Overview:
This manual provides comprehensive instructions for the installation and operation of the Custom Mark III CP Series Oil Fired Unit. The manual begins with a detailed explanation of unpacking and locating the unit, emphasizing the importance of proper placement and clearance for cleaning. It then covers piping and wiring requirements, highlighting the control system components and offering guidance on special control system configurations.
The manual emphasizes the importance of proper chimney and breeching requirements for optimal performance and safety, including guidelines on vent sizing, insulation, and draft regulation. It provides detailed instructions on burner adjustment, including positioning of the nozzle and electrodes, as well as setting the air shutters for efficient combustion. The manual concludes with tips on maintaining the unit and addressing common soot issues, ensuring prolonged performance.
Key findings:
- The Custom Mark III CP Series Oil Fired Unit is a high-quality heating unit that provides comfortable and economical heat when properly installed and maintained.
- The manual emphasizes the importance of proper installation, including adequate clearance for cleaning, proper chimney connection, and correct burner settings for optimal efficiency and safety.
- The manual emphasizes the importance of regular maintenance to prevent soot buildup and ensure efficient operation.
Learning:
- Proper Installation and Placement: The manual stresses the importance of placing the unit in a location that allows for adequate clearance for cleaning and easy access to controls. It also emphasizes the importance of proper chimney connection for optimal performance and safety.
- Burner Adjustment: The manual provides detailed instructions on adjusting the burner for efficient combustion, including positioning of the nozzle and electrodes, setting the air shutters, and checking for proper flame pattern.
- Maintenance: The manual emphasizes the importance of regular maintenance to prevent soot buildup and ensure efficient operation. It includes a troubleshooting checklist that addresses common soot issues and provides guidance on addressing them.
Historical Context:
- The manual was written in 1984, a time when oil-fired heating systems were a common choice for residential and commercial buildings.
- This manual reflects the technological advancements in heating systems during that era, emphasizing the importance of efficient combustion, proper ventilation, and preventative maintenance.
Facts:
- Fuel Efficiency: The unit is designed for efficient heat production, with the goal of providing comfortable and economical heat.
- Manufacturing Location: The unit is manufactured by the Axeman-Anderson Company, located in South Williamsport, Pennsylvania.
- Standard Nozzles: Standard nozzles supplied with the burner are calibrated to produce the rated capacity when used with Commercial Standard No. 2 Fuel Oil at a pressure of 100 lbs. per square inch.
- Chimney Requirements: The unit requires a vertical vent system that prevents positive pressure in the flue, backward flow of flue gas, and condensation in the flue.
- Draft Regulator: A draft regulator should be installed in the chimney flue for extremely high chimneys, unlined chimneys, or chimneys located on the exterior of the house.
- Domestic Hot Water: The instantaneous domestic hot water coil requires a boiler water temperature of 200° F to achieve rated capacity.
- Flow Regulator and Tempering Valve: Flow regulators and tempering valves are recommended for instantaneous domestic hot water coil systems.
- Air Shutter Settings: The air shutter settings may vary depending on the grade of fuel oil being used.
- Flame Pattern: The flame should be bright yellow in color with the tips turning orange.
- Flue Gas Analysis: Final burner adjustments should be made using a flue gas analyzer to measure CO2 content and a smoke meter to determine smoke levels.
- Motor Cooling Air: The air drawn in for motor cooling purposes affects the CO2 reading in the flue gas.
- Limit Control Setting: The minimum limit setting for a hot water boiler should be 140 degrees F to prevent corrosion.
- Belt Adjustment: The proper tension on the fuel unit belt drive should be checked periodically.
- Soot Buildup: Soot buildup can be caused by various factors, including dirty nozzles, flame impingement, leaks, improper burner settings, and lack of maintenance.
- Nozzle Types: Different nozzle types are available, and selecting the correct one is crucial for proper operation.
- Diffuser and Choke Ring: Maintaining the proper clearance and dimensions of the diffuser and choke ring is important for preventing soot buildup and ensuring efficient combustion.
- Electrodes: The position of the electrodes relative to the nozzle is critical for proper ignition.
- Retention Ring: The retention ring should be concentric with the choke for optimal flame pattern and prevention of soot buildup.
- Visual Inspection: Visual inspection of the flame pattern is essential for ensuring proper burner operation.
- Preventive Maintenance: Regular maintenance is crucial for preventing soot buildup and ensuring efficient and safe operation of the unit.
- Combustion Air: Adequate ventilation is essential for providing sufficient combustion air.
- Oil Pressure: Oil pressure should be checked and adjusted during startup to compensate for tank elevation differences.
Statistics:
- Burner Input: The free area of outside air openings should not be less than 7 square inches per 100,000 Btuh burner input.
- Flue Gas Loss: Readings of 5 to 8% CO2 taken after the fan correspond to 10 to 12% CO2 taken in the rear uptake of the boiler.
- Belt Tension: The proper belt tension should be between 1-3/4″ and 1-7/8″ when measured midway between the sheaves.
- Boiler Water Temperature: The boiler water temperature should be maintained at 200° F for optimal domestic hot water performance.
- Smoke Levels: Smoke levels should not exceed a “TRACE” as measured by a Bacharach model smoke meter or equivalent.
Terms:
- Aquastat: A device that controls the temperature of water in a heating system.
- Cadmium Photocell: A light-sensitive device used to detect flame presence in the burner.
- Circulator Relay: A relay that controls the operation of the circulating pump in a heating system.
- Choke Ring: A component in the burner that regulates the flow of air to the combustion chamber.
- Diffuser: A component in the burner that helps to mix air and fuel for efficient combustion.
- Flue Gas Analyzer: A device used to measure the composition of gases emitted from the combustion process.
- Induced Draft Fan: A fan that draws flue gases out of the boiler, creating a draft.
- Nozzle: A component in the burner that delivers fuel to the combustion chamber.
- Thermo-altimeter: A device that measures both temperature and pressure.
Examples:
- Soot Buildup: If the flame pattern is erratic, or if there is evidence of excessive soot buildup, the burner may need to be adjusted.
- Incorrect Nozzle: Using the wrong type of nozzle can lead to poor combustion and soot buildup.
- Insufficient Air: If the air shutters are set too tightly, there will be insufficient air for combustion, resulting in a smoky flame.
- Poor Ignition: If the electrodes are out of position, the flame may not ignite properly.
- High CO2 Levels: High CO2 levels in the flue gas indicate incomplete combustion, which can lead to soot buildup.
- Dirty Fuel System: Dirty fuel lines and filters can reduce fuel flow and hinder proper combustion.
- Lack of Maintenance: Neglecting routine maintenance can lead to a variety of issues, including soot buildup, reduced efficiency, and potential safety hazards.
- Draft Issues: If the draft in the chimney is insufficient, the flue gases may not be properly vented.
- Incorrect Vent Sizing: Using a vent that is too small can hinder proper ventilation and lead to issues with smoke and draft.
- Improper Vent Insulation: If the vent is not properly insulated, condensation may form within the vent, leading to corrosion.
Conclusion:
This manual provides a comprehensive guide to installing and operating the Custom Mark III CP Series Oil Fired Unit, a high-quality heating system designed for efficient and economical heat production. Proper installation, including clearance, chimney connection, and burner settings, are crucial for optimal performance and safety. Regular maintenance, including burner adjustment, fuel line cleaning, and checking for soot buildup, is essential for preventing problems and ensuring the unit’s longevity. By following the instructions provided in this manual, homeowners and technicians can ensure the reliable and efficient operation of this oil-fired heating system for many years to come.