unit This causes the switch relay to energize the boost pump which starts and stops automatically with the oil burner For initial start up the switch relay may be held in manually or a manual ON OFF switch may be connected across the low voltage wire leading from the switch relay to the pressure switch With the manual switch in the ON position the boost pump runs continuously START UP 1 Start boost pump manually 2 Set boost pump pressure in manifold to 10 psi or less at closest burner to the boost pump Il 30 4 5 FIGURE 5 WIRING FOR CONSTANT OPERATION NNECT PR PRESSURE SWITCH pc oe NORMALLY OPEN UNIT GAGE PORT NT PARTNO ee 1 8 NIPPLE OF LENGTH TO CLEAR STRAINER COVER 1 8 1 8 PIPE PLUG MANUAL BOOST LOW VOLTAGE if PUMP SWITCH cLOSED CONTINUOUS OPERATION TWO CONDUCTOR lt fi OPEN OPERATES ONLY UPON BURNER DEMAND SWITCH RELAY MINNEAPOLIS HONEYWELL TYPE NO RA89A GENERAL CONTROLS 0 TYPE NO 50000D6 PENN CONTROLS INC NO 791BEOILU WHITE ROGERS CO NO 809A 3 OR EQUIVALENT WIRE LINE VOLTAGE TO BOOST POWER SUPPLY PUMP MOTO FIGURE 6 WIRING FOR INTERMITTENT OPERATION Pressurized system bleed manifold of all air All systems bleed pumps starting with closest to
18. needle jiggling Step 5 If reading is high or low readjust pressure adjustment screw NOTE On Model J or Model H fuel units there may be some leakage with the acorn nut removed This will stop when the nut is replaced Step 6 Turn burner OFF The pressure should fall to zero or to the amount of head on the fuel unit IV 10 PORT PRESSURE INLET PORT INLET PORT 1 4 NPTF 1 4 NPTF NOZZLE PORT PRESSURE PRESSURE ADJUSTMENT EASY FLOW BLEED amp GAGE PORT 1 8 NPTF FIGURE 4 PRESSURE GAGE LOCATIONS FOR OPERATING PRESSURE TEST FUEL UNIT OPERATING AND CUT OFF PRESSURE Step 1 Step 2 Step 3 Step 4 Step 5 NOTE Install gage into nozzle port Turn burner ON and observe gage Adjust pressure if necessary Turn burner OFF and observe gage Pressure should drop to 80 or higher pressure drops below 80 or continues to decay the fuel unit has faulty cut off and should be repaired or replaced A and B model pumps could theoretically have a cut off pressure of less than 80 The important operation is that it drops to some value and stops IV 11 STRAINERS FIELD SERVICE Fuel unit strainers are intended as a back up to not a replacement for proper system filtering Clogged strainers restrict oil flow into the gear set cause fuel units to operate at higher vacuum and eventually fail To diagnose a clogged strainer before it causes fuel unit failure it m
19. 0 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 87 8 83 70 62 52 41 35 TWO STAGE 7WO P PE MAXIMUM LINE LENGTH H R Lift H Figure 5 1725 RPM 3450 RPM 3 8 OD Tubing 1 2 OD Tubing 3 8 OD Tubing 1 2 OD Tubing 3 GPH 7 GPH 3 GPH 7 GPH 3 GPH 7 GPH 3 7 GPH 100 100 89 80 70 61 51 41 32 22 91 83 75 100 100 100 100 100 100 100 100 100 88 Il 5 100 100 100 100 100 100 100 100 100 74 93 85 77 69 60 52 44 27 80 73 66 59 52 45 38 36 3T 27 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 93 76 65 PUMP USAGE IDENTIFICATION IDENTIFICATION EXAMPLE MODEL STRAINER SERIES NUMBER Sava 7112 ROTATION amp NOZZLE LOCATION A B Max Nozzle Max Nozzle Model GPH Model GPH At 100 PSI At 100 PSI A1V 7100 3 B1V 8200 3 A2V 7100 B2V 8200 3 A2V 7400 B1Y 8900 7 A1Y 7900 B2Y 8900 7 A2Y 7900 Strainer UL Strainer Rating GPH Strainer Type 2 Fuel Oil A V 3 Y 7 T 16 G 23 B C D Maximum firing rate not to exceed maximum nozzle capacity or strainer rating whichever is less A greater firing r
20. 15 LIFT CONDITION MAXIMUM LINE LENGTH H une 1 2 Tubing 1725 RPM Figure 3 JJ JA JB J J J 2 2 2 2 3 4 0 100 100 100 100 100 100 100 100 100 100 100 89 91 91 91 75 73 73 73 60 55 55 55 45 36 36 36 30 18 18 CONDITION MAXIMUM LINE LENGTH H Lift 1 0 0 0 Tubing 3450 RPM Figure 3 HH HB H H H 2 2 2 3 4 100 100 100 100 100 100 100 100 100 100 100 93 100 100 94 100 96 83 73 90 83 72 76 70 60 53 62 57 49 43 48 44 33 30 26 23 FIGURE 3 Figure 3 continued on next page 11 16 LIFT CONDITION MAXIMUM LINE LENGTH H mm 5 8 O D Tubing 3450 RPM Figure 3 JJ JA JB J J J 2 2 2 2 3 4 0 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 83 51 51 51 41 LIFT CONDITION MAXIMUM LINE LENGTH H R 5 8 O D Tubing 3450 RPM Lift H Figure3 HH HA HB H H H 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 92 92 85 73
21. 3 DO NOT INSTALL BY PASS PLUG Connect inlet line to pump inlet Start burner Arrange primary burner control for continuous operation during purging Open easy flow bleed valve 1 turn CCW Bleed unit until all air bubbles disappear HURRIED BLEEDING WILL IMPAIR EFFICIENT OPERATION OF UNIT Tighten easy flow bleed valve securely For additional information see Single Pipe Installation Section page 111 1 of this manual ONE PIPE SYSTEM MODEL A FUEL UNIT AUX MAXIMUM ONE PIPE LIFT 8 FT EE FIGURE 3 The SUNTEC MODEL 70 FUEL UNIT be installed ONE PIPE with gravity feed or lift The maximum allowable lift is 8 ft see Figure 3 IMPORTANT One pipe installations must be absolutely airtight or leaks or loss of prime may result Bleed line and fuel unit completely Bleed for 15 seconds after last air is seen from easy flow to be certain lines are air free Il 9 L Line Length in Feet H Head in Feet Q Firing Rate in GPH 3 8 Line L 6 75H 1 2 Line L 6 75H 0086 Q 00218 If tank is above pump change to Fittings valves and filters will reduce total length allowed TWO PIPE SYSTEM FIGURE 4 REMOVE 1 16 55 PLUG FROM PLASTIC ATTACHED TO UNIT Remove 1 4 plug from return port Insert by pass plug see Figure 1 or 2 tighten plug Attach return and inlet lines Start burner air bleeding is automatic Opening easy flow air bleed valve will allow a
22. 64 FIGURE 3 Il 17 INSIDE OR OUTSIDE TANK FUEL UNIT BELOW BOTTOM OF TANK AIR VENT FILL PIPE 4 DO USE LESS THAN 3 8 0 0 TUBING UNIT 12 FIGURE 4 GRAVITY FEED MAXIMUM LINE LENGTH H A Distance 3 8 O D Tubing 1725 RPM PS J J H H 5 6 4 5 0 41 31 75 75 70 60 jl 45 34 78 78 72 62 2 48 36 80 80 75 64 Distance 3 8 O D Tubing 3450 RPM J HA HB 6 2 2 2 5 0 19 15 25 25 25 T 21 16 26 26 2 23 27 28 Distance O D Tubing 3 Fig 4 HH HB 2 2 100 100 100 100 100 100 1 18 PUMP USAGE IDENTIFICATION EXAMPLE J3 100 PRESS RATING NO LETTER 100 PSI ROTATION STRAINER TYPE MODEL Strainer UL Strainer Rating GPH Type 2 Fuel Oil Pe 7 amp Unites J PUMP Nozzle Capacity Max Nozzle Capacity GPH at Rated GPH at Rated Model Pressure Model Pressure 1725 3450 1725 3450 RPM RPM RPM RPM JA2B 7 HA2B JB2B 10 HA2P JJ2B 3 HH2B J2B 16 H2B J2BF 16 H2P J3B 20 ta 14 J3P B 14 H3B C J4P pm 158 H3P N C JSP J6B B J6B N C J6B C H5P JK H6B C H6P H6P C N C H7P B H7P H8P HP N C Maximum
23. 725 2850 3450 rpm e Suitable for no 2 no 1 fuel oil or kerosene e Mounting in any position e Factory set at 100 psi e Adjustable range 100 150 psi at 3450 rpm 100 135 psi at 1725 rpm Models available to 200 and 300 psi SPECIFICATIONS ORDERING INFORMATION Pressure Gauge Port 1 8 NPTF 1 8 NPTF FI Inlet Port 1 4 NPTF Single Stage Models lange Mount Inlet Port 1 4 NPTF r Return amp Internal Bleeder Valve By Pass Port 1 4 NPTF Model Number RPM Rotation Nozzle Port Location Strainer amp Nozzle Rating at 100 psi Special Features A1VA 7112 A1VB 7113 A1VC 7114 A1VD 7741 A1YA 7912 A2VA 7142 A2VA 7116 A2NB 7117 A2VC 7118 A2VA 7416 A2YA 7916 A2YA 7430 A2VD 7519 A2RA 7736 A2RA 7737 A1RA 7738 1725 1725 1725 1725 1725 2850 3450 3450 3450 3450 3450 3450 3450 R H R H L H LH R H R H R H R H L H R H R H R H L H 3450 1725 RH 3450 1725 1725 L H LH R H R H R H R H LH L H R H R H R H R H 3 gph 3 gph 3 gph 3 gph 7 gph 2 25 gph 3 gph 3 gph 3 gph 3 gph 7 gph 7 gph 3 gph 2 5 2 5 gph 2 5 2 5 gph 25 Also apply to 6 model numbers shown on fuel unit For example 7916 6 etc Viewed from shaft end Use gage port for rated flow 1725 rpm no c
24. D FROM THE FIELD WILL BE STAMPED IN A SIMILAR MANNER AS ABOVE THEREFORE REPAIRED PRODUCTS WILL HAVE AT LEAST TWO DATE CODES STAMPED ON THEM THE LATEST DATE WILL PREVAIL IN ALL CASES RETURNED GOODS Product should be returned to Suntec prepaid unless prior written approval has been received from Suntec In warranty product will be repaired and returned at no additional cost If the product is out of warranty the customer will be notified of the cost to repair it and given the option of having it repaired or having the unrepaired product returned collect Suntec DOES NOT issue credit for product being returned for repair whether the product is or is not in warranty When an unusual situation arises and product must be returned to Suntec written approval must first be received from Suntec Upon inspection of the returned product Suntec will determine if the product is suitable for resale If it is the customer will be assessed a 35 restocking charge and the balance credited to the customer s account less any consequential charges incurred IV 20
25. INLET 1 4 i 28 0 ewmmme A2RA 7736 Fa EASY FLOW 1 4 BLEED VALVE FIGURE 4 Install a vacuum gage in the inlet line close to the pump or in unused inlet port During operation vacuum must not exceed the operating vacuum previously listed in this section PRIMING PROCEDURE It is advisable on initial start up to prefill the pump with clean room temperature oil through the inlet port Start pump and open bleed valve Bleed pump for several minutes or until air free oil is observed flowing from bleed port Il 22 BOOST PUMPS LIFT PUMPS TRANSFER PUMPS CENTRAL SYSTEMS It is easier to push fuel oil to a given location than to pull it to the same location This is easily understood when you consider the forces available Fuel oil starts to separate or boil at vacuum levels as low as 10 in hg This is equivalent to a pressure differential of 4 9 psi If you push the oil you have pressure differentials of up to 300 psi available with no separation or boiling of the oil Simplified this means that having the pump lift oil you are limited to about 15 feet of vertical lift With a pressure of only 100 psi the oil can be pushed or pumped up more than 200 feet IMPORTANT POINTS TO REMEMBER 1 A boost pump is a fuel oil pump subject to the same restrictions as any other fuel pump 2 Install boost pump as close to the supply of fuel oil as economically and physically possible
26. ION LINE GULU 1 8 NPTF EASY FLOW BLEED VALVE INLET PORT RETURN amp INTERNAL 1 4 NPTF BY PASS PORT OPTIONAL 1 4 NPTF N NLET FIGURE 1 INLET PORT INLET PORT 1 4 NPTF 1 4 NPTF INLET OR SUCTION OPTIONAL O LINE PRESSURE ADJUSTMENT R H NOZZLE PORT 1 8 NPTF EASY FLOW BLEED amp GAGE PORT 1 8 NPTF FIGUHE 2 11 1 DO NOT Install by pass plug Will damage seal e Use compression fittings Will eventually leak Use teflon tape Will void warranty e Use check valves Especially on gravity feed systems See Thermal Expansion page 111 12 e Exceed 10 psi manufacturer or 3 psi NFPA inlet line pressure e Exceed 6 hg running vacuum for Suntec and fuel units 2 hg running vacuum for Suntec J and fuel units DO Use 37 JIC flare fittings e Use anon hardening thread sealing compound e Prefill prime the pump on long runs to reduce dry running time e Check all unused pump fittings for tightness Bleed system Open bleed port approximately one turn Bleed for 15 seconds after clear oil begins flowing out of port Close bleeder valve tightly e See page IV 1 if pump fails to prime or deliver TANK ABOVE THE PUMP OR GRAVITY FEED SHUT OFF DO NOT USE 477 VALVE CHECK VALVES FOR SERVICE IN GRAVITY FEED INSTALLATION FILTER FIGURE 3 NOTES FOR FIGURE 3 1 H vertical distance
27. LE FREE LOOP SYSTEM USE THE FOLLOWING GUIDELINES 1 The manifold is to be above all the pumps being supplied 2 The manifold should be level at worst case A slight rise in the system will aid in air purging 3 A2 ft riser or kick at the end of the run will insure the manifold fills 4 Alarge return line is necessary to prevent siphoning of the manifold and or overflowing of the vent 5 Pumps on burners supplied by the boost pump should be connected or installed single pipe No by pass plug and no return lines on the burners Il 26 MAX INTAKE GAGE 1 2 0 0 TUBING De PRESSURE AT FIRST MANIFOLD LINE BURNER 10 PSI USE A 0 30 PSI GAGE SHUT OFF VALVE XILIARY FILTER RS 1 1 4 PIPE 1 2 TUBING RETURN LINE SUNTEC BOOST PUMP amp MOTORSET APPROX 3 INCHES FIGURE 2 LOOP SYSTEM INSTALLATION Boost Pump 1 2 Tube 1 2 Pipe 3 4 Pipe B 300 500 2500 H3 175 300 1800 H6 50 100 600 TABLE 2 MAXIMUM HORIZONTAL LINE LENGTH 10 20 PSI SPRING FACTORY PRESET AT 10 PSI longer runs contact the factory 6 Maximum pressure at the inlet port to any of the burner pumps is 10 psi by design However N F P A states that maximum allowed is 3 psi Use the lowest number per applicable codes If the pressure is going to be higher than permissible a pressure reducing and or a vacuum valve must be installed to reduce inlet pressure to the pump
28. LE INLET 1 4 PORT 1 8 __ PRESSURE GAGE PORT 1 7 INLET 1 4 1 16 BY PASS PLUG INSERT FOR 2 PIPE SYSTEM USE 5 32 ALLEN WRENCH FIGURE 2 RETURN 1 4 VACUUM CHECK A vacuum gage may be installed in either of the 1 4 inlet ports or in the 1 8 return port on single pipe installations whichever is most convenient The Model A pump should be used where the vacuum does not exceed 6 hg single pipe and 12 hg two pipe The Model B should be used where vacuum does not exceed 17 hg Running vacuum is the total of all pressure drops AP from the tank to the inlet of the pump CAUTION Pressurized or gravity feed installations must not exceed 10 P S I on inlet line or return line at the pump A pressure greater than 10 P S I may cause damage to the shaft seal TWO STEP PUMPS FIGURE 2 MODEL SHOWN IS RIGHT HAND ROTATION ALL PORTS ARE REVERSED FOR LEFT HAND ROTATION SOLENOID WIRING Refer to burner manufacturer s manual for instructions Il 8 REGULATOR SETTING Install pressure gage in gage port remove after adjustment proper nozzle in nozzle line e Low Fire With solenoid de energized adjust low fire regulator to desired pressure Range 100 to 200 PSI e High Fire With solenoid energized adjust high fire regulator to desired pressure Range 200 to 300 PSI NOTE EXTERNAL CUTOFF VALVE IS REQUIRED ONE PIPE SYSTEM FIGURE
29. Model A Model J Model B Model H Single Pipe System Gin hg 2 in hg 6 in hg 2 in hg Two Pipe System 12 in hg 12in hg 17 in 17 in hg Step 4 If the gage reading exceeds the level indicated for the fuel unit being used check the piping and the system layout refer to Suntec installation bulletins for details Step 5 If the lift and run is not excessive for the fuel unit model the problem could be caused by a the number and type of bends in the piping includes kinks and flattening b the number and types of fittings in the piping c the number type and condition of filters and strainers d the number and type of valves in the system and or e the level of contaminate build up on the inside walls of the System piping Step 6 If the vacuum level is NOT excessive and there is air in the oil there is usually a leak in the piping To check a Close the tank valve b Pull a vacuum on the system by the fuel unit c Shut the burner OFF System should hold the vacuum level for five minutes If system is two pipe the return line will have to be closed off at shutdown PRESSURE TEST FOR FUEL UMTS AND SYSTEMS SYSTEM PRESSURE WITH SYSTEM OPERATING Step 1 If fuel unitis on a positive head system shut tank valve OFF before installing gage Step 2 Install gage in gage port Step 3 Turn burner ON if pump is on single pipe lift system bleed pump at the bleed valve Step 4 Observe gage disregard
30. NS Occasionally you will find existing installations which do not conform to good practice or proper installation The correct procedure is to replace these piping configurations with correct piping However in the real world this is sometimes impractical or financially impossible The following information will help you identify and work with these types when you encounter them in the field MULTIPLE UNITS WITH UNDERSIZE OR OVERSIZE INLET MANIFOLDS S NGLE PIPE TANK ABOVE OR BELOW FUEL UNITS 26 r gen MANIFOLD NOT RECOMMENDED FIGURE 10 Line Sizing The manifold or supply line must be sized to accommodate the total firing rate of all units connected to the manifold A B C D as shown above See Installation Section for specific model for single line calculation formula Priming Bleed or prime units beginning with the unit closest to the tank and working outward Since priming this type of system would require extended operation of the fuel units with dry gear sets the fuel unit should be filled with oil before beginning Recommendation This type of system should be supplemented with a boost pump system to provide the proper oil supply to the fuel units See Boost Pumps or Transfer Pumps page II 23 11 10 TWO PIPE 7ANK ABOVE OR BELOW FUEL UNITS INLET MANIFOLD RETURN MANIFOLD NOT RECOMMENDED FIGURE 11 Line Sizing The manifolds or supply lines must be
31. PREFACE This manual was assembled with the service person and technician in mind Our objective was to give procedures and guidelines for efficient and successful fuel pump installation and service Many technical manuals contain the necessary information finding it is the problem This manual is divided into four major sections Sales What models to use and how they are identified Installation How to install the model selected Piping Good practice piping installations and how to cope with non recommended piping found in previous installations Service How to test and service new and existing installations We have addressed situations found in the field which are not good practice but since they have been in use we must contend with them If you have problems which you cannot answer please contact Suntec s field service department at 800 367 7116 We at Suntec appreciate your support and look forward to many more years of working with you TABLE OF CONTENTS SALES FUEL UNITS Model A Single Stage Model B Two Stage Model B Two Stage Two Step Model B Special Pressures Model J Single Stage Model H Two Stage VALVES Models and Solenoid INSTALLATION FUEL UNITS Model A Single Stage Model B Two Stage Model A Single Stage Two Step Model B Two Stage Two Step Model B Special Pressures Model J Single Stage Model H Two Stage OTHER PUMPS Model A Waste Oil Model J Waste Oil Boost Pumps an
32. SURE REGULATE PRESSURE PORT 1 8 EASY FLOW AIR BLEED VALVE OPTIONAL a DO NOT READ INLET 1 4 OPERATING PRESSURE RETURN 1 4 1 16 BY PASS PLUG INSERT FOR 2 PIPE SYSTEM RETURN LINE USE 5 32 ALLEN WRENCH FIGURE 5 INLET PORTS 1 4 USE EITHER NEW EASY FLOW af 2 AIR BLEED VALVE REGULATE i AND GAGE PORT PRESSURE PORT 1 8 BY PASS PLUG RETURN INSERT FOR TWO PIPE PORT 1 4 SYSTEM RETURN LINE FIGURE 6 4 Connect the return line to the fuel unit return port Use 37 JIC flare fittings Use a non hardening thread sealing compound Prefill prime the pump on long runs to reduce dry running time Start fuel unit without bleeding a properly installed two line system is self priming e See page IV 1 if pump fails to prime or deliver NOTE Atwo pipe or two line system has three lines connected to the fuel pump They are the inlet or suction line return line and nozzle line TANK ABOVE THE PUMP OR GRAVITY FEED SHUT OFF VALVE FOR SERVICE DO NOT USE CHECK VALVES QN GRAVITY FEED SYSTEMS 3 4 INCHES RETURN ABOVE INLET FIGURE 7 NOTES FOR FIGURE 7 1 H vertical distance from top of tank to centerline of pump 2 H must not exceed 27 feet to be within manufacturer s 10 psi inlet pressure limit or 8 feet to be within NFPA s 3 psi inlet pressure limit 3 See page lll 7 for line sizing 4 IMPORTANT Singl
33. Step 2 Turn burner ON and open bleed Step 3 When vacuum reaches 15 in hg close bleed port Step 4 Turn burner OFF Pump should hold vacuum level for five minutes NOTE If fuel unit cannot attain 15 in hg or hold that vacuum level for five minutes it should be repaired or replaced FUEL UNIT TWO PIPE SYSTEM PRESSURE 7 ADJUSTMENT D EASY FLOW BLEED GAGE PORT 1 8 NPTF FIGURE 2 VACUUM GAGE LOCATION FOR TWO PIPE SYSTEM Step 1 Remove inlet line from fuel unit and install vacuum gage in the inlet port see Figure 2 Step 2 Remove return line IV 8 Step 3 Turn burner ON Step 4 When vacuum reaches 15 in hg plug return port and turn burner OFF Step 5 Pump should hold vacuum level for five minutes NOTE If fuel unit cannot attain 15 in hg or hold that vacuum level for five minutes it should be repaired or replaced VACUUM TEST FOR SYSTEM SINGLE PIPE OPTIONAL INLET TWO PIPE OPTIONAL RETURN INLET FIGURE 3 VACUUM GAGE LOCATION FOR SYSTEM TEST Step 1 Install vacuum gage in the optional inlet port or tee into the supply line at the fuel unit If the optional inlet is used for the supply line install the gage in the cover inlet See Figure 3 Step 2 Turn burner ON and bleed the fuel unit if one pipe system Step 3 Close bleed valve and read gage Readings should be as follows IV 9 SINGLE STAGE TWO STAGE
34. TION 2 The pressure in the manifold must not exceed 10 psi nor less than zero when the boost pump is running and all burners are firing 3 The burner pumps must have vacuum valves on their inlets 4 The maximum horizontal run of the manifold line must be matched with selections from Table 2 Other configurations which are not recommended PSEUDO TWO PIPE Il 29 The intent is to gain the advantages of a two pipe operation while not causing the boost pump to supply burner pump gearset demand Actually the pump already does this internally without the external plumbing This system includes unnecessary piping and fittings which are possible sources of problems PRESSURIZED LOOP The intent is to have a full loop without vent and large manifold return Problems are 1 Requires boost pump pressure to be set higher than recommended to prevent oscillations between pump valve and manifold valve 2 Possible plugging of manifold valve putting too high pressure in manifold WIRING INSTRUCTIONS Wiring the system depends upon the operation desired constant or intermittent A CONSTANT OPERATION A voltage switch between the power source and the boost pump motor is used for simple ON OFF operation Figure 5 illustrates this circuit B INTERMITTENT OPERATION A pressure switch Suntec part number 128117 is connected in the gage port of each heater s fuel unit Figure 6 shows the switch s installation
35. VENT ELECTRICAL SHOCK OR EQUIPMENT DAMAGE Lead wires on these devices are long enough to reach the junction box on most burner installations Wire solenoid in parallel with burner motor see Figure 3 All electrical work should be done according to local and national codes Solenoid 115V 0 1A 60 Hz BURNER SOLENOID MOTOR TO RELAY 115V 60 Hz FIGURE 3 ONE PIPE SYSTEM DO NOT INSTALL BY PASS PLUG Connect inlet line to pump inlet Start burner Arrange primary burner control for continuous operation during purging Open easy flow bleed valve 1 turn CCW Bleed unit until all air bubbles disappear HURRIED BLEEDING WILL IMPAIR EFFICIENT OPERATION OF UNIT Tighten easy flow bleed valve securely Figure 4 For additional information see Single Pipe Installation Section 111 1 of this manual The SUNTEC MODEL A 70 FUEL UNIT may be installed ONE PIPE with gravity feed or lift The maximum allowable lift is 8 feet see Figure 4 IMPORTANT One pipe installations must be absolutely airtight or leaks or loss of prime may result Bleed line and fuel unit completely Bleed for 15 seconds after last air is seen from easy flow to be certain lines are air free L Line Length in Feet H Head in Feet Q Firing Rate in 3 8 Line L 6 75H 1 2 Line L 6 75H 0086 00218 Q If tank is above pump change to Fittings valves and filters will reduce total length allowed Il 3 FUEL
36. ate requires a suitable external strainer ALL INSTALLATIONS SHOULD BE MADE IN ACCORDANCE WITH LOCAL AND NATIONAL CODES Il 6 MODEL A SINGLE STAGE TWO STEP MODEL B TWO STAGE TWO STEP FUEL UNITS AND MODEL B TWO STAGE HIGH PRESSURE FUEL UNITS PRESSURE GAGE PORTUM RETURN 1 8 READ OPERATING PRESSURE REGULATE PRESSURE INLET 1 4 EASY FLOW AIR BLEED VALVE INLET 1 4 DO NOT READ OPERATING Lae PRESSURE 1 16 BY PASS PLUG INSERT FOR 2 PIPE SYSTEM USE 5 32 ALLEN WRENCH RETURN 1 4 FIGURE 1 GENERAL INFORMATION ALL SYSTEMS IMPORTANT INFORMATION Long or oversized inlet lines may require the pump to operate dry during initial bleeding period In such cases the priming may be assisted by injecting fuel oil into the pump gearset Under lift conditions oil lines and fittings must be air tight To assure this pipe dope may be applied to both the used and unused inlet and both return fittings DO NOT USE TEFLON TAPE DO NOT USE COMPRESSION FITTINGS MOUNTING POSITION Model Single Stage Fuel Unit may be mounted in any position Model Two Stage Fuel Unit may be mounted in any position except upside down 1 8 ports pointed down Il 7 REGULATOR SETTING W SOLENOID DE ENERGIZED REGULATOR SETTING LOW PRESSURE W SOLENOID ENERGIZED HIGH PRESSURE EASY FLOW AIR BLEED VALVE READ OPERATING PRESSURE NOZZ
37. contaminants to get into the pumping mechanism STRAINERS AS DIAGNOSTIC INDICATOR What you see in a strainer can be an indicator of what conditions may exist within the system a Clogged strainer Primary filter has failed or is missing b Sludge on strainer Water in the tank allowing biological growth Rust flakes on strainer Rusted tank or components Field replacement of 3 gph and 7 gph rated strainers Figure 1 All models and revisions of Model A70 and Model B80 fuel units To simplify field replacement and improve overall strainer efficiency only two strainer models are offered for replacement in standard Model A and Model B fuel units As shown a spring is required in some instances to compensate for the difference in strainer height and cover depth see Figure 1 Model Strainer Capacity Model Data Cover Strainer Spring Series Designation Revision Code Depth Part No Part No A All All 1 133 3715732 Not Req Y82 amp Earlier 1 345 3715732 3773231 3754732 D82 amp Later 1 620 3715744 Not Req 2 3 4 All 1 345 3715732 3773231 3754732 5 All 1 620 3715744 Not Req All All 1 620 3715742 Not Req All All 1 620 3715746 Not Req Model Revision last number of model number EXAMPLE B2VA 8216 5 FIGURE 7 STRAINER REPLACEMENT IV 18 Installation of strainer part no 3715732 in medium height c
38. d Central Systems PIPING Single Pipe Gravity Feed Lift Feed Two Pipe Gravity Feed Lift Feed LINE SIZING Single Pipe Two Pipe Adding Additional Units Priority Controls Multiple Units with Manifold Piping Gravity Feed Lift Feed Check Valves Thermal Expansion SERVICE Routine or Annual Checkout Trouble Call System Troubleshooting Sequence Troubleshooting Guide for Fuel Pump Testing Fuel Units and Systems Vacuum Test Fuel Units Vacuum Test System Pressure Test Operating and Cutoff Test Strainers and Field Service Filters and Filteration Solenoid Valves and Field Service Warranty Policy SUNTEC PERFORMANCE PROVEN FUEL UNITS AND VALVES for residential and commercial applications SUNTEC THE INDUSTRY LEADERS BUILT ON OUR COMMITMENT Knowing the industry s needs and responding to them with the right products and services is one of the responsibilities of leadership Over the years Suntec has been committed to being involved asking questions listening and providing answers Today as the industry leaders our involvement is as strong as ever We still work hard to earn your trust in us as the experts in our field You shouldn t have to settle for less MODEL A 7000 S NGLE STAGE FUEL UMTS Single pipe installations to 6 hg vacuum e Two pipe installations to 12 hg vacuum e or gravity feed applications with 10 psi maximum inlet return pressure e Choice of 1
39. e Boost pumps should be installed two pipe for air removal and self priming Two pipe requires installation of the by pass plug for proper operation In Figure 1 H is the vertical lift from the bottom of the tank to the center line of the boost pump R is the horizontal run or distance in feet from the tank to the boost pump Table 1 gives limits not to exceed in the installation of the inlet line to the boost pump PRESSURE OR SUPPLY SIDE There are two common systems used the loop system and the pressurized system Use of an auxiliary tank is a form of the loop system There are other piping configurations which are not recommended but are in use and will be discussed LOOP SYSTEM Figure 2 illustrates a single loop system It offers the advantage of only needing to keep the manifold full of oil supplied at a rate greater than the total firing rate of all the burners being supplied by the system Table Il 25 0 0 TUBING INLET LINE SUNTEC BOOST me PUMP amp MOTORSET Line Size 1 2 0 D Tubing 5 8 O D Tubing 1 2 Pipe Lift 0 7 15 0 7 15 0 7 10 100 100 24 17 TABLE 1 MAXIMUM INLET LINE LENGTH Pump Model 2 lists the maximum horizontal runs not to be exceeded These are calculated for standard boost pumps with the 10 20 psi spring For higher boosts or longer runs call the factory and get prompt help to install your system FOR A TROUB
40. e pipe installation is recommended for gravity feed systems It produces lower inlet line flow and longer filter life For example an A 70 fuel unit firing 1 gph single pipe has 1 gph flowing through the filter an A 70 pump firing 1 gph two pipe has 19 gph flowing through the filter 11 5 TANK BELOW THE PUMP OR LIFT FEED NOZZLE RETURN LINE TERMINATES 3 4 INCHES ABOVE INLET LINE FIGURE 8 NOTES FOR FIGURE 8 1 2 3 H vertical distance from bottom of tank to the centerline of the pump H must not exceed 12 feet for single stage fuel units or 18 feet for two stage fuel units IMPORTANT distance allowed is reduced by the number of fittings filters and valves installed in the line If the fuel lines extend higher than the centerline of the fuel unit they should not exceed 24 feet above the bottom of the tank or the fuel unit will not prime boost pump would be required See page 11 23 System running vacuum should not exceed 12 in hg for single stage fuel units or 17 in hg for two stage fuel units IMPORTANT Vacuum requirements are not limited by fuel unit capability Fuel oil will boil or de gas at vacuums as low as 10 in hg These bubbles can get into the nozzle line and cause a smoky or unstable flame Suntec two stage pumps are designed to prevent this with vacuums up to 17 in hg See page 111 7 for line sizing Ill 6 LINE SIZING 7WO P PE SYSTEMS
41. el Number Nomenclature Model J amp Model H T L Model Revision No Capacity Special Feature Strainer Capacity Special Customer Rotation amp Nozzle Req Location Mounting Style Piston Typ Pressure Range model number appears on the top of the fuel unit MODEL 7WO STAGE FUEL UNITS Two pipe high lift installations to 17 hg vacuum e Capacities to 83 gph e Lift or gravity feed applications with 10 psi maximum inlet return pressure e Six pressure options 10 to 300 psi e For no 4 and lighter fuel oils gasoline and JP fuels special e Three hub and flange mounting options Model H may be mounted with the valve horizon tal at either the top or bottom Valve may be mounted vertical provided the adjusting screw is at the top of CW rotation left nozzle and CCW rotation right nozzle models or adjusting screw at bottom on CW rotation right nozzle and CCW rotation left nozzle models SPECIFICATIONS ORDERING INFORMATION 004 Inlet Port Inlet Port Dashed Line 100 Mount Solid Line 300 Mount R H Nozzle Port Easy Flow Bleeder Valve Mo 1 8 NPTF Or Gauge Port 1 8 NPTF hanga Mount 1 4 NPTF Maximum Firing Rate gph 1725 rpm 3450 rpm 100 psi 300 psi 100 psi 300 psi HA2 7 H2 16 20 24 26 30 33 40 46 55 Model Number Special Pressure Spring Choices A 20 40 psi C 150 300 psi E 10 20
42. ems during alternate fuel operation b Where ambient temperature around the supply line is higher than the fuel temperature ceilings of industrial commercial buildings boiler rooms mobile home enclosed furnace vestibules 11 12 PREVENTION OF THERMAL EXPANSION PROBLEMS a Install relief valves in problem areas see Figure 14 b Do not use check valves c Install an accumulator in the line SUPPLY CHECK PRESSURE VALVE CONTROL VALVE BURNER FIGUHE 12 CLOSED OIL SYSTEMS 1 Aclosed system will occur between the check valve and the pressure control valve during burner off cycle 2 Aclosed system will occur between the pressure control valve and the burner pump since the regulating valve in the pump is also a positive shut off valve 3 Since the regulating piston in the pump is also a positive shut off valve a closed system will occur during burner off cycle even without the vacuum safety valve installed MANUAL SHUT OFF DUAL FUEL BURNER VALVE Y FIGURE 13 CLOSED OIL SYSTEM DUAL FUEL BURNER 1 A closed circuit will occur between the manual valve and the burner if the valve is closed during alternate fuel operation SUPPLY CHECK BY PASSING VACUUM OPERATED LINE VALVE RELIEF VALVE SAFETY VALVE BURNER RETURN TO SUPPLY FIGURE 14 BY PASSING RELIEF VALVE INSTALLATION 111 13 NOTE All installations should be in compliance with local and national codes Typical i
43. ew system into an old one Before tying into an existing system consider 1 What the running vacuum of the present system is See Vacuum Testing page 9 2 What the extra distance will be to the new fuel unit 1 8 If a new identical fuel unit will be installed side by side with the existing unit its addition will at least double the vacuum with both units running Line Sizing Lines should be sized to have a small enough inside diameter to allow complete purging of air during priming or bleeding and large enough to not cause excessive pressure drop or line losses which would cause the pump to operate with too high a vacuum Priority Contro s Relays which give operating preference to a specific unit can be used to assure that only one fuel unit is operating at a time For example priority is usually given to a hot water heater rather than a furnace or boiler INSTALLING PRIORITY CONTROLS 7wo options exist 1 Less than ideal Priority controls controlled by low voltage from the thermostat Disadvantage If the primary unit locks out on safety the secondary system cannot automatically operate 2 Preferred Use a power relay to establish priority based on line voltage demand Advantage Allows the line voltage to be available to the secondary unit if a fault occurs in the primary unit Should be installed by a qualified electrician 1 9 SERVICING NON RECOMMENDED EXISTING INSTALLATIO
44. fective products at their option with a new or rebuilt unit Suntec shall not be liable for damages for any breach of warranty in any amount exceeding the purchase price of the product found to be defective In no event shall Suntec be liable for incidental or consequential damages No agent dealer or other person is authorized to give any warranty on behalf of Suntec with respect to any Suntec product THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE PRODUCT DATE CODING PRIOR TO JANUARY 1991 THE MONTH INDICATED BY A CODE LETTER THE YEAR IS INDICATED BY THE LAST TWO DIGITS IN A THREE DIGIT CODE OR THE TWO MIDDLE DIGITS INAFOUR DIGIT IV 19 CODE EXAMPLES OF CODES THREE DIGIT H85 FOUR DIGIT C852 REFER TO THE CHART BELOW TO DETERMINE IF PRODUCT IS IN WARRANTY THIS SYSTEM WILL APPLY TO ALL PRODUCTS cx S MIT H Y DRAULIC MONTH JAN FEB MAR APRIL MAY JUNE JULY AUG SEPT OCT NOV DEC AFTER JANUARY 1991 THE MONTH IS INDICATED BY THE FIRST NUMBER IN A THREE NUMBER CODE AND THE FIRST TWO NUMBERS IN A FOUR NUMBER CODE THE YEAR IS INDICATED BY THE LAST TWO NUMBERS IN ATHREE OR FOUR NUMBER CODE co 1 2 314 5 6 718 9 101112 MONTH JAN FEB MAR APRIL MAY JUNE JULY AUG SEPT OCT NOV DEC ALL UNITS DATED AFTER MANUFACTURE REPAIRED PRODUCTS RETURNE
45. for power to the coil If YES go to Step 5 If NO repair electrical supply and recheck Step 5 Remove nut which holds the coil into the valve assembly Step 6 Remove coil from valve and slide it over an insulated handle screwdriver IMPORTANT to apply power to the coil without a screwdriver or other magnetic material in the center hole will cause the coil to overheat swell and fail CAUTION Even though the coil is f ully insulated care should be exercised to avoid touching the coil when energized except with insulated tools Step 7 Apply power to the coil You should feel vibrations and or magnetic pull on the screwdriver If YES go to Step 8 If NO replace coil and go to Step 2 Step 8 Replace tube assembly or complete valve assembly Step 9 Remove power from coil and start burner Check to see if oil is passing through the valve If YES replace tube assembly or valve assembly and go to Step 1 If NO valve is performing satisfactorily IV 17 VALVE ASSEMBLY PARTS 0 SO Q 9 No Description Part Order Number R Valve Valve Coil nut 3753818 3753818 Coil for R642N 3713642 R641D 3713809 R753 3713790 C642N 3713642 C641D 3713809 C753 3713790 Base plate screw 2 3773421 3773421 Base plate 3753762 3753864 Tube assembly 3713766 3713766 O ring 3773461 3773461 Valve Body 3723810 3723815 Gasket 2 2779261 Nozzle Screw 3753835 Electrical connector
46. from top of tank to centerline of pump 2 H must not exceed 27 feet to be within manufacturer s 10 psi inlet pressure limit or 8 feet to be within NFPA s 3 psi inlet pressure limit 3 See page 11 3 for line sizing 2 TANK BELOW THE PUMP OR LIFT FEED FIGURE 4 NOTES FOR FIGURE 4 1 H vertical distance from bottom of tank to centerline of pump 2 H must not exceed 8 feet for Suntec Model A and Model B fuel units or 2 feet for Suntec Model J and Model H fuel units 3 See page 11 3 for line sizing Even though pumps are capable of higher vacuums good practice dictates that initial installation of Model A and B pumps and J and H pumps with an F piston do not exceed 6 inches of mercury vacuum on initial installation when installed single pipe J and H pumps without an F piston should not exceed 2 inches of mercury vacuum on initial installation when installed single pipe TWO PIPE OR TWO LINE SYSTEM DO NOT e Use compression fittings Will eventually leak e Use teflon tape Will void warranty e Exceed 10 psi manufacturer or 3 psi NFPA inlet and return line pressures e Use check valves in gravity feed systems DO e Connect inlet or suction line to the fuel unit inlet port e Install the by pass plug as shown Failure to do so will cause improper fuel unit operation 1 3 PRESSURE GAGE PORT 1 8 READ OPERATING RETURN 1 8 PRES
47. ing to inlet of pumps It can cause seal damage FILTERS Waste oil pumps have an internal secondary 30 x 30 mesh strainer An external primary 50 x 50 mesh strainer is required This is supplied by the burner furnace manufacturer For transfer systems this must be supplied by installer user Il 20 TYPICAL TANK INSTALLATIONS A2RA 7736 RESERVOIR OR A2RA 7737 SIPHON PICK UP A1RA 7738 1 2 OR LARGER DISCHARGE LINE FILTER FROST SIPHON BY PASS 1 2 OR 3 4 I D INLET LINE RETURN FROM RESERVOIR OR FLOATING PICK UP FIGURE 7 TYPICAL TANK INSTALLATION R J3NBN A132B TO TANK OR HEATER 1 2 OR LARGER 50 x 50 MESH DISCHARGE LINE STRAINER SUNTEC S WASTE OIL TRANSFER PUMP AND MOTORSET 3 4 OR 1 I D INLET LINE WASTE OIL R FLOATING PICK UP FIGURE 2 TYPICAL TANK INSTALLATION Floating pickups are manditory for all waste oil systems They must be a comparable line size with the rest of the inlet line If ambient temperatures to oil supply lines are lower than recommended strip heaters should be installed 11 21 PUMP CONNECTIONS SUNTEC MODEL J3NBN A132B INLET 1 2 NPTF DISCHARGE 1 4 PRESSURE ADJUSTMENT BLEED PORT AND PRESSURE GAGE PORT 1 8 NPTF VACUUM GAGE FIGURE 3 SUNTEC MODELS A2RA 7736 A2RA 7737 A1RA 7738 ALTERNATE NOZZLE PORT PRESSURE GAGE PORT 1 8 DISCHARGE PORT 1 8
48. ks in the line due to using compression fittings bad flare fittings porous fittings loose fittings or leaky lines Disadvantages Check valves increase the amount of vacuum the fuel unit must overcome to supply oil to the system and reduce the distance supply lines can be run When installed near the fuel unit check valves cause turbulence and stripping of air from the oil resulting in dirty and or noisy combustion Do not use check valves in gravity feed tank above pump single pipe systems or in a system supplied by a boost or transfer pump Thermal expansion can cause serious problems Thermal Expansion Thermal expansion is a phenomenon in which a fluid increases in volume when heated When fuel oil is heated from 40 F to 70 F it will increase in volume by 1 1 2 Since oil will only compress at a rate of 1 10 thermal expansion will greatly increase the oil pressure in a closed system In a typical single pipe system an air pocket within the pump serves as a cushion against changes in pressure In a gravity feed or boost pump supplied system the air cushion is eventually absorbed creating a hydraulically hard or closed system which is unable to absorb pressure increases EFFECTS OF THERMAL EXPANSION a Leaks at pipe joints and fittings b Broken pressure gages c Leaks at filters d Leaks at fuel unit seals CONDITIONS WHERE THERMAL EXPANSION CAN CAUSE PROBLEMS a In single pipe dual fuel syst
49. n replacing filter elements care should be taken to not introduce the contaminant downstream to the fuel unit f If a filter element has collapsed the fuel unit and lines must be flushed prior to resuming burner operation g If filter has a screen in it make sure it is non corroding material Some are and some are not Field notes a Some filter elements will cause outgassing of fuel oil at low flows and relatively low vacuums 1 2 in hg This usually appears as a loss of prime on one pipe installations A field cure for this is to shut off the tank valve while priming the pump and put as much vacuum as possible on filter Open the tank valve and resume normal priming b When changing filters take care not to introduce contaminate from dirty element into down stream piping and fuel pump IV 15 c High vacuums across a filter element that appears to be clean can be caused by greasy bridging type contaminant IV 16 SOLENOID VALVES SERVICE R VALVE C VALVE INSTALLATION Model R valves mount directly into the nozzle port of the fuel unit Model C valves mount to the burner chassis or otherwise remote from the fuel unit OPERATIONAL CHECK Step 1 Remove nozzle line at the burner assembly end and place into container to catch oil Step 2 Start burner and watch for oil to run from the open line If YES go to Step 9 go to Step 3 Step 3 Turn burner OFF Step 4 Check
50. nstallation diagrams contained in this Technical Service Manual are for reference only 11 14 SERVICE Service on fuel units should not be attempted without the aid of good vacuum and pressure gages Many system problems can be detected with the aid of these gages Service falls into two categories routine and trouble ROUTINE ANNUAL OR OTHER CHECK OUT Check line filter and pump strainer for amount of contaminate If close to needing service replace to prevent a call back in near future If using inlet into the side of the pump it isn t necessary to remove cover to check the strainer Remove inlet line and view strainer through inlet opening If it s clean there it will be clean the rest of the way around If strainer is plugged remove cover and clean strainer with a brush and clean fuel Replace cover gasket before reinstalling System running vacuum should be checked as part of routine Running vacuum should not exceed 6 inches mercury for single stage one pipe 12 inches mercury for single stage two pipe 17 inches mercury for two stage two pipe Check and adjust system pressure if necessary Check CO or O and system draft Check for smoke and adjust to a trace Zero smoke is unclear as to where you are in adjustment Check for leaks at fittings and filters Correct any leaks that are found TROUBLE CALL In response to a trouble call approach the problem in a logical and systematic seq
51. odel number appears on the valve label 12 FOR A 7000 SINGLE STAGE AND B 8000 TWO STAGE FUEL UNITS MODELS 1 amp B1 FOR 1725 RPM BLACK LABEL MODELS A2 amp B2 FOR 3450 RPM WHITE LABEL PRESSURE GAGE PORT 1 8 READ OPERATING PRESSURE Tm REGULATE PRESSURE gt INLET 1 4 PORT 1 8 EASY FLOW AIR BLEED VALVE DO NOT USE TO CHECK PRESSURE SEE BELOW INLET 1 4 a RETURN 1 4 1 16 BY PASS PLUG INSERT FOR 2 PIPE SYSTEM USE 5 32 ALLEN WRENCH FIGURE 1 GENERAL INFORMATION ALL SYSTEMS IMPORTANT INFORMATION Long or oversized inlet lines may require the pump to operate dry during initial bleeding period In such cases the priming may be assisted by injecting fuel oil into the pump gearset Under lift conditions oil lines and fittings must be air tight To assure this pipe dope may be applied to both the used and unused inlet and both return fittings DO NOT USE TEFLON TAPE DO NOT USE COM PRESSION FITTINGS MOUNTING POSITION Model A Single Stage Fuel Unit may be mounted in any position Model B Two Stage Fuel Unit may be mounted in any position except upside down 1 8 ports pointed down 11 1 FOR ELECTRICAL READ OPERATING CONNECTIONS SEE PRESSURE SOLENOID WIRING REGULATE m di PRESSURE INLET 1 4 PORT 1 8 EASY FLOW AIR BLEED VALVE PRESSURE GAGE PORT INLET 1 4 wae RETURN 1 4 1
52. overs FIGURE 2 STRAINER INSTALLATION Step 1 Set spring part no 3773231 or 3754732 in cover with large coils up Step 2 Set strainer part no 3715732 on large coil Step 3 Install new gasket Step 4 Slide cover over gearset IV 14 FILTERS AND FILTRATION Filters are necessary in all fuel systems to capture contaminants which might develop and create operational problems They are the first line of defense while the strainers within a fuel unit serve as a secondary or back up filter Contaminants come in many varieties a Abrasive Accelerate wear on moving parts b Blocking Clog filters strainers and oil passages c Corrosive Chemically attack metal elements d Biological Cause all of the above Relative contaminant size a Smallest particle visible to the human eye 40 microns b Bacteria 2 microns 1 micron 000039 inch d 100 mesh screen opening 0059 inch 149 microns Contamination notes If filters require changing more than once year the filter is too small or the fuel system is too dirty b Ifthe fuel system is dirty it should be pumped out treated and refilled with clean oil If moisture is present it can rust the fuel system and parts and provide a breeding ground for bacteria d If the fuel tank is treated with a bacticide use only the recommended amount Too heavy a concentration can cause the fuel unit to become inoperative e Whe
53. psi B 75 200 psi D 40 80 psi Do not adjust H2 and 3450 rpm only models HA HB HH to higher than 110 psi 2Requires spring 100 300 psi range 3Requires C spring and hardened gear M DER amp SHUT OFF VALVES For instantaneous redundant cutoff of fuel supply e Provides back up protection e Closes when current to solenoid coil is interrupted Blocks oil flow to nozzle e Delay or non delay opening e Two model choices Model R mounts to fuel unit Model C mounts to burner or other remote locations e Easy installation e Use with any fuel unit rated up to 16 gph e Suitable for no 2 no 1 fuel oil or kerosene e Mount in any position l 10 SPECIFICATIONS ORDERING INFORMATION 3 8 Flexible Twin Lead Conduit AWG 18 105C SPT 1 Fitting Nozzle Plug Face Model R Twin Lead 3 8 Flexible AWG 18 105C SPT 1 Conduit Fitting 1 8 NPTF Model C Valve Model No Maximum Color Code Opening Voltage Pump Burner Response 50 60 Hz OPerating Mount Mount i Pressure Coll readies R642N C642N Non Delay 115 300 psi Black Orange White R641D C461D Delay 115 150 psi Grey Orange White R753N C753N Non Delay 220 300 psi Black Red White R261N C261N Non Delay 24 300 psi Green Blue Brown Yellow amp Green Typical Model Number Nomenclature Model amp Model C The m
54. s determined by the nozzle size pressure of the burner pump Example 2 We have five burners with the following firing rates 1 5 GPH Nozzle 150 1 8 3 0 GPH Nozzle 300 5 2 12 0 GPH Nozzle 100 12 0 5 0 GPH Nozzle amp 125 psi 5 6 1 25 Nozzle 100 psi 1 25 Total 25 85 nou m dg ou Select a BH1030 which will supply 30 GPH Remember 1 The boost pump is installed two pipe with a by pass plug installed and a return line 2 The burner pumps are installed single pipe no by pass plug installed and no return line If a pump is installed two pipe its return line will demand its gearset capacity If you had the smallest pump made this would be 20 GPH Installed single pipe the pump only demands its firing rate which is determined by the size of the nozzle in the burner 11 24 Example 2 100 A2VA 7116 100 A2VA 7116 INCORRECT PH Lg p LG MAG 5 GPH 2 GPH 12 GPH 1 GPH 7 154 GPH 2 100 A2VA 7116 H3BA 100 5 GPH 2 GPH 12 GPH 1 GPH INSTALLATION INSTRUCTIONS Note Install in accordance with the National Board of Fire Underwriters requirements local codes and ordinances where applicable INLET OR SUCTION SIDE OF BOOST PUMP Figure 1 illustrates the installation of the inlet or suction side of the boost pump and its return lin
55. se Tighten four screws on cover Air pocket between cut off valve and nozzle Run burner stopping and starting unit until smoke and after fire disappears Air leak in intake line Tighten intake fittings Tighten unused intake port and return plug Partially clogged nozzle Clean strainer or change nozzle Leak at nozzle adaptor Change nozzle and adaptor IV 6 FIELD TESTING FUEL UNITS INTRODUCTION Fuel units are sized to an application based on their pressure vacuum and flow ratings With today s high efficiency furnaces and boilers it is extremely important to check these parameters when the initial installation is made and also during later service calls to assure that high efficiency operation is being maintained It is also important to check fuel unit pressure and vacuum levels during trouble calls to help differentiate pump problems from system problems VACUUM TEST FOR FUEL UNITS AND INLET LINES FUEL UNIT SINGLE PIPE SYSTEM INLET PORT 1 4 NPTF PRESSURE ADJUSTMENT EASY FLOW BLEED amp GAGE PORT 1 8 NPTF FIGURE 7 VACUUM GAGE LOCATION FOR SINGLE PIPE SYSTEM IV 7 Step 1 Remove inlet line from fuel unit and install vacuum gage in the inlet port see Figure 1 If unit has been running dry pour oil into pump prior to testing
56. sized to accommodate the total gear set capacity not firing rate of all units connected to the manifold A C D as shown above See Line Sizing page III 7 for fuel unit gear set capacities If lines are undersized they must be replaced or use priority controls Return line manifold piping and input manifold piping must be the same size Priming Return line must terminate below the surface of the oil in the tank to maintain prime Start or prime units beginning with the unit closest to the tank and working outward Since priming this type of system would require extended operation of the fuel units with dry gear sets the fuel unit should be filled with oil before starting DRAWBACKS a Problems with one unit affects all units b Line sizes are a compromise c Troubleshooting is more complicated d Making and keeping system air free is time consuming RECOMMENDATIONS a Install individual lines to multiple units or b Incorporate a boost pump system to supply adequate fuel to the multiple units See Boost Pumps or Transfer Pumps page II 23 11 11 CHECK VALVES OTHER VALVES AND THERMAL EXPANSION Check Valves A properly installed fuel oil heating system does not require check valves for proper operation However check valves are often used to compensate for deficiencies in oil line piping For example a Not having the return line submerged in the oil in the tank b Having vacuum lea
57. ts Install return line hum eliminator in return line PULSATING PRESSURE Partially clogged strainer OF sasssa skanna Air leak in intake line ser Remove and clean strainer Replace filter element ibis Tighten all fittings IV 5 FUEL PUMP TROUBLESHOOTING GUIDE CAUSE REMEDY a PULSATING PRESSURE cont d Air leaking around cover Be sure strainer cover screws are tightened securely Check for damaged cover gasket LOW OIL PRESSURE Defective gage Check gage against master gage or other gage Nozzle capacity is greater than fuel unit capacity Replace fuel unit with unit of correct capacity See form no 2100 for GPH psi and R P M N IMPROPER NOZZLE CUT OFF To determine the cause of improper cut off insert a pressure gage in the nozzle port of the fuel unit After a minute of operation shut burner down If the pressure drops from normal operating pressure and stabilizes the fuel unit is operating properly and air is the cause of improper cut off If however the pressure drops to 0 psi fuel unit should be replaced NOTE The A 70 pump circuitry is designed to give a high cut off of superb quality Never use the amount of pressure drop as an indication of the quality or speed of cut off Filter leaks Check face of cover and gasket for damage Strainer cover loo
58. uence Jumping to a conclusion can sometimes temporarily fix the problem but not uncover the root cause of the problem An example is if there is water in the fuel which causes the pump to fail and you replace the pump only You will eventually be called back to replace the new pump SS lt In addition to the mechanical tools required also must have pressure and vacuum and suitable combustion analyzers IV 1 LARGER PAGE THAN THESE IV 2 LARGER PAGE THAN THESE IV 3 FUEL PUMP TROUBLESHOOTING GUIDE CAUSE REMEDY eee OTC NO OIL FLOW AT NOZZLE Oil level below intake line in supply tank Clogged strainer or filter Clogged nozzle Air leak in intake line Restricted intake line high vacuum reading A two pipe system that becomes airbound A single pipe system that becomes airbound Slipping or broken coupling Rotation of motor and fuel unit is not the same as indicated by arrow on pad at top of unit Frozen pump shaft Fill tank with oil Remove and clean strainer Replace filter element Replace nozzle Tighten all fittings in intake line Tighten unused intake port plug Check filter cover and gasket Replace any kinked tubing and check any valves in intake line Check form 440100 for line sizes Check for and insert by pass plug Make sure return line is below oil level in tank Loosen gage port plug or
59. ust be removed and visually inspected If a strainer looks clogged it usually is and should be cleaned or replaced IMPORTANT NOTE Current regulations on the use of asbestos in gasket materials require that new non asbestos gaskets be installed any time a fuel unit cover is removed Make this a common practice to avoid expensive call backs for that purpose STRAINER IDENTIFICATION MODEL J AND MODEL H FUEL UNITS Strainer models are designated by the first character following the gear size designation in the fuel unit model number as indicated below Examples J3PBN C200H 4 P Strainer JA2BA 100 B Strainer Nozzle Capacity Rating No strainer used in certain lube pumps 7 gph metal frame 4 5 gph obsolete use B or N 7 gph plastic frame Unlimited do not use in Models J7 J8 H7 H8 Unlimited requires spacer between pump body and cover MODEL A AND MODEL B FUEL UNITS Strainer models are designated by the first character following the gear size designation in the fuel unit model number as indicated below Examples A2VA 7116 4 V Strainer B2TA 8851 5 T Strainer IV 12 Strainer Model Designation Nozzle Capacity Rating 3 gph 7 gph V Y T 16 gph G 23 gph IMPORTANT DO NOT use strainer which is too long for the cover indicated by a 1 8 or more cover gap when spring is fully compressed Forcing would crush the strainer body and allow
60. ut off Note All ports shown in diagram are reversed for left hand nozzle fuel units Solenoid dumping fuel unit 3 gph at 200 psi Solenoid dumping fuel unit Solenoid dumping fuel unit 32mm hub Waste oil application 10 20 psi waste oil application Waste oil application Typical Model Number Nomenclature Model A amp Model B TT 7112 Seres Model Revision Number I D Number Strainer Model Features Rotation amp Nozzle Location The model number appears on the fuel unit label MODEL B 8000 TWO STAGE FUEL UNITS Two pipe installations up to 17 hg vacuum e Lift or gravity feed applications with 10 psi maximum inlet re turn pressure e Capacities to 7 gph except boost pumps e Factory set at 100 psi Pressure adjustable from 100 to 150 psi at 3450 rpm 100 to 135 psi at 1725 rpm Models available to 200 and 300 psi e Choice of 1725 2850 3450 rpm e Suitable for no 2 no 1 fuel oil or kerosene e Mounting in any position except upside down SPECIFICATIONS ORDERING INFORMATION 3 625 008 Pressure Gauge Port 1 8 NPTF Met Fort Nozzle Port 1 8 NPTF Easy Flow Inlet Port Return amp Internal 1 4NPTF By Pass Port Bleeder Valve 1 4 NPTF Two Stage Models Flange Mount Nozzle Strainer amp Rotation Port Nozzle Rating Location at 100 psi B1VA 8212 R H R H 3 gph B2VA 8216 R H R H 3 gph B2YA 8916 R H
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