Word Pro - Installation and Service Manual - Section II
Contents
1. 100 100 100 83 59 12 TT 77 62 48 36 100 100 100 100 100 73 52 14 39 39 31 24 18 100 100 100 100 100 63 45 16 100 100 100 1 100 87 53 38 18 100 100 97 83 70 49 37 FIGURE 3 Figure 3 continued on next page II 15 LIFT CONDITION MAXIMUM LINE LENGTH H R Lift H 1 2 O D Tubing 3450 RPM peo em qune 6 91 91 91 91 91 75 57 44 8 r 73 73 73 73 60 46 35 10 55 55 55 55 55 45 34 27 12 36 36 36 36 36 30 23 18 14 18 18 18 18 18 LIFT CONDITION MAXIMUM LINE LENGTH H R Lift H 1 2 O D Tubing 3450 RPM Ligures RUNE CNECHNCHNCNE HN NN M 0 100 100 100 100 100 100 2 100 100 100 100 100 100 90 TT 4 100 100 100 100 100 93 81 69 6 100 100 100 100 94 83 72 62 8 100 100 100 96 83 73 64 54 10 100 97 90 83 72 63 55 47 12 89 82 76 70 60 53 46 40 14 72 67 62 r 49 43 38 32 16 56 51 48 44 38 33 29 25 18 39 36 33 30 26 23 20 FIGURE 3 Figure 3 continued on next page II 16 LIFT CONDITION MAXIMUM LINE LENGTH H R L2. 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 REGULATE PRESSURE PRESSURE NOZZLE 17 INLET 1 4 PORT 1 8 EASY FLOW AIR BLEED VALVE DO NOT USE TO CHECK PRESSURE SEE BELOW e 0 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 COMPRESSION 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 FOR ELECTRICAL CONNECTIONS SEE SOLENOID WIRING READ OPERATING PRESSURE REGULATE L PRESSURE INLET 1 4 NOZZLE PORT 1 8 EASY FLOW AIR BLEED VALVE PRESSURE GAGE PORT RETURN 1 4 MODEL B TWO STAGE FUEL UNIT INLET 1 4 HAS SAME PORTING ARRANGEMENT AS MODEL A 1 16 BY PASS PLUG INSERT FOR 2 PIPE SYSTEM USE 5
3. SUNTEC S WASTE OIL TRANSFER PUMP AND MOTORSET 3 4 OR 1 1 0 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 In ambient temperatures to oil supply lines are lower than recommended strip heaters should be installed II 21 PUMP CONNECTIONS SUNTEC MODEL J3NBN A132B 1 2 NPTF DISCHARGE 1 4 NPTF 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 INLET 1 4 EASY FLOW INLET 1 4 BLEED VALVE FIGURE 4 Install a vacuum gage in the inlet line close to the pump or in an 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 II 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
4. OD Tubing Tubinc 3GPH 7 GPH 0 100 91 100 100 93 80 100 100 2 100 83 100 100 85 73 100 100 4 89 75 100 100 77 66 100 100 6 80 67 100 100 69 59 100 100 8 70 59 100 100 60 52 100 100 10 61 51 100 100 52 45 100 100 12 51 43 100 100 44 38 100 100 14 41 35 100 100 36 ST 100 100 16 32 27 100 100 27 24 100 93 18 22 88 74 76 65 H 5 PUMP USAGE IDENTIFICATION IDENTIFICATION EXAMPLE MODEL STRAINER SERIES NUMBER ATVA A 7112 V ROTATION amp NOZZLE LOCATION A B Max Nozzle Max Nozzle Model Capacity GPH RPM Model Capacity GPH RPM At 100 PSI At 100 PSI A1V 7100 3 1725 B1V 8200 3 1725 A2V 7100 3 3450 B2V 8200 3 3450 A2V 7400 3 3450 B1Y 8900 7 1725 A1Y 7900 7 1725 B2Y 8900 7 3450 A2Y 7900 7 3450 Strainer UL Strainer Rating GPH Designator Rotation Nozzle Location Type 2 Fuel Oil A RH RH V 3 B RH LH Y 7 LH LH 16 D LH RH G 23 Maximum firing rate not to exceed maximum nozzle capacity or strainer rating whichever is less A greater firing rate requires a suitable external strainer ALL INSTALLATIONS SHOULD BE MADE IN ACCORDANCE WITH LOCAL AND NATIONAL CODES II 6 MODEL A SINGLE STAGE TWO STEP MODEL B TWO
5. 32 ALLEN WRENCH 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 OR 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 II 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 PREVENT ELECTICAL SHOCK OR EQUIPMENT DAMAGE Lead wires on these devices are long enough to reach the juction box on most burner installations
6. 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 AIR FUEL UNIT NT PIPE VE AUX FILTER Ut FIGURE 5 II 4 A SINGLE STAGE TWO PIPE MAXIMUM LINE LENGTH H R Lift H 1725 RPM 3450 RPM Figure 5 3 8 OD 1 2 OD 3 8 OD 1 OD 0 86 100 84 71 100 100 1 80 100 78 66 100 100 2 75 100 73 62 100 100 3 70 100 68 57 100 100 4 64 100 63 53 100 100 5 59 100 57 48 100 100 6 54 100 52 44 100 100 7 49 100 47 39 100 100 8 43 100 42 35 100 100 9 37 100 36 31 100 100 10 32 100 31 27 100 100 11 26 100 26 22 100 87 12 21 85 21 18 83 70 13 63 62 52 14 3 42 41 35 B TWO STAGE TWO PIPE MAXIMUM LINE LENGTH H R 2 1725 RPM mm 3450 RPM mm Figure 5 3 8 OD Tubing 1 2
7. 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 11 1 of this manual ONE PIPE SYSTEM MODEL A FILTER i MAXIMUM ONE PIPE FIGURE 3 The SUNTEC MODEL A 70 FUEL UNIT may 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 II 9 L Line Length in Feet Head Feet Q Firing Rate in GPH 3 8 Line L 6 75H 1 2 Line L 6 75H 0086 Q 00218 Q If tank is above pump change to Fittings valves and filters will reduce total length allowed TWO PIPE SYSTEM FIGURE 4 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 tighten plug 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 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 Sect
8. 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 II 30 FIGURE 5 WIRING FOR CONSTANT OPERATION E CONNECT PRESSURE PRESSURE SWITCH SWITCH TO FUEL NORMALLY OPEN UNIT GAGE PORT n 1 8 NIPPLE OF LENGTH TO CLEAR STRAINER ue COVER f TO 1 8 TEE 1 8 PIPE PLUG MANUAL BOOST LOW VOLTAGE PUMP SV CLOSED CONTINUOUS OPERATION TWO CONDUCTOR C QPEN OPERATES ONLY UPON WIRE Sw BURNER DEMAND SWITCH RELAY MINNEAPOLIS HONEYWELL Ag TYPE NO RA89A S GENERAL CONTROLS CO s TYPE NO 5000006 e PENN CONTROLS INC j VN TYPE NO 791BEOILU WHITE ROGERS CO LINE VOLTAGE TO BOOST TYPE NO 8094 3 POWER SUPPLY PUMP M T R EQUIVALENT FIGURE 6 WIRING FOR INTERMITTENT OPERATION 3 Pressurized system bleed manifold of all air 4 All systems bleed pumps starting with one closest to boost pump and proceeding to the furthest away 5 System should be ready for normal service SERVICE 1 Check periodically for water accumulation 2 Change filter external as needed 3 Check pump strainer 4 Periodically check for manifold pressure II 31 PROBLEM SOLUTION Boost pump Check electrical connections and supply check for does
9. 1 4 PIPE Ht 1 27 0 D 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 For 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 II 27 VENT on 1 2 FT MIN AUX m TANK p 4 Be E FEEDER pes L LS 35 FT MAX SUSPENDED FURNACES SHUT OFF VALVE 1 2 0 D TUBING AUXILIARY FILTER INLET LINE Lite r 1 1 4 PIPE 1 2 0 0 TUBING yak RETURN LINE Dig a SJ 1 a x X 15FT SUNTEC MAX LIFT bd BOOST PUMP TANK amp MOTORSET iL 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 auxi
10. 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 less 1 2 copper tubing On all installations running vacuum and return line pressure should be checked before leaving any installation II 14 LIFT CONDITION MAXIMUM LINE LENGTH H R Lift H 3 8 O D Tubing 1725 RPM 0 100 2 68 68 55 42 32 100 83 70 60 51 4 58 58 47 36 28 92 76 64 55 47 6 49 49 39 30 23 84 70 58 50 42 8 39 39 32 24 18 76 63 53 45 38 10 29 29 24 18 14 68 56 47 40 34 12 19 19 16 60 49 41 36 30 14 52 43 36 31 26 16 43 36 30 26 22 18 35 29 24 21 Lift H 7 100 100 100 100 100 100 100 100 100 100 100 2 100 100 100 100 100 100 100 100 100 100 100 87 4 100 100 100 100 100 100 100 100 100 100 100 80 6 100 100 100 100 91 100 100 100 100 100 100 73 8 100 100 100 95 73 100 100 100 100 100 93 66 10 100 100 94 71 55 1100 100
11. H R 3 8 O D Tubing 1725 RPM Fira F Tu T 9 0 64 64 53 47 31 75 75 70 60 51 30 20 T 69 69 57 45 34 78 78 72 62 52 31 21 2 74 74 61 48 36 80 80 75 64 54 32 22 DEAE Figure 45 JA Je ds Ju Je de Ba He Hs He Hs m 20 17 18 19 31 31 IT IT 31 25 19 15 25 25 25 25 25 23 33 33 33 33 33 27 21 16 26 26 26 26 26 25 22 35 35 35 35 35 29 23 17 27 28 28 28 29 26 23 OLD Tubing 2450 RPM piure a 3 ox ps gt gt gt T Te no s 9 100 1100 1 100 100 1100 99 77 59 100 100 100 1100 1100 1 94 81 69 100 1100 1100 1100 1100 99 85 72 100 1100 1 100 100 1100 100 1 89 63 II 18 PUMP USAGE IDENTIFICATION EXAMPLE J3 B A B 100 L MOUNTING PRESS RATING NO LETTER 100 PSI ROTATION STRAINER TYPE MODEL Strainer UL Strainer Rating GPH Type 112 Fuel Oil B 7 P Unlimited J PUMP H PUMP Max Nozzle Max Nozzle Capacity Capactiy GPH at Rated _ Rated at Rated _ Rated Model Pressure M
12. RA 7737 1725 10 20 psi 2 5 GPH 1 8 HP 1 8 HP 3450 10 20 psi 2 5 GPH 1 7 HP 1 7 HP A1RA 7738 1725 100 150 psi 2 5 GPH 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 Number Inlet Line Size 1 0 Inlet Line L Maximum J3NBN A132B 3 4 in 20 ft J3NBN A132B 1 in 60 ft A2RA 7786 7737 7738 1 2 in 20 ft A2RA 7736 7737 7738 3 4 in 90 ft VVaste 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 pipr fittings only Do not exceed 10 psi manufacturer or 3 psi NFPA when supplying to inlet of pumps t 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 II 20 TYPICAL TANK INSTALLATIONS A2RA 7736 A2RA 7737 A1RA 7738 RESERVOIR OR SIPHON PICK UP 4 1 2 OR LARGER DISCHARGE LINE FILTER po ia RETURN FROM RESERVOIR OR SIPHON BY PASS 1 2 OR 3 4 1 0 INLET LINE FLOATING PICK UP FIGURE 1 TYPICAL TANK INSTALLATION J3NBN A132B TO TANK OR HEATER 1 2 OR LARGER 50 x 50 MESH DISCHARGE LINE STRAINER
13. 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 II 8 REGULATOR SETTING Install pressure gage in gage port remove after adjustment proper nozzle in nozzle line Low Fire With solenoid de energized adjust low fire regulator to desired pressure Range 100 to 200 PSI 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 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
14. STAGE TWO STEP FUEL UNITS AND MODEL B TWO STAGE HIGH PRESSURE FUELS UNITS PRESSURE GAGE PORT 1 8 RETURN 1 8 READ OPERATING PRESSURE REGULATE 7 PRESSURE NOZZLE PORT 1 8 INLET 1 4 EASY FLOW AIR BLEED VALVE DO NOT READ OPERATING INLET 1 4 PRESSURE 1 16 BY PASS PLUG RETURN 1 4 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 COMPRESSION 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 II 7 REGULATOR SETTING W SOLENOID DE ENERG ZED LOW PRESSURE REGULATOR SETTING W SOLENOID ENERGIZED HIGH PRESSURE NOZZLE PORT 1 8 INLET 1 4 T ME LI EASY FLOW STUTNTT ET AIR BLEED VALVE B 8800 READ OPERATING PRESSURE PRESSURE GAGE gt PORT 1 8 INLET 1 47 X 1 16 BY PASS iacu INSERT FOR 2 PIPE SYSTEM USE 5 32 ALLEN WRENCH FIGURE 2
15. Wire solenoid in parallel with burner motor see Figure 3 All electical work should be done according to local and national codes Solenoid 115V 0 1A 60 Hz BURNER MOTOR SOLENOID 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 page 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 GPH 3 8 Line L 6 75H 1 2 Line L 6 75H 0086Q 00218Q If tank is above pump change to Fittings valves and filters will reduce total length allowed II 3 FUEL UNIT AUX lt FILTER T MAXIMUM SHUT OFF VALVE ONE PIPE INLET LIFT 8 FT FIGURE 4 TWO PIPE SYSTEM REMOVE 1 16 BY PASS PLUG
16. able external strainer II 11 SUNTEC ROTA ROLL FUEL UNITS MODEL J SINGLE STAGE AND MODEL H TWO STAGE INLET PORTS 1 4 USE EITHER PORT MODEL J SINGLE STAGE Y NEW EASY FLOW AIR BLEED VALVE a amp AND GAGE PORT REGULATE PRESSURE NOZZLE PORT 1 8 BY PASS PLUG INSERT FOR RETURN TWO PIPE PORT 1 4 SYSTEM 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 11 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 II 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 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 F
17. antages 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 RELIEF VALVE 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 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
18. by the size of the nozzle in the burner II 24 Example 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 line 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 t offers the advantage of only needing to keep the mainfold full of oil supplied at a rate greater than the total firing rate of all the burners being supplied by the system Table 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 run
19. ift H 5 8 O D z 0 100 100 100 100 100 100 100 100 2 100 100 100 100 100 100 100 100 4 100 100 100 100 100 100 100 100 6 100 100 100 100 100 100 100 100 8 100 100 100 100 100 100 100 98 10 100 100 100 100 100 100 96 74 12 100 100 100 100 100 83 64 49 14 51 51 51 51 51 41 32 25 LIFT CONDITION MAXIMUM LINE LENGTH R Lift H 5 8 O D Tubing 3450 RPM 0 100 100 100 100 100 100 100 100 2 100 100 100 100 100 100 100 100 4 100 100 100 100 100 100 100 100 6 100 100 100 100 100 100 100 100 8 100 100 100 100 100 100 100 100 10 100 100 100 100 100 100 100 100 12 100 100 100 100 100 100 100 100 14 100 100 100 100 100 100 100 89 16 100 100 100 100 100 92 80 69 18 100 100 92 85 73 64 56 48 FIGURE 3 II 17 INSIDE OR OUTSIDE TANK FUEL UNIT BELOW BOTTOM OF TANK AIR VENT 4 FILL PIPE D0 N T USE LESS THAN 3 8 0 D TUBING FUEL UNIT MAX 12 AUX FILTER SHUT OFF VALVE SHUT OFF FIGURE 4 GRAVITY FEED e MAXIMUM LINE LENGTH
20. ion page 11 3 of this manual TWO PIPE SYSTEM MODEL A AND B OUTSIDE TANK FUEL UNIT ABOVE BOTTOM OF TANK FILL PIPE RETURN LINE FIGURE 4 Alvvays terminate return line as shovvn in Figure 4 Line lengths include both vertical and horizontal lengths ALL INSTALLATIONS SHOULD BE MADE IN ACCORDANCE WITH LOCAL AND NATIONAL CODES II 10 LINE LENGTH H R MODEL A SINGLE STAGE TWO STEP e TWO PIPE MAXIMUM 3450 RPM Lift Figure 4 3 8 OD Tubing 0 33 29 T 3T 27 2 28 25 3 25 23 4 23 20 5 21 18 18 16 T 16 14 8 13 12 9 11 9 10 1 2 OD Tubing 5 8 OD Tubing 100 100 100 100 100 100 100 88 72 39 MODEL B TWO STAGE TWO STEP AND TWO STAGE HIGH PRESSURE e TWO PIPE MAXIMUM LINE LENGTH H R 3450 RPM Lift H Figure 4 3 8 OD Tubing 60 64 55 58 50 52 44 45 39 39 34 33 28 27 23 21 18 100 100 100 100 100 100 100 100 81 57 100 100 100 100 100 100 94 76 59 41 5 8 OD Tubing 100 100 100 100 100 100 100 100 100 100 Maximum firing rate not to exceed maximum nozzle capacity or strainer rating whichever is less A greater firing rate requires a suit
21. liary tanks should be complied with The auxiliary tank doesn t need to be more than a few gallons in capacity It s advantages are 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 the 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 II 28 MANIFOLD AIR BLEED MAX INTAKE PRESSURE HIGHEST POINT IN LINE AT BURNER 10 PSI PIPE CAP 1 2 0 0 TUBING eh 0 30 PS 30 PSI MANIFOLD LINE s PRESSURE GAGE x r PRV 38 VALVES AUXILIARY i UT OFF FILTER SHUT OF 1 2 0 D TUBING INLET LINE SUNTEC BOOST K VALVE PUMP amp MOTORSET i B L 15 FT MAX 1 2 0 0 TUBING RETURN LINE APPROX 3 INCHES FIGURE 4 PRESSURIZED SYSTEM INSTALLATION 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 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 II 29 The intent is to gain the adv
22. n t run discharge and return line blockages Boost pump Measure inlet vacuum If too high check inlet line runs but doesn t supply oil filler 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 loop 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 II 32
23. odel Pressure Pressure PSI Pressure PSI 1725 3450 1725 3450 RPM RPM RPM RPM JA2B 0 7 100 HA2B 0 7 100 JB2B 0 10 100 HA2P 0 7 100 JJ2B 0 3 100 HH2B 0 3 100 J2B 3 16 100 H2B 3 16 100 J2BF 3 16 100 H2P 3 16 100 J3B 7 20 100 H3B B 0 14 200 J3B B 0 14 200 H3B 7 20 100 J3P B 0 14 200 H3B C 0 7 300 10 30 100 H3P 7 20 100 J5B 16 40 100 H3P B 0 14 200 J5P 16 40 100 H3P N C 0 14 300 J6B B 15 50 200 H4P C 0 16 300 J6B 20 55 100 H4P 10 30 100 J6B C 7 40 300 H4P N C 15 20 300 J6K 20 55 100 H5P 16 40 100 H6B C 7 40 300 H6P 20 55 100 H6P C 7 40 300 H6P N C 10 45 300 H7P B 30 80 200 H7P 40 N A 100 H8P 80 N A 100 H8P N C 55 N A 300 Maximum firing rate not to exceed maximum nozzle capacity or strainer rating whichever is less A greater firing rate requires a suitable external strainer II 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 32 F minimum and straight weight oils such as 40W 50W 90W and heavier gear lubes maintained at 50 F minimum 2 Maximum Horsepovver Pump RPM Delivery Flow Operatin Model No Pressure GPH PS I 9 1000 CST gt 1000 CST Vacuum J3NBN A132B 1725 20 40 psi 18 20 In Hg 1 6 HP 1 4 HP A2RA 7736 1725 30 psi 2 5 GPH 1 8 HP 1 8 HP 3450 0 100 psi 2 5 GPH g 1 7 HP 1 7 HP A2
24. or 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 OIL TANK SHUFOFF VALVE LINE FILTER FIGURE 1 NOTE J MODELS NOT RECOMMENDED FOR LIFT H ABOVE TWO FEET SHUT OFF SINGLE PIPE VALVE EXCEPTION J2 F MODELS WHICH INCLUDE THE NEW BLEED CHECK VALVE 13 FIGURE 2 13 L Line Length in Feet Head in Feet Q Firing Rate in GPH 3 8 Line L 2 75H 1 2 Line L 2 75H 0086 Q 00218 Q 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 self priming Model J can be used two pipe to 12 inch mercury vacuum Model H can be used to 17 inch mercury vaccum 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 00 NOT USE LESS THAN WITH UNDERWRITERS AND 3 8 0 D TUBING LOCAL REGULATIONS FILL AIR INTAKE dem PIPE vent RETURN INSTALL AS SHOWN UNLESS PROHIBITED BY LOCAL REGULATIONS R FIGURE
25. 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 8 GPH 2 75 GPH 3 1 35 GPH 4 2 25 Total 5 15 required Select BB1020M which will supply 20 Remember The firing rates are determined by the nozzle size and pressure of the burner pump Example 2 We have five burners with the following firing rates 1 1 5 Nozzle 150 psi 1 8 GPH 2 3 0 Nozzle 300 psi 5 2 GPH 3 12 0 GPH Nozzle 100 psi 12 0 GPH 4 2 5 0 Nozzle 125 psi 5 6 GPH 5 1 25 GPH Nozzle 100 psi 1 25 GPH Total 25 85 GPH Select a BH1030 which will supply 30 GPH Remember 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
26. s call the factory and get prompt help to install your system II 25 1 2 0 0 TUBING INLET LINE SUNTEC BOOST 99 2 e a NINN 2 T4 rv a PUMP amp MOTORSET FILTER ETSI TL 1 2 0 0 TUBING RETURN LINE SPROUTS APPROX 3 INCHES t FIGURE 1 LOW PRESSURE SIDE INSTALLATION Line Size 1 2 Tubing 5 8 O D Tubing 1 2 Pipe Lift 0 7 10 15 0 7 10 15 0 7 10 15 Pump B 100 100 100 H3 64 49 24 100 100 65 100 100 100 H6 44 34 LA 100 95 48 100 90 65 TABLE 1 MAXIMUM INLET LINE LENGTH FOR A TROUBLE FREE LOOP SYSTEM USE THE FOLLOWING GUIDELINES 1 2 The manifold is to be above all the pumps being supplied 3 A 2 ft riser or kick at the end of the run will insure the manifold fills The manifold should be level at worst case A slight rise in the system will aid in air purging A large return line is necessary to prevent siphoning of the manifold and or overflowing of the vent 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 II 26 MAX INTAKE GAGE PRESSURE AT FIRST BURNER 10 PSI _ USE A 0 30 PSI 1 2 0 D TUBING VENT MANIFOLD LINE i 2 FT MIN GAGE FEEDER ba ree LINES Bil SUSPENDED FURNACE SHUT OFF VALVE AUXILIARY FILTER gt gt 1
27. 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 a boost pump as close to the supply of fuel oil as economically and physically possible 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 Includes Pump Delivery Item Pump Rotation GPH 2 Model from shaft end RPM 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 H3BA E100B R H 30 Motor BH 1070R H6BA E100B R H 70 Pressure Switch P N 128117 40 VA amp 50 psi close 200 psi Max Adapter for 48N Motor P N 134462 II 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
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