,,installation ,,and ,operation ,instructions ,,for ,,custom ,,mark ,,iii ,,cp ,,series ,,oil ,,fired ,,unit ,,manufactured ,,by ,,axeman-,,anderson ,,company #cjj ,east ,mountain ,avenue ,south ,williamsport1 ,,pa #aggja ,,cpo#b,o--#hdaj--e;,c ,,installation ,,and ,,operating ,,instructions ,,custom ,,mark ,,iii ,,cp ,,series ,,oil ,,fired ,,unit ,,general ,the ,custom ,mark ,,iii ,,cp ,series ,oil ,fired ,unit is a high quality heating unit that will provide many years of comfortable and economical heat if properly installed and given proper care4 ,it is ,,important therefore that these instructions should be followed carefully4 ,,shipment ,the unit is completely assembled at the factory except for the following parts which are packed in a separate carton and strapped to the skids inside the shipping carton3 #a - #c_/d ,close ,steel ,nipple #a - #c_/d #c_/d #a_/b ,tee #a - ,fig4 #aje ,tridicator #a - #c_/d ,no4 #aj-djb-je ,,asme ,relief ,valve #a - #c_/d ,no4 #fjj-ai ,boiler ,drain #a - ,t#hg;,f-#bjee ,thermostat ,the jacket extension for #abh;,,cpo is shipped in separate carton4 ,,damage ,,in ,,transit ,upon receipt of shipment of this material1 inspect all cartons for external damage4 ,if external damage is noted1 open the carton and inspect for damage to equipment4 ,mark the number of cartons received in this condition on the delivering carrier's waybill1 and request the services of their inspector4 ,if1 upon opening a carton1 concealed damage is discovered1 open the entire shipment and note all equipment so damaged4 ,contact the delivering carrier and request inspection of the damaged equipment4 ,do not destroy the carton4 ,the inspector from the freight company will need this to determine reason for damage4 ,normally claims for any and all damages should be filed with the freight company within five working days after receipt of shipment4 ,all materials are sold ,f4,o4,b4 ,factory4 ,it is the responsibility of the consignee to file claim with the delivering carrier for material received in a damaged condition4 ,,locating ,,unit ,,before ,,removing ,,shipping ,,carton1 ,,locate ,,unit ,,in ,,its ,,final ,,position ,the carton is plainly marked so as to indicate which is the outlet burner end of the unit which is also the end where the return and flue are located4 ,clearance should be provided in both the front and rear of the unit for cleaning4 ,where possible it is good practice to locate the unit so its sides are parallel to the chimney flue4 ,in all instances locate unit as near chimney flue as possible in order to avoid use of a long flue pipe4 ,,removing ,,carton ,once the packaged unit is in its proper place1 cut all around the carton on the scored line as shown on carton4 ,the entire carton may then be lifted from the skids4 ,if it is found necessary to move the unit a little more to place it in the exact location ready for piping1 do so before removing skids4 ,,do ,,not ,,push ,,against ,,any ,,part ,,of ,,jacket ,,or ,,oil ,,burner ,,when ,,moving ,,unit4 ,,to ,,move ,,unit1 ,,push ,,against ,,skids1 ,,flue ,,box ,,or ,,smoke ,,box4 ,,pushing ,,against ,,jacket ,,will ,,result ,,in ,,damage4 ,,removing ,,skids ,the skids are specially designed for easy removal4 ,it is necessary1 however1 to follow these instructions carefully4 ,a4 ,after unit is in proper place1 remove the two cross pieces from skids by pulling out all scaffolding 7double headed7 nails4 ,b4 ,by inserting pinch bar or #b #d underneath the smoke box 7rear of unit71 tilt one side of unit just high enough to lift lugs out of holes in skid1 then knock skid out from underneath unit4 ,then do the same thing on the other side of unit4 ,,the ,,unit ,,is ,,not ,,bolted ,,to ,,the ,,skids4 ,the #c_/d lugs welded to the unit simply fit into the #c_/d holes in the skids4 ---------------------------------------- ------ ,,important ,,do ,,not ,,tilt ,,unit ,,by ,,pushing ,,against ,,jacket ,,it ,,is ,,not ,,necessary ,,and ,,by ,,doing ,,so ,,the ,,jacket ,,will ,,be ,,damaged ---------------------------------------- ------ ,,leveling ,,unit ,in case floor is uneven1 unit may easily be made level by inserting shims under the #d shipping lugs4 ,these lugs also keep the jacket #a_/b off the floor1 protecting it from wet floors and dampness4 ,,piping ,,and ,,wiring ,once the unit is in its proper location with the packing carton1 skids and packing material removed1 it is ready for piping and connection from ,room ,thermostat and #aaj ,v4 #fj ,cy4 ,a4,c4 ,current4 ,,control ,,system ,the controls furnished are for a one zone ,forced ,water ,system consisting of ,t#hg;,f ,room ,thermostat1 ,l#habd;,a-#ajjg ,triple ,acting ,aquastat and ,circulator ,relay1 ,c#eed;,a-#ajah ,cadmium ,photocell1 ,r#hahd;,g-#ajje ,burner ,relay and ,v#djdf;,a-#ajji ,oil ,valve4 ,description and complete wiring diagram will be found packed with each control4 ,,special ,,control ,,systems ,for special control systems such as multiple installations1 zone controlled1 unit heater1 radiant panel1 etc41 write to factory for wiring diagrams4 ,,chimney ,,and ,,breeching ,,requirements ,the ,,cp boiler should be connected to a vertical vent system that will prevent3 7#a7 positive pressure in the flue1 7#b7 backward flow of flue gas through the unit when the burner stops1 and 7#c7 condensation in the flue4 ,use double-walled or insulated pipe for sections of the flue in cold areas4 ,all outside vents1 except for short extensions1 must be insulated to avoid condensation in the flue4 ,several types of prefabricated chimneys are available providing double-walled or insulated pipe1 some with ceramic and others with metallic liners4 ,while the unit is equipped with an induced draft fan1 proper size vent must be provided to remove the gases of combustion4 ,it is recommended that a #d to #e increaser be used for venting the #hg;,,cpo and #ajh;,,cpo and a #d to #f increaser be used for the #abh;,,cpo4 ,for abnormal runs 7exceeding #aj ft471 consult factory4 ,vent and breeching must be gas tight by sealing with asbestos or thermo-setting pressure sensitive tape4 ,,draft ,,regulator ,it is recommended that a draft regulator be installed in chimney flue just below the flue pipe opening1 if the unit is attached to an extremely high chimney2 an unlined chimney2 or a chimney which is constructed on the exterior of the house4 ,,controls ,,and ,,trim ,controls are installed in place at the ,factory4 ,attach thermo-altimeter in #a_/b tapping in top front of boiler4 ,install #c_/d close nipple in #c_/d top connection with #c_/d #c_/d #a_/b ,tee4 #c_/d ,tee opening for installation of the relief valve and #a_/b opening for expansion tank4 ,,wiring ,controls are all in place and wired at the factory except connection to circulator4 ,,regulating ,,oil ,,pressure ,standard nozzles furnished with the burner will produce the stamped rated capacity when used with ,commercial ,standard ,no4 #b ,fuel ,oil1 and operated with a pressure of #ajj lbs4 per square inch4 ,the standard setting of the fuel unit is #ajj lbs4 ,due to difference in tank elevations1 the pressure should be adjusted at the time of start up4 ,,fuel ,,lines ,care should be employed when attaching the oil lines to the fuel unit4 ,overtightening or twisting will twist the pump-motor mounting plate and put a stress on the motor bearings4 ,,start ,,up ,,procedure ,general3 #a4 ,make certain that correct voltage has been supplied to motor and control circuit4 #b4 ,insure that outside air openings are provided in the boiler room for ventilation1 and for admission of air for combustion4 ,the free area of such openings should not be less than #g square inch opening per #ajj1jjj ,btuh burner input1 or more as required by local codes4 #c4 ,check to see that flue1 wiring and water level are in order4 #d4 ,start burner fan motor to prime pump4 ,if pump does not pick up oil within a few minutes1 prime the pump with lubricating oil4 ,do not allow pump to run more than a few minutes without additional lubrication4 #e4 ,check oil pressure and adjust if necessary4 7,see ,,regulating ,,oil ,,pressure74 #f4 ,set air shutters4 7,see ,,adjusting ,,burner7 ,refer to ,figure #a4 #g4 ,generously lubricate the front motor bearing with ,,sae #bj oil4 ,,adjusting ,,burner 7,see ,figure #a7 ,positioning of the nozzle in relation to the face of the cone and the electrodes in relation to the nozzle are very important1 also the face of the cone in relation to the face of the choke ring must be set according to the chart for each rate4 ,if the air shutter openings are too large the oil may not ignite4 #a4 ,this setting will vary somewhat depending upon the grade of oil being used or if ,no4 #a is used instead of ,no4 #b4 #b4 ,the approximate burner air setting may be determined by observing the fire through the observation port on the front of the boiler4 ,if the flame is smoky1 the air shutter should be opened until the fire burns clean1 without any trace of smoke4 ,the flame should be bright yellow in color with the tips of the flame turning orange4 ,if the flame is too white1 reduce the amount of air admitted2 and1 if too red or smoky increase the air4 #c4 ,final adjustments should be made using a flue gas analyzer to measure the ,,co#b content of the flue gas and a ,bacharach model smoke meter or equivalent to determine the amount of smoke 7not to exceed a ,,trace74 ,for checking efficiency only the stack temperature and ,,co#b may be taken immediately after the fan and refer to the standard efficiency charts for the results4 ,readings of #e to #h taken after the fan correspond to #aj to #ab taken in the rear uptake of the boiler4 ,the reduction in ,,co#b reading in the flue is caused by the air being drawn in around the motor shaft for cooling purposes4 ,the motor cooling air is at ambient temperature and1 therefore1 does not add energy to or subtract energy from the flue gas analysis1 it only adds volume to the flue gas4 ,therefore1 applying this data to standard efficiency charts will give a true indication of flue gas loss4 ---------------------------------------- ----- ,,note ,final adjustment should be made after the burner has been firing continuously for at least #aj minutes1 as the fan pulls less air when the flue gases are hot4 ---------------------------------------- ----- ,a4 ,,check ,,limit ,,control ,run the burner long enough to bring the water temperature up to at least #aij degrees then turn the limit control setting until the burner stops4 ---------------------------------------- ----------- ,,note ,the ,minimum limit setting for any hot water boiler should be #adj degrees ,f4 in order to prevent corrosion of the flues on the fire side4 ,the burner should be run with the primary control thermostat terminals jumpered and the burner controlled directly from an aquastat keeping the boiler hot all the time1 thus eliminating the sweating of the flues on the fire side caused by starting from a cold start4 ---------------------------------------- ----------- ,,belt ,,adjustment ,the proper tension on the fuel unit belt drive is set at the factory4 ,however1 the belt should be checked periodically to see that the setting is maintained4 ,to check setting1 first1 remove the belt guard and then1 using fingers1 compress the belt at a point midway between the sheaves4 ,the proper setting at this point measured between the outer edges of the belt1 should be between #a-c_/d and #a-g_/h4 ,if adjustment is necessary loosen the two mounting bolts1 and move the fuel unit up or down to give the necessary belt setting4 ,then re-tighten the mounting bolts securely and replace the belt guard4 ,,performance ,,check ,,list ,,question3 ,what ,causes ,unit ,to ,soot ,up8 ,answers3 #a4 ,nozzles #b4 ,flame ,impingement #c4 ,firing ,head #d4 ,leaks #e4 ,improper ,burner ,settings #f4 ,lack of ,normal ,maintenance #g4 ,poor ,ignition #h4 ,retention ,ring ,cokes ,definitions of ,answers3 #a4 ,nozzles ,a4 ,dirty ,b4 ,wrong type of nozzle1 or manufacturing defect #b4 ,flame ,impingement ,a4 ,high ,,co#b ,b4 ,diffuser and choke ring clearance not uniform ,c4 ,dirty nozzle1 or poor patterns ,d4 ,leaks #c4 ,firing ,head ,a4 ,diffuser and choke ring clearance not uniform ,b4 ,diffuser and choke ring face dimension out of tolerance4 7,see ,a ,dimension1 ,figure #a7 ,c4 ,dirty fuel systems #d4 ,leaks ,a4 ,induced fan gasket1 or burner gasket improperly sealed ,b4 ,front cover assembly improperly installed or sealed #e4 ,improper ,burner ,settings ,a4 ,unit not checked out completely by the serviceman ,b4 ,flame pattern erratic 7,not concentric74 ,burner set up by ,,co#b only 7,burner should be set up by ,,co#b1 smoke and visual observation47 #f4 ,lack of ,normal ,maintenance ,a4 ,self explanatory 7,recognition of the advantages of preventive maintenance74 #g4 ,poor ,ignition ,a4 ,no delay in oil valve1 unit flutters on start up4 ,b4 ,electrodes out of position ,c4 ,too much combustion air 7,air shutter open too wide7 #h4 ,retention ,ring ,cokes ,a4 ,defective nozzle ,b4 ,cone1 choke and nozzle out of adjustment 7,see ,figure #a7 ,c4 ,fluttering starts ,,domestic ,,hot ,,water ,in order to obtain the rated capacity of the instantaneous domestic hot water coil limit control should be set to maintain #bjj ,f boiler water temperature4 ,flow regulator and tempering valve should be installed on all instantaneous domestic hot water coil systems4 ,,burner ,,setting ,the burner is adjusted at the factory before shipment but in case of improper operation at some future date ,figure #a will show proper setting4 ,in all cases the flame retention ring should be concentric with the choke4 ,illustration3 ,,figure #a ---------------------------------------- ------------------------ ,,model ,,nozzle ,,choke ,,ring ,a ,i4 ,d4 ,,no4 ,,delavan ,,size ,,no4 ,,diameter ,,dim4 ,,vanes ---------------------------------------- ------------------------ #hg;,,cpo #a4be ,,gph #gj ,a #adbfdj-jjb #b-e_/h ,d ,,flush #b-be_/cb #ajh;,,cpo #a4fe ,,gph #fj ,a #adbfda #b-ca_/cb ,d -#c_/af #b-be_/cb #abh;,,cpo #b4jj ,,gph #gj ,a #adbfda-jjc #b-ca_/cb ,d #a_/d #b-bi_/cb ---------------------------------------- ------------------------ ,illustration3 7parts listed counter-clockwise from left side7 ,tubes #cg;,,cp#ai #jh;,,cp#ai #gbh;,,cp#ai #d;,,cp#be #djfbd #addeci #acdiee #addech #acagih #acafea #adjgcd #adbgdc ,r#hahd;,g ,v#djdf;,a-#af #a,r#aaa;,b-#a;,,bp #adjfaa #adagda #addfia #adagdj ,,mm#aafc #adafdf-;,g#jc #adjfjf