Crusade-a-Therm Service Manual
Contents
1. www dynathermboiler com SERVICE MANUAL BETHELEHEM CRUSADE A THERM Manufactured By DYNATHERM Boilers 43 E Cherry Road Quakertown 18951 215 536 4078 215 536 8960 www dynathermboiler com TABLE OF CONTENTS INSTALLING BETHLEHEM CRUSADE A THERM INSTALPINGJACKET a Ru Dd u a qa al n PIPING TO BOILER CONTROLS ung sua CRUSADE A THERM RATINGS AND DRAWINGS BIEL OF MATERIAL S uQ uu n Danu hu umaq asi iah basa asa aS GENERAL ARRANGEMENT INSTALLING BETHLEHEM CRUSADE A THERM INSTALLING JACKET Remove the proper knockouts and place the top panel over the unit put the side panels in place and slide the edges of the top panel down over the side panels lock the panels together with bolts and nuts and sheet metal screws provided for that purpose close the two ends by putting the respective door panels in place PIPING TO BOILER Connect the riser and return piping to the Crusade A Therm The riser should be run a vertical distance of at least 12 above the boiler outlet The return must be run horizontally and at right angles to the centerline of the boiler for a distance of at least 13 so a2. Gross 1000 s 120 Boiler Output Kilogram Calorie Rating 1000 s 30 Nozzle Size Nominal gal hr 1 00 Firing Rate gal hr 1 12 Chimney Size in 8x8 Boiler Outlet Size in 3 Boiler Return Size in 2 Safety Valve Size in 1 Crate width in 20 1 2 length in 62 height in 36 Shipping weight crated lbs 775 Shipping weight of Jacket lbs 150 NET RATING Actual Standing Radiation with piping pick up and domestic hot water allowances already made GROSS RATING Actual boiler Output which is 30 greater than Net Rating DYNATHERM BILL OF MATERIALS DWG G 367 WHIRLING FLAME SHEET REVISED BETHLEHEM CRUSADE A THERNE 1 NO SF CODE DESCRIPTION NO SPARODE DESCRIPTION 6C 919 100 Electrode Bracket 74 Fuel Unit 7L Knurled Pin 79 Temperature Pressure Gauge 13 Oil Spider 80 Ns Boiler Body Steam 15 5 Motor 80 Boiler Body Water 17 511 000 Nozzle 110 Hinge Pin 25 Electrode 116 L Tank Heater Coil 35 Transformer 117 Return Ell 41 ProtectoRelay 127 E 210 000 Scroll 46 Junction Box Cover 137 J 207 003 Orifice Plate 67N Housing 144 503 006 Liners 67 N 1 Coupling Cover 146 921 001 Refractory Insert 69A Elbow 147G Air Silencer 69M 200 103 Flue Connection 157 Nose Piece 70G Clean Out Cover 157A Sleeve 70 J Clean Out Cover 158A Nozzle Plate 71 Peephole Slide 160 Delay Relay 72 202 102 Peephole Cover DT 36 Tankless Heater Coil 72 Peephole Gasket 73 102 316 Peephole Lever 100 317 Pee
3. tip should 1 4 behind the orifice place in the nosepiece 4 Oil Motor The motors have sleeve bearings and are wick oiled Fill the reservoir with high grade spindle oil that will flow at low temperatures 5 See that the proper fuel oil is in the tank The Bethlehem Crusade A Therm has been approved to burn not heavier than Commercial Standard 2 Fuel Oil 6 Be sure that the combustion control is in the starting position 7 See that all joints of smoke pipe are tightly made up and sealed to the chimney 8 See that the system is fully supplied with water as required 9 Set room thermostat at a point slightly above room temperature 10 See that the boiler control is in the ON position 11 Open valve in fuel oil line 12 Gravity Feed Installations To vent the fuel unit on a single pipe system remove the plug located in the side of the regulating valve chamber With the fuel unit in operation allow enough oil to drain out to purge the entire system of air Catch the overflow in a suitable container This same tapping is for use of the pressure gauge when setting the Crusade A Therm for 11 Sub Gravity Installations These must have a return line from the fuel unit to the storage tank In all other respects the starting instructions are the same as for gravity feed installations ADJUSTING BETHLEHEM CRUSADE A THERM COMBUSTION EFFICIENCY OIL PRESSURE ETC The Bethlehem Crusade A Therm by virtue of its
4. within the jacket immediately below and through the same opening as the return piping or through on e of the openings provided in the side panels When the Crusade A Therm is used in connection with steam vapor or gravity hot water systems connect the thermostat in the low voltage terminals in the combustion control FLUE GAS OUTLET Connect the flue gas outlet of the Crusade A Therm with the chimney using 6 dia Galvanized stove pipe The chimney should not be smaller than 8 round or square DOMESTIC HOT WATER Make connections to the hot water coil and provide valves for back flushing the coil WATER SUPPLY TO BOILER Connect water supply to return piping of the unit Fill boiler and system with water and check for leaks FUEL SUPPLY TO BURNER The Bethlehem Crusade A Therm is listed by the Underwriters to burn 2 Commercial Standard grade fuel oil Since the grades marketed by different oil distributors vary it is advantageous for you to be familiar with the quality of fuels available in your territory STARTING BETHLEHEM CRUSADE A THERM Before starting burner Check electrical connections 2 Check oil connections to tank pump 3 See that the electrodes properly positioned electrodes should be 3 8 above the center of the nozzle tip and 1 16 forward of the face of the nozzle tip The gap should be 3 16 wide See that the electrodes are spaced 1 4 from any grounded metal The face of the nozzle
5. construction is distinctive in its operation Positive pressure is generated throughout the combustion zone thus eliminating the necessity for ideal draft conditions the so called chimney pull that most conventional types of burners depend upon It is designed to operate at its maximum efficiency when producing its rated output with 11 CO in the combustion gas and any other setting will result in increased stack temperature and lowered efficiency For this reason it is not possible to adjust the burner by observing the color or character of the flame THE FLUE GASES MUST BE ANALYZED AND THE CO CONTENT CHECKED TO DO THIS PROCEED AS FOLLOWS Allow the burner to operate for about 10 minutes them remove the pipe plug from the smoke pipe elbow at the upper rear of the unit Insert the sampling tube of an Orsat and pump a representative sample of flue gas into the Orsat These for the content If analysis shows more or less than 11 either increase or decrease the oil pressure until the correct treading is obtained Increasing the oil pressure increase the CO2 content decreasing the oil pressure decreases the CO content The oil pressure can be varied by removing the cover over the adjusting screw and turning this screw To increase oil pressure turn screw clockwise and to decrease oil pressure turn screw counter clockwise Be sure to replace cover and gasket when adjustment is completed When 11 CO is obtained the oil pressu
6. phole Glass 213 16 415 16 DT 35 TANKLESS COIL 1 2 PIPE CONNECTIONS 5 e 5 I e 61 36 10 3 8 3 21 12 79 21 8 1 2 COUPLING 3 COUPLING 1 COUPLING 3 r 6 SNS ye k 17 gt 116 L TANK HEATER COIL 6114 3 8 TRYCOCKS 3 4 PIPE GONNEGTIONS I 127 117 FE NIA WATER LEVEL 0 gt 2 519 8 13 7L ua _ L 71 1 pet ZA 7 67 1 8 GLASS 55 em 70G a x 146 M 147 G ag 5 S 2 COUPLI 110 _ 160 ty FLOOR LINE 5 7 DYNATHERM 43 E CHERRY RD QUAKERTOWN PA 18951 BETHLEHEM SCALE DRAWN BY CRUSADE A THERM FRACTIONAL TITLE CT 36 GENERAL ARRANGMENT ANGULAR DATE DRAWING NUMBER 2 27 50 G 367
7. re should be in the range of 80 Ibs to 125 Ibs If oil pressure is below 80 Ibs when 11 CO is obtained install the next smaller size nozzle If above 125 lbs when 11 CO is obtained install the next larger size nozzle and again adjust the oil pressure for 11 USE A PRESSURE GAUGE WHEN INCREASING OR DECREASING OIL PRESSURE NOZZLES It is very important that the proper nozzle size and spray angle be used with the Bethlehem Crusade A Therm The following sizes and spray angles must be used 36 1 00 30 deg or 1 25 30 deg Hollow If other than 30 degree nozzles are used the result will be carbon deposits in the nose piece and combustion tube which will cause unsatisfactory operation and safety shut down CONTROLS Carefully check the operation of all controls and make sure that they function properly IF THE OPERATION IS NOT NORMAL CHECK THE FOLLOWING 1 If the motor does not start trip the safety switch button on the combustion control If this fails to produce the desired result follow the instructions in the control instruction pages 2 If motor starts and safety shut down continues the oil systems should be rechecked for leaks or air traps Check the fuel unit if it is air bound remove pipe plug and allow air to escape and then replace pipe plug when oil CRUSADE A THERM RATINGS AND DATA BOILER NUMBER 36 Steam sq ft 350 Vapor Net Rating sq ft 375 Hot Water sq ft 560 Boiler Output BTU per hr _
8. s to clear the side panel of the jacket FUEL LINES TO BURNER Connect the suction line from the oil storage tank to the pump using an unbroken length of copper tubing and flare type fittings The suction line should pass within the jacket immediately below and through the same opening as the return piping or through one of the openings provided in side panels If an outside storage tank is used a return line to the tank must be provided ELECTRICAL WIRING All auxiliary electrical equipment and wiring are to be installed by an experienced electrician in accordance with the National Electrical Code and with Local Ordinances Wiring is to be done in BX cable or conduit All connections must be soldered or approved connectors used Minimum conductor size should be 14 See rear of Manual for electrical wiring diagrams The thermostat is to be installed preferably on the main floor in one of the normally occupied rooms the living room being a desirable location in most instances Locate the thermostat not more than five feet above the floor in a position where it will be least affected by draft radiation the cooling affect of a window or an outside wall When in thermostat leads are brought through a hole made in the wall the space around the leads should be packed with asbestos wool Connect the power service line from a switch on the wall to the two wires in the junction box marked H for hot and G for ground This service line should pass
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