Word Pro - Installation and Service Manual - Section III.lwp
Contents
1. 3 4 INCHES RETURN ABOVE INLET RETURN LINE FIGURE 7 NOTES FOR FIGURE 7 1 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 111 7 for line sizing 4 IMPORTANT Single 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 70 pump firing 1 gph two pipe has 19 gph flowing through the filter TANK BELOW THE PUMP OR LIFT FEED FILTER a NOZZLE RETURN LINE TERMINATES 3 4 INCHES ABOVE INLET LINE FIGURE 8 NOTES FOR FIGURE 8 l 2 vertical distance from bottom of tank to the centerline of the pump 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 requir2. 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 GAUGE PORT 1 8 NPTF NOZZLE PORT INLETPORT a 1 4 NPTF INLET PORT 1 4 NPTF OPTIONAL R H NOZZLE PORT 1 8 NPTF EASY FLOW BLEED amp GAGE PORT 1 8 NPTF OPTIONAL RETURN 1 8 NPTF INLET PORT 1 4 NPTF SUCTION Mj wA EASY FLOW BLEED VALVE RETURN amp INTERNAL BY PASS PORT OPTIONAL 1 4 NPTF INLET FIGURE 1 INLET PORT 1 4 NPTF INLET OR SUCTION LINE PRESSURE ADJUSTMENT FIGURE 2 DO NOT e Install by pass plug Will damage seal e Use compression fittings Will eventually leak e Use teflon tape Will void warranty Use check valves Especially on gravity feed systems See Thermal Expansion page 111 12 Exceed 10 psi manufacturer or 3 psi NFPA inlet line pressure Exceed 6 hg running vacuum for Suntec A and B fuel units or 2 hg running vacuum for Suntec J and H fuel units Use 37 JIC flare fittings Use a non hardening thread sealing compound Prefill prime the pump on long runs to reduce dry running time Check all unused pump fittings for tightness Bleed system Open bleed port approximately one turn Bleed for 15 seconds a
3. alled 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 leaks 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 1096 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 ab
4. ally 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 SERVICING NON RECOMMENDED EXISTING INSTALLATIONS 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 e SINGLE PIPE TANK ABOVE OR BELOW FUEL UNITS 1 4 m _ aca Il T A MANIFOLD NUT 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 supplement
5. e 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 new 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 IV 9 2 What the extra distance will be to the new fuel unit 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 Controls 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 Two 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 automatic
6. ed with a boost pump system to provide the proper oil supply to the fuel units See Boost Pumps or Transfer Pumps page 11 23 TWO PIPE e TANK ABOVE OR BELOW FUEL UNITS INLET MANIF LU RETURN MANIFOLD NOT RECOMMENDED FIGURE 11 Line Sizing The manifolds or supply lines must be sized to accommodate the total gear set capacity not firing rate all units connected to the manifold A B D as shown above See Line Sizing page 111 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 Problems with one unit affects all units Line sizes are a compromise Troubleshooting is more complicated Making and keeping system air free is time consuming a Oo FF 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 11 23 CHECK VALVES OTHER VALVES AND THERMAL EXPANSION Check Valves properly inst
7. ements 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 for line sizing LINE SIZING TWO PIPE SYSTEMS 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 O F and 20 F respectively GEARSET INLET LINE FLOW e GALLONS PER HOUR Suntec A B B B Mode T2 H2 N 7 3 3 7 s50 8852 J3 P 96 gs H5 H7 0 GPH GPH GPH GPH GPH 29 Flow at 16 18 18 22 38 26 31 36 42 rpm Flow at 17 20 21 25 28 33 39 38 46 60 78 61 69 79 93 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 FIGURE 9 L Horizontal run in feet from tank to fuel unit H Vertical distance in feet from b
8. essures Use check valves in gravity feed systems Connect inlet or suction line to the fuel unit inlet port Install the by pass plug as shown Failure to do so will caus improper fuel unit operation 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 otart fuel unit without bleeding a properly installed two line system is self priming See page IV 1 if pump fails to prime or deliver PRESSURE GAGE PORT 1 8 BEAD OPERATING PRESSURE RETU NOZZLE PORT 1 8 OPTIONAL INLET 1 4 ge TB BY PASS PLUG IMSERT FOR z PIPE SYSTEM USE 5 32 ALLEN WRENCH INLET PORTS 1 Rh t a REGLILATE PRESSURE AIR BLEED VALVE DU HOT READ OPERATING PRESSURE RETURM 1 4 RETURN LINE n FUSE EITHER PORT MODEL REGULATE RESSURE 55 PLUG INSERT FOR TWO PIPE SYSTEM 9 n NEW EASY FLOW BLEED VALVE AND GAGE PORT P ibat PORT 1 4 7 RETURN LINE NOTE A two 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 e e e DO NOT USE CHECK VALVES QN GRAVITY FEED SYSTEMS c a GEM RB A a co
9. fter clear oil begins flowing out of port Close bleeder valve tightly oee page IV 1 if pump fails to prime or deliver TANK ABOVE THE PUMP OR GRAVITY FEED DO NOT USE VALVE CHECK VALVES FOR SERVICE IN GRAVITY FEED INSTALLATION FILTER FIGURE 3 NOTES FOR FIGURE 3 1 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 11 3 for line sizing TANK BELOW THE PUMP OR LIFT FEED FIGURE 4 NOTES FOR FIGURE 4 1 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 Il 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 a 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 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 pr
10. n SUPPLY CHECK BY PASSING VACUUM OPERATED LINE VALVE RELIEF VALVE SAFETY VALVE XL 7 4 4 2 Ao BURNER RETURN TO SUPPLY FIGURE 14 BY PASSING RELIEF VALVE INSTALLATION NOTE All installations should be in compliance with local and national codes Typical installation diagrams contained in this Technical Service Manual are for reference only
11. ottom 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 formulae can be used to determine what the vacuum should be on various line lengths of different size line tubing The resulting figures may be used to determine if the configuration of an existing installation could cause system performance problems Tube Size Tank Below Pump Tank Above Pump O D inches Single Stage Two Stage Single Stage Two Stage 035 wall 12 75H 2 17 75 12 75H 17 75H 0086Q 0086Q 0086Q 0086Q 12 75H es 17 75H 12 75H rz 17 75H 00218Q 00218Q 00218Q 00218Q 12 75H s 17 75H T 12 75H iras 17 75H 000785Q 000785Q 000785Q 22 000785Q Tube Size O D inches 035 wall Tank Below Pump Tank Above Pump D L 0086Q 75H V L 0086Q 75H 00218Q 75H 002188 75H E 1 00785Q 75H 000785Q 75H Does not include valves filters etc in the line NOTES 1 Kinks or sharp bends in lines will increase vacuuum 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 formulae 4 If the system configuration causes operation outside the recommended limits consider the following options a Reconfigur
12. sorb 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 systems during alternate fuel operation b Where ambient temperature around the supply line is higher than the fuel temperature ceilings of industrial lcommercial buildings boiler rooms mobile home enclosed furnace vestibules 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 LINE VALVE CONTROL VALVE Bunn FK a p 1 FIGURE 12 CLOSED OIL SYSTEMS 1 A closed system will occur between the check valve and the pressure control valve during burner off cycle 2 A closed 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 SHUTOFF DUAL FUEL BURNER VALVE er 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 operatio
Download Pdf Manuals
Related Search