Word Pro - Installation and Service Manual
Contents
1. 3450 3450 100 3450 1725 3450 1725 1725 3450 1725 R H R H L H L H R H L H L H R H Also apply to 6 model numbers shown on fuel unit For example 7916 6 etc Viewed from shaft end Use gage port for rated flow 1725 rpm no cut off Note All ports shown in diagram are reversed for left hand nozzle fuel units I 2 3 gph 3 gph 3 gph 3 gph 7 gph 2 25 gph 3 gph 3 gph 3 gph 3 gph 7 gph 7 gph 3 gph 3 gph 2 5 4 gph 2 5 2 5 gph 2 5 2 5 gph 2 5 2 5 1 5 gph 3 bolt mtg hub Solenoid dumping fuel unit 3 gph at 200 psi Solenoid dumping fuel unit Solenoid dumping fuel unit 32mm hub Waste oil application Waste oil application 10 20 psi waste oil application Waste oil application 30 50 psi waste oil Typical Model Number Nomenclature Model A amp Model B Series Model Revision Number Speed I D Number Strainer Model Features Rotation amp Nozzle Location The model number appears on the fuel unit label MODEL B 8000 TWO STAGE FUEL UNITS Two pipe installations up to 17 hg vacuum e Lift or gravity feed applications with 10 psi maximum inlet return pressure e Capacities to 7 gph except boost pumps Factory set at 100 psi Pressure adjustable from 100 to 150 psi at 3450 rpm 100 to 135 psi at 1725 rpm Models available to 200 and 300 psi e Choice of 1725 2850 3450 rpm e Suitable for no 2 no 1 fuel oil2. 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 13 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 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 55 100 100 100 100 100 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 16 100 100 100 100 87 53 38 18 100 100 97 83 70 49 31 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 IS peo em a qune 6 91 91 91 91
3. 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 commercial buildings boiler rooms mobile home enclosed furnace vestibules PREVENTION OF THERMAL EXPANSION PROBLEMS a b C Install relief valves in problem areas see Figure 14 Do not use check valves Install an accumulator in the line SUPPLY CHECK PRESSURE LINE VALVE CONTROL VALVE BURNER 1 FIGURE 12 CLOSED OIL SYSTEMS A closed system will occur between the check valve and the pressure control valve during burner off cycle 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 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 SHUT OFF DUAL FUEL BURNER VALVE gp FIGURE 13 CLOSED OIL SYSTEM DUAL FUEL BURNER A closed circuit will occur between the manual valve and the burner if the valve is closed during alternate fuel operation SUPPLY CHECK BY PASSING VACUUM OPERATED LINE VALV
4. GED SS any Nee i Easy i Bleeder Valve ANE Soli tine 400 Mount or Gauge Port 1 8 NPTF Hub Mount Maximum Firing Rate gph 1725 3450 rpm 100 psi 300 psi 100 psi 300 psi JJ2 Std 3 2 Std 7 JB2 Std 10 J2 Std 3 16 J3 Std 7 20 G 8 24 10 N 9 26 14 J4 Std 11 30 17 N 13 33 23 J5 Std 17 40 28 N 19 5 46 32 J6 Std 24 7 55 40 N 26 10 60 45 Special Pressure Spring Choices A 20 40 psi C 150 300 psi E 10 20 psi B 75 200 psi D 40 80 psi 1Do not adjust J2 and 3450 rpm only models JA JB JJ to higher than 100 psi Requires C spring 100 300 psi range Requires C spring and hardened gear I 7 Typical Model Number Nomenclature Model J amp Model H Series Model Revision No Capacity Special Feature Strainer Capacity Special Customer Rotation amp Nozzle Req Location Mounting Style Piston Typ Pressure Range The model number appears on the top of the fuel unit MODEL H TWO STAGE FUEL UNITS Two pipe high lift installations to 17 hg vacuum e Capacities to 83 gph e Lift or gravity feed applications with 10 psi maximum inlet return pressure Six pressure options 10 to 300 psi Forno 4 and lighter fuel oils gasoline and JP fuels special Three hub and flange mounting options Model H may be mounted with the valve horizontal at either the top or bottom Valve may be mounted vertical provided the adjustin
5. PREFACE This manual was assembled with the service person and technician in mind Our objective was to give procedures and guidelines for efficient and successful fuel pump installation and service Many technical manuals contain the necessary information finding it is the problem This manual is dividend into four major sections Sales What models to use and how they are identified Installation Hovv to install the model selected Piping Good practice piping installations and how to cope with non recommended piping found in previous installations Service How to test and service new and existing installations We have addressed situations found in the field which are not good practice but since they have been in use we must contend with them If you have problems which you cannot answer please contact Suntec s field service department at 800 367 7116 We at Suntec appreciate your support and look forward to many more years of working with you TABLE OF CONTENTS SALES FUEL UNITS Model A Set oreet eost n eate be cede a E Eee I 1 Model BT Wa States co cuu aduer a EM a A p e EI alturas I 3 Model B Two Stage Two Step cs cose a sce a aa Reds I 5 Model B SpecidbPressutest es ct estote ce SOS eterne gases eut Rae awe I 5 Model J Single Stale es RS sane te EY da he BAN Rh en ead ds I 6 Model H Ewo Statene def Vna vius M2 Sed Y Tes ig uerbo voee re Ted divi I 8 VALVES Models R and C Solenoid c
6. 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 dic d re e Jer MANIFOLD NOT 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 supplemented with a boost pump sys
7. 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 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
8. Figure 4 3 8 OD Tubing 0 33 29 T 3T 27 Zz 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 suitable 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 an A AND GAGE PORT REGULATE PRESSURE NOZZLE PORT 1 8 BY PASS PLUG INSERT FOR RETURN TWO PIPE PORT 1 4 SYSTEM GENERAL INFORMATION e 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 o
9. KLIN RIRS 4 v Check for leaks at fittings and filters Correct any leaks that are found TROUBLE CALL In response to a trouble call approach the problem in a logical and systematic sequence Jumping to a conclusion can sometimes temporarily fix the problem but not uncover the root cause of the problem An example is if there is water in the fuel which causes the pump to fail and you replace the pump only you will eventually be called back to replace the new pump In addition to the mechanical tools required you also must have gages pressure and vacuum and suitable combustion analyzers IV 1 SYSTEM TROUBLESHOOTING DIAGNOSTIC FLOW CHART Follow a logical equence of troubleshooting from the no heat call through to system operational using the following chart or Yes Check for oil in tank No Yes Check to see that all valves are properly No positioned open or closed Yes Check for line voltage at primary control No Yes Check to see that thermostat is calling No for heat Yes Check combustion chamber for excess Yes oil No Disconnect nozzle line from burner Place container under nozzle line and start burner Yes Motor comes up to speed Audible click No when start windings drop out Yes Ignition working No Yes Steady stream of oil from pump No Have oil delivered Set valves to correct position Check and correct electrical supp
10. PORT PRESSURE INLET PORT 1 4 NPTF PRESSURE ADJUSTMENT EASY FLOW BLEED amp GAGE PORT 1 8 NPTF FIGURE 4 PRESSURE GAGE LOCATIONS FOR OPERATING PRESSURE TEST FUEL UNIT OPERATING AND CUT OFF PRESSURE Step 1 Step 2 Step 3 Step 4 Step 5 Install gage into nozzle port Turn burner ON and observe gage Adjust pressure if necessary Turn burner OFF and observe gage Pressure should drop to 8096 or higher If pressure drops below 80 or continues to decay the fuel unit has faulty cut off and should be repaired or replaced NOTE A and B model pumps could theoretically have a cut off pressure of less than 80 The important operation is that it drops to some value and stops IV 11 STRAINERS FIELD SERVICE Fuel unit strainers are intended as a back up to not a replacement for proper system filtering Clogged strainers restrict oil flow into the gear set cause fuel units to operate at higher vacuum and eventually fail To diagnose a clogged strainer before it causes fuel unit failure it must be removed and visually inspected If a strainer looks clogged it usually is and should be cleaned or replaced IMPORTANT NOTE Current regulations on the use of asbestos in gasket materials require that new non asbestos gaskets be installed any time a fuel unit cover is removed Make this a common practice to avoid expensive call backs for that purpose STRAINER IDENTIFICATION MODEL J AND MODEL H FUEL UNITS Stra
11. 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 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 informat
12. against master gage or other gage Nozzle capacity is greater than fuel unit capacity i e za cad reor Replace fuel unit with unit of correct capacity See form no 2100 for GPH psi and R P M IMPROPER NOZZLE CUT OFF To determine the cause of improper cut off insert a pressure gage in the nozzle port of the fuel unit After a minute of operation shut burner down If the pressure drops from normal operating pressure and stabilizes the fuel unit is operating properly and air is the cause of improper cut off If however the pressure drops to 0 psi fuel unit should be replaced NOTE The A 70 pump circuitry is designed to give a high cut off of superb quality Never use the amount of pressure drop as an indication of the quality or speed of cut off Filler leaks iii Check face of cover and gasket for damage Strainer cover loose Tighten four screws on cover Air pocket between cut off valve and nozzle Run burner stopping and starting unit until smoke and after fire disappears Air leak in intake line Tighten intake fittings Tighten unused intake port and return plug Partially clogged nozzle strainer Clean strainer or change nozzle Leak at nozzle adaptor Change nozzle and adaptor IV 6 FIELD TESTING FUEL UNITS INTRODUCTION Fuel units are sized to an application based on their pressure vacuum and flo
13. 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 INLET PORT 1 4 NPTF INLET PORT 1 4 NPTF OPTIONAL INLET 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 INLET OR SUCTION LINE a Z 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 III 1 DO NOT Install by pass plug Will damage seal Use compression fittings Will eventually leak e Use teflon tape Will void warranty e Use check valves Especially on gravity feed systems See Thermal Expansion page 11 12 e Exceed 10 psi manufacturer or 3 psi NFPA inlet line pressure e Exceed 6 hg running vacuum for Suntec A and B fuel units or 2 hg running vacuum for Suntec J and H fuel units DO e Use 37 JIC flare fittings e Use a non hardening thread sealing compound e 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 after clear oil begins flowing out of port Close bleeder valve tightly See page IV 1 if pump fails to prime
14. e Easy installation Use with any fuel unit rated up to 16 gph Suitable for no 2 no 1 fuel oil or kerosene e Mount in any position 1 10 SPECIFICATIONS ORDERING INFORMATION 3 8 Flexible Twin Lead Conduit AWG 18 105C SPT 1 Fitting 1 B NPTF t 4 5 16 Nozzle Plug Face 3 8 Model R Twin Lead 3 8 Flexible AWG 18 105C SPT 1 Condutt Fitting 1 1 8 NPTF 1 1 8 NPTF 2 18 Model C Valve Model No Maximum Color Code Pump Burner opening Voltage Operating Mount Mount Response 50 60 Hz Pressure Coil Lead Wires R642N C642N Non Delay 115 300 psi Black Orange White R641D C641D Delay 115 150 psi Grey Orange White R753N C753N Non Delay 220 300 psi Black Red White l Blue Brown R261N C261N Non Delay 24 300 psi Green Yellow amp Green Typical Model Number Nomenclature Model R amp Model C Style LE Operation Voltage The model number appears on the valve label FOR A 7000 SINGLE STAGE AND B 8000 TWO STAGE FUEL UNITS MODELS A1 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 INLET A e RETURN 1 4 1 16 BY PASS PLUG INSERT FOR 2 PIPE SYSTEM USE 5 32 AL
15. eu s opea VOU ROC SOY PROC TIME Wines a Vete Kay vof I 10 INSTALLATION FUEL UNITS ModebA Simgle Stdges ss dace tale ue Ban Pasa s b II 1 Model B Two Stage su ss tati even Ea be E RE E Sade Oda V II 1 Model A Smegle Stage Two Step caesar cee a ed REGIE RE RUNG RR A II 7 Model B Two Stage T WO SfIep oe ex ecd pae bte e Pec d erbe dd err Kan ted Ph be der ds II 7 Mod l B Sp cia l Pressures oes oce is soot e Lu ve S S a mda pM KE Au II 7 Mod l J Singl St ag noe Od ec cine uve m A ou L II 12 Mode H TWO Stade ea courier Bad rede iau NE MEG HG RAS Put d II 12 OTHER PUMPS Model r Waste Oll REE A A Vea punt Id bee yaq A oe 11 20 Mode T Waste OM da de atte qox ula R A ana Ru TAN dS 11 20 Boost Pumps and Central St ala 11 23 PIPING Smpgle PIDE i eea ii ca ene II SENS III 1 Of iV sca s ba ai Weotd uiti dec Y eu Nac wilde pud qtd Vestis HI 2 Lili Feed suya aaa E Y A S pn III 3 27 6000000000 0002000700 0 III 3 Gravity Peed eyn ove ca esce stes db ie Ue e die ad ats ewe III 5 Lift Feed petando se d Eua rice og eed adco das do olco d sabi III 6 LINE SIZING Single PIPE xu ese eR SU qo ese AAA oin See Specific Model Installation J3WOSPIDE Dus dera parece e deua cip OISEAU THER AS Ce eaten tardo pde ed d pue 11 7 Adding Additional Units sr A A AAA SA III 8 Priority CONO o Dose a deed aote od s cal du III 9 Multiple Units with Manifold P
16. 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 3 8 s 12 75H L 17 75H e 12 75H 17 75H 0086Q 0086Q 0086Q 0086Q 1 2 12 75H L 17 75H m 12 75H L 17 75H 00218Q 00218Q 00218Q 00218Q 5 8 12 75H ps 17 75H Y 12 75H pe 17 75H 000785Q 000785Q 000785Q 000785Q Tube Size Vacuum O D inches 035 wall Tank Below Pump Tank Above Pump 3 8 V L 0086Q 75H V L 0086Q 75H 1 2 V L 00218Q 75H V L 00218Q 75H 5 8 V L 00785Q 75H V L 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 Reconfigure the syste
17. or deliver TANK ABOVE THE PUMP OR GRAVITY FEED SHUT OFF DO NOT USE VALVE CHECK VALVES FOR SERVICE IN GRAVITY FEED INSTALLATION FIGURE 3 NOTES FOR FIGURE 3 1 H 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 l 3 for line sizing TANK BELOW THE PUMP OR LIFT FEED FIGURE 4 NOTES FOR FIGURE 4 1 H 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 l 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 Exceed 10 psi manufacturer or 3 psi NFPA inlet and return line pressures Use check valves in gravity feed systems DO e Connect inlet or suction line to the fuel unit inlet
18. 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 Max 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 100psi 2 5 GPH g 1 7 HP 1 7 HP A2RA 7737 1725 10 20 psi 2 5 GPH g 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 Inlet Line L Maximum J3NBN A132B 3 4 in 20 ft J3NBN A132B 1 in 60 ft A2RA 7736 7737 7738 1 2 in 20 ft A2RA 7736 7737 7738 3 4 in 90 ft Waste 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 NFP
19. s 10 psi inlet pressure limit or 8 feet to be within NFPA s 3 psi inlet pressure limit 3 See page ll 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 A 70 pump firing 1 gph two pipe has 19 gph flowing through the filter TANK BELOW THE PUMP OR LIFT FEED a NOZZLE RETURN LINE TERMINATES 3 4 INCHES ABOVE INLET LINE FIGURE 8 NOTES FOR FIGURE 8 1 2 vertical distance from bottom of tank to the centerline of the pump H must not exceed 12 feet for single stage fuel units or 18 feet for two stage fuel units IMPORTANT H 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 II 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 requirements 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 prev
20. 0 100 100 100 100 100 100 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 H R 3 8 O D Tubing 1725 RPM Fira F Tu T o o e f a e f e e 0 64 64 53 41 37 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 4 33 JA JBa de ds Ju Je de HHs HAs Ba He Hs He Hs Ho 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 2
21. 00 100 27 24 100 93 18 22 88 74 76 65 H 5 PUMP USAGE IDENTIFICATION IDENTIFICATION EXAMPLE MODEL STRAINER SERIES NUMBER f 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 C LH LH T 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 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 LL 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
22. 6 23 Diane piure a 3 ox ps x se Jue 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 2 Fuel Oil B 7 P Unlimited J PUMP H PUMP Max Nozzle Max Nozzle Capacity Capactiy GPH at Rated _ Rated GPH at Rated _ Rated Model Pressure Model 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 J4P 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
23. 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 III 3 of this manual Figures 3 and 4 are illustrations of typical two pipe installations INSIDE OR OUTSIDE TANK FUEL UNIT ABOVE BOTTOM OF TANK INSTALL IN ACCORDANCE DO 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 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 11 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
24. 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 11 16 LIFT CONDITION MAXIMUM LINE LENGTH H R Lift H 5 8 O D Ap 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 e MAXIMUM LINE LENGTH H R Lift H 5 8 O D Tubing 3450 RPM 0 100 10
25. A when supplying to inlet of pumps It 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 e po ia RETURN FROM RESERVOIR OR SIPHON BY PASS 1 2 OR 3 4 1 D 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 SUNTEC S WASTE OIL TRANSFER PUMP AND MOTORSET 3 4 OR 1 I D 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 EA
26. AUTION Even though the coil is fully insulated care should be exercised to avoid touching the coil when energized except with insulated tools Apply power to the coil You should feel vibrations and or magnetic pull on the screwdriver If YES go to Step 8 If NO replace coil and go to Step 2 Replace tube assembly or complete valve assembly Remove power from coil and start burner Check to see if oil is passing through the valve If YES replace tube assembly or valve assembly and go to Step 1 If NO valve is performing satisfactorily IV 16 L G OO o 0 5262 Q gt 8 0 T A Part Order Number Item No Description R Valve C Valve 1 Coil Nut 3753818 3753818 2 Coil for R642N 3713642 R641D 3713809 R753 3713790 C642N 3713642 C641D 3713809 C753 3713790 3 Base plate screw 2 3773421 3773421 4 Base plate 3753762 3753864 5 Tube assembly 3713766 3713766 6 O ring 3773461 3773461 7 Valve body 3723810 3723815 8 Gasket 2 2779261 9 Nozzle screw 3753835 10 Electrical connector 3753865 11 Electrical connector 12 Electrical connector IV 17
27. E RELIEF VALVE SAFETY VALVE 3 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 SERVICE Service on fuel units should not be attempted without the aid of good vacuum and pressure gages Many system problems can be detected with the aid of these gages Service falls into two categories routine and trouble ROUTINE ANNUAL OR OTHER CHECK OUT Check line filter and pump strainer for amount of contaminate If close to needing service replace to prevent a call back in near future If using inlet into the side of the pump it isn t necessary to remove cover to check the strainer Remove inlet line and view strainer through inlet opening If it s clean there it will be clean the rest of the way around If strainer is plugged remove cover and clean strainer with a brush and clean fuel Replace cover gasket before reinstalling System running vacuum should be checked as part of routine Running vacuum should not exceed 6 inches mercury for single stage one pipe 12 inches mercury for single stage two pipe 17 inches mercury for two stage two pipe Check and adjust system pressure if necessary Check CO or O and system draft Check for smoke and adjust to a trace Zero smoke is unclear as to where you are in adjustment
28. GUIDE CAUSE REMEDY NO OIL FLOW AT NOZZLE Oil level below intake line in supply Clogged Nozzle Air leak in intake line Restricted intake line high vacuum reading A two pipe system that becomes airbound A single pipe system that become airbound Slipping or broken coupling Rotation of motor and fuel unit is not the same as indicated by arrow on pad at top of unit Frozen pump shaft Fill tank with oil Remove and clean strainer Replace filter element Replace nozzle Tighten all fittings in intake line Tighten unused intake port plug Check filter cover and gasket Replace any kinked tubing and check any valves in intake line Check form 440100 for line sizes Check for and insert by pass plug Make sure return line is below oil level in tank Loosen gage port plug or easy flow valve and bleed oil for 15 seconds after foam is gone in bleed hose Check intake line fittings for tightness Check all pump plugs for tightness Tighten or replace coupling Install fuel unit with correct rotation See form no 440100 Return unit to approved service station or Suntec factory for repair Check for water and dirt in tank FUEL PUMP TROUBLESHOOTING GUIDE CAUSE REMEDY OIL LEAK Loose plugs o
29. HITE ROGERS CO LINE VOLTAGE TO BOOST TYPE NO 8094 3 POWER SUPPLY PUMPMOTOR ga EQUIVALENT FIGURE 6 WIRING FOR INTERMITTENT OPERATION Pressurized system bleed manifold of all air 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 doesn 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 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
30. LEN 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 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 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
31. LIARY E UT OFF FILTER ares OF 1 2 0 0 TUBING INLET LINE SUNTEC BOOST K VALVE PUMP amp MOTORSET i FA 15 FT MAX 1 2 0 D 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 advantages 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
32. NFORMATION 3 5 16 Max md G Strainer __ 27 8Max 2 T Strainer 3 8 Flexible Conduit Fitting 115 or 220 VAC 39 16 nlet Port 1 4 NPTF Nozzle Port Easy Flow Bleeder Valve 1 8 NPTF Nozzle Line or Gauge Port lencid il High Fire Adjustment Reqd for y Return amp internal 200 300 PSI Cut Off By Pass Port Solenoid Energized 1 4 NPTF I 5 Model Nozzle ARE Number RPM Rotation Port Location Rating at 300 psi High Capacity Units B2VA 8243 3450 R H R H 3 gph B2TA 8245 3450 R H R H 16 gph B2TA 8248 3450 R H R H 8 gph Two Step Units B2TA 8850 3450 R H R H 10 gph B2TA 8851 3450 R H R H 16 gph B2GA 8852 3450 R H R H 23 gph Also apply to 8 model numbers shown on fuel unit For example 8850 8 etc Viewed from shaft end At 130 psi MODEL J SINGLE STAGE FUEL UNITS e Single pipe gravity feed installations Two pipe lift installations to 12 hg vacuum e Lift or gravity feed applications with 10 psi maximum inlet return pressure e Capacities to 60 gph Six pressure options 10 to 300 psi Forno 4 and lighter fuel oils gasoline and JP fuels special e Hub and flange mounting in any position 1 6 3At 150 psi SPECIFICATION ORDERING INFORMATION Inlet Port 1 4 NPTF Inlet Port 11 32 Spot Drill 2 Holes
33. SY 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 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 e
34. Step 4 When vacuum reaches 15 in hg plug return port and turn burner OFF Step 5 Pump should hold vacuum level for five minutes NOTE If fuel unit cannot attain 15 in hg or hold that vacuum level for five minutes it should be repaired or replaced VACUUM TEST FOR SYSTEM SINGLE PIPE COVER INLET s Vus 10 4 m NOz E 2 TO SUPPLY TANK s BLEEDER OPTIONAL CAN INLET TWO PIPE COVER INLET TO NOZZLE Ik OPTIONAL y RETURN INLET FIGURE 3 VACUUM GAGE LOCATION FOR SYSTEM TEST Step 1 Install vacuum gage in the optional inlet port or tee into the supply line at the fuel unit If the optional inlet is used for the supply line install the gage in the cover inlet See Figure 3 Step 2 Turn burner ON and bleed the fuel unit if one pipe system Step 3 Close bleed valve and read gage Readings should be as follows IV 9 SINGLE STAGE TWO STAGE Model A Model J Model B Model H Single Pipe System 6 in hg 2 in hg 6 in hg 2 in hg Two Pipe System 12 in hg 12 in hg 17 in hg 17 in hg Step 4 If the gage reading exceeds the level indicated for the fuel unit being used check the piping and the system layout refer to Suntec installation bulletins for details Step 5 If the lift and run is not excessive for the fuel unit model the problem could be caused by the number and type of bends in the piping inclu
35. X m TANK p y A 4 Be E FEEDER pes L LS 35 FT MAX SUSPENDED FURNACES SHUT OFF VALVE 1 2 0 D TUBING AUXILIARY FILTER INLET LINE 1 Lite r 1 1 4 PIPE 1 2 0 0 TUBING AY RETURN LINE a Dig ee 1 IATA x X 15FT SUNTEC MAX LIFT bd BOOST PUMP TANK amp MOTORSET gt 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 auxiliary 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 D TUBING gt eh 0 30 PS 30 PSI MANIFOLD LINE s PRESSURE GAGE x r PRV 38 VALVES AUXI
36. 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 H Head in 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 e 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 Section 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
37. des kinks and flattening the number and types of fittings in the piping the number type and condition of filters and strainers the number and type of valves in the system and or the level of contaminate build up on the inside walls of the system piping Step 6 If the vacuum level is NOT excessive and there is air in the oil there is usually a leak in the piping To check a Close the tank valve b Pull a vacuum on the system by the fuel unit c Shut the burner OFF System should hold the vacuum level for five minutes If system is two pipe the return line will have to be closed off at shutdown PRESSURE TEST FOR FUEL UNITS AND SYSTEMS SYSTEM PRESSURE WITH SYSTEM OPERATING Step 1 If fuel unit is on a positive head system shut tank valve OFF before installing gage Step 2 Install gage in gage port Step 3 Turn burner ON if pump is on single pipe lift system bleed pump at the bleed valve Step 4 Observe gage disregard needle jiggling Step 5 If reading is high or low readjust pressure adjustment screw NOTE On Model J or Model H fuel units there may be some leakage with the acorn nut removed This will stop when the nut is replaced Step 6 Turn burner OFF The pressure should fall to zero or to the amount of head on the fuel unit IV 10 GAGE PORT PRESSURE PRESSURE ADJUSTMENT Se N BLEEDER NOZZLE E PORT PRESSURE INLET PORT 1 4 NPTF NOZZLE M
38. eate operational problems They are the first line of defense while the strainers within a fuel unit serve as a secondary or back up filter Contaminants come in many varieties a Abrasive Accelerate wear on moving parts b C d Blocking Clog filters strainers and oil passages Corrosive Chemically attack metal elements Biological Cause all of the above Relative contaminant size a b C d Smallest particle visible to the human eye 40 microns Bacteria 2 microns 1 micron 000039 inch 100 mesh screen opening 0059 inch 149 microns Contamination notes a If filters require changing more than once a year the filter is too small or the fuel system is too dirty If the fuel system is dirty it should be pumped out treated and refilled with clean oil If moisture is present it can rust the fuel system and parts and provide a breeding ground for bacteria If the fuel tank is treated with a bacticide use only the recommended amount Too heavy a concentration can cause the fuel unit to become inoperative When replacing filter elements care should be taken to not introduce the contaminant downstream to the fuel unit If a filter element has collapsed the fuel unit and lines must be flushed prior to resuming burner operation If filler has a screen in it make sure it is non corroding material Some are and some are not Field notes a Some filter elements will cause outgassing of fue
39. ent this with vacuums up to 17 in hg See page 111 7 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 A B B B WIESE MASON ERO SMIEROSSUEROLS B B J2 H2 us a l da Sans ass os fos gs ESI LH e freee as GPH GPH GPH GPH GPH Flow at 1725 16 is 18 22 2938 26 31 36 42 69 98 rpm Flow at 3450 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 bottom of tank to centerline of pump Q Gearset or line flow in gallons per hour gph V Vacuum in inches of mercury in
40. er 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 HT SUSPENDED FURNACES SHUT OFF VALVE AUXILIARY FILTER gt gt 1 1 4 PIPE Ht 1 2 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 AU
41. et 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 It 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 runs call the factory and get prompt help to install your system II 25 1 2 0 D TUBING INLET LINE SUNTEC BOOST 99 2 MESS e a NINN 2 T4 re s a PUMP amp MOTORSET FILTER y r N TL 1 2 0 D TUBING RETURN LINE Lia aaa APPROX 3 INCHES t FIGURE 1 LOW PRESSURE SIDE INSTALLATION Line Size 1 2 O D 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 Model H3 64 49 24 100 100 65 100 100 100 H6 44 34 1r 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 ris
42. f this manual 2 Oil lines 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 For additional information see Single Pipe Installation Section page Ill 1 of this manual Figures 1 and 2 are typical one pipe systems INSTALL IN ACCORDANCE WITH LOCAL AND UNDERWRITERS REGULATIONS OIL TANK SHUT OFF 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 H Head in Feet Q Firing Rate in GPH 3
43. 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 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
44. firing rates 172 1 5 GPH Nozzle 150 psi 1 8 GPH 2 3 0 GPH Nozzle 300 psi 5 2 GPH 3 12 0 GPH Nozzle 100 psi 12 0 GPH 4 2 5 0 GPH Nozzle 125 psi 5 6 GPH 5 1 25 GPH Nozzle Q 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 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 inl
45. 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 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 330 1 8 TEE 1 8 PIPE PLUG MANUAL BOOST LOW VOLTAGE PUMP SV CLOSED CONTINUOUS OPERATION TWO CONDUCTOR C OPEN OPERATES ONLY UPON WIRE f NE BURNER DEMAND SWITCH RELAY MINNEAPOLIS HONEYWELL Ag TYPE NO RA89A S GENERAL CONTROLS CO AS TYPE NO 50000D6 e PENN CONTROLS INC j VN TYPE NO 791BEOILU W
46. g screw is at the top of CW rotation left nozzle and CCW rotation right nozzle models or adjusting screw at bottom on CW rotation right nozzle and CCW rotation left nozzle models 1 8 SPECIFICATIONS ORDERING INFORMATION 162 Easy Flo Or Gauge Port 1 8 NPT t Pressure Adjustment Bieecer Valve E Return Port 1 1 n 4 5 8 Fn Flat 396 ui Dashed Line 100 Mount Solid Line 300 Mount Flange Mount Maximum Firing Rate gph NO ae 1725 rpm 3450 rpm yp 100 psi 300 psi 100 psi 300 psi HA2 Std 7 H2 Std 3 16 H3 Std 7 20 G 8 24 10 N 9 26 14 H4 Std 11 30 17 N 13 33 23 H5 Std 17 40 28 N 19 5 46 32 H6 Std 24 7 55 40 N 26 10 60 45 H7 Std 40 17 N 42 20 H8 Std 80 47 N 83 55 Special Pressure Spring Choices A 20 40 psi C 150 300 psi E 10 20 psi B 75 200 psi D 40 80 psi 1Do not adjust H2 and 3450 rpm only models HA HB HH to higher than 110 psi Requires C spring 100 300 psi range Requires C spring and hardened gear I 9 MODEL R amp C SHUT OFF VALVES For instantaneous redundant cutoff of fuel supply e Provides back up protection Closes when current to solenoid coil is interrupted Blocks oil flow to nozzle Delay or non delay opening Two model choices Model R mounts to fuel unit Model C mounts to burner or other remote locations
47. iner models are designed by the first character following the gear size designation in the fuel unit model number as indicated below Examples J3PBN C200H 4 P Strainer JA2BA 100 B Strainer Nozzle Capacity Rating A No strainer used in certain lube pumps B 7 gph metal frame C 4 5 gph obsolete use B or N N 7 gph plastic frame P Unlimited do not use in Models J7 J8 H7 H8 K Unlimited requires spacer between pump body and cover MODEL A AND MODEL B FUEL UNITS Strainer models are designated by the first character following the gear size designation in the fuel unit model number as indicated below Examples A2VA 7116 4 Y Strainer B2TA 8851 5 T Strainer IV 12 Strainer Model Designation Nozzle Capacity Rating V 3 gph Y 7 gph T 16 gph G 23 gph IMPORTANT DO NOT use a strainer which is too long for the cover indicated by a 1 8 or more cover gap when spring is fully compressed Forcing would crush the strainer body and allow contaminants to get into the pumping mechanism STRAINERS AS A DIAGNOSTIC INDICATOR What you see in a strainer can be an indicator of what conditions may exist within the system a Clogged strainer Primary filter has failed or is missing b Sludge on strainer Water in the tank allowing biological growth c Rust flakes on strainer Rusted tank or components Field replacement of 3 gph and 7 gph rated strainers Figure 1 Al
48. ing questions listening and providing answers Today as the industry leaders our involvement is as strong as ever We still work hard to earn your trust in us as the experts in our field You shouldn t have to settle for less MODEL A 7000 SINGLE STAGE FUEL UNITS e Single pipe installations to 6 hg vacuum Two pipe installations to 12 hg vacuum Lift or gravity feed applications with 10 psi maximum inlet return pressure Choice of 1725 2850 3450 rpm e Suitable for no 2 no 1 fuel oil or kerosene Mounting in any position Factory set at 100 psi Adjustable range 100 150 psi at 3450 rpm 100 135 psi at 1725 rpm Models available to 200 and 300 psi I 1 SPECIFICATIONS ORDERING INFORMATION 2 7 8 Max 7900 Series 2 11 32 Max Pressure Gauge 7100 Series Port 1 8 NPTF Inlet Port 1 4 NPTF Nozzle Port 1 8 NPTF p Easy Flow nlet Port Bleeder Valve 1 4 NPTF Return amp Internal By Pass Port Single Stage Models Flange Mount 1 4 NPTF Model Number RPM Rotation Nozzle Port Location Strainer 8 Nozzle Rating at 100 psi Special Features A1VA 7112 A1VB 7113 A1VC 7114 A1VD 7741 A1YA 7912 A2VA 3006 A2VA 7142 A2VA 7116 A2VB 7117 A2VC 7118 A2VA 7416 A2YA 7743 A2YA 7916 A2YA 7430 A2VD 7519 A2RA 7710 A2RA 7736 A2RA 7737 A1RA 7738 A2RA 7739 1725 1725 1725 1725 1725 2850 3450 3450 3450 3450 3450 2850 3450 3450
49. ion see Two pipe Installation Section page III 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 Lease FILTER Am AE 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 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 1
50. iping Gravity Feeder e de ec ber ep Seba da REI ay RA aea Pt aly 11 10 CAN ues dua ux 0 o 11 11 Check AVES ou ees oss d RISO 11 12 Thermal Expansi n bsos pps aida pis 11 12 SERVICE Routine or Annual Checkollt s treo arit Su dut Pario atate Fat aed ea tide GRA IV 1 Trouble Call ou dde pi b s IV 1 System Troubleshooting Sequence 2535 3 ad YR Ru MOERORE YS Meng Vader OE S ues IV 2 Troubleshooting Guide for Fuel Pump S roe Feb VOCI Lh cir ADU ds IV 4 Testing Fuels Units and Systems zs aaa ea a AA ee IV 7 Vacuum Test Fuel Units cog s Lans RU EA NUR IV 7 Vacuum Lest System 2r ure e e et d y da ays AA geld IV 9 Pressure Test octo WEE a C a oO eee IRAN Ue Ot uH ea Sun Cae bo I IV 10 Operating and Cutoff Vest eaa a et de a RPG VA S pd tex aw Ais IV 11 Stramers dnd Field Service ua ew dad HOT EAS Put AUS TAX DEREN AA ER IV 12 Kilters dnd Eiltrdtloth 925 etr es EHE RL SP ek os LE bue d RAR IV 15 Solenoid Valves and Field Series a Ae RD EDU a POU nd Sede x ata a eae ded CAT S IV 17 SUNTEC PERFORMANCE PROVEN FUEL UNITS AND VALVES for residential and commercial applications SUNTEC THE INDUSTRY LEADERS BUILT ON OUR COMMITMENT Knowing the industry s need and responding to them with the right products and services is one of the responsibilities of leadership Over the years Suntec has been committed to being involved ask
51. l models and revisions of Model A70 and model B80 fuel units To simplify field replacement and improve overall strainer efficiency only two strainer models are offered for replacement in standard Model A and Model B fuel units As shown a spring is required in some instances to compensate for the difference in strainer height and cover depth see Figure 1 Model Strainer Capaelt Model Date Cover Strainer Spring Series Designation GPH Revision Code Depth Part No Part No A V 3 All All 1 133 3715732 Not Req A Y 7 Y82 amp Earlier 1 345 3715732 3773231 3754732 A Y 7 D82 amp Later 1 620 3715744 Not Req B VEY 387 2 3 4 All 1 345 3715732 3773231 3754732 B V amp Y 3 amp 7 5 All 1 620 3715744 Not Req B T 16 All All 1 620 3715742 Not Req B G 23 All All 1 620 3715746 Not Req Model Revision last number of model number EXAMPLE B2VA 8216 5 FIGURE 1 STRAINER REPLACEMENT IV 13 Installation of strainer part no 3715732 in medium height covers M 1 615 in FIGURE 2 STRAINER INSTALLATION Step 1 Set spring part no 3773231 or 3754732 in cover with large coils up Step 2 Set strainer part no 3715732 on large coil Step 3 Install new gasket Step 4 Slide cover over gearset IV 14 FILTERS AND FILTRATION Filters are necessary in all fuel systems to capture contaminants which might develop and cr
52. l oil at low flows and relatively low vacuums 1 2 in hg This usually appears as a loss of prime on one pipe installations A field cure for this is to shut off the tank valve while priming the pump and put as much vacuum as possible on filter Open the tank valve and resume normal priming When changing filters take care not to introduce contaminate from dirty element into down stream piping and fuel pump High vacuums across a filter element that appears to be clean can be caused by greasy bridging type contaminant IV 15 SOLENOID VALVES SERVICE R VALVE C VALVE INSTALLATION Model R valves mount directly into the nozzle port of the fuel unit Model C valves mount to the burner chassis or otherwise remote from the fuel unit OPERATIONAL CHECK Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Remove nozzle line at the burner assembly end and place into container to catch oil Start burner and watch for oil to run from the open line If YES go to Step 9 If NO go to Step 3 Turn burner OFF Check for power to the coil If YES go to Step 5 If NO repair electrical supply and recheck Remove nut which holds the coil into the valve asembly Remove coil from valve and slide it over an insulated handle screwdriver IMPORTANT to apply power to the coil without a screwdriver or other magnetic material in the center hole will cause the coil to overheat swell and fail C
53. ly Set fix or replace thermostat Clean remove or replace combustion chamber If rust or bacteria in pump fuel tank No or Replace Pump has water in it and need attention Yes Yes 4 Check for seized pump No Repair or replace motor and or primary control Replace pump Repair or replace ignition system No A Check for clogged strainer in No Check vacuum capability of pump or filter external pump Technical Bulleting 223 Yes v IV 2 SYSTEM TROUBLESHOOTING DIAGNOSTIC FLOW CHART cont d Step Yes Install pressure gage in pump nozzle Repeat step 7 Yes Start burner check and set correct pump No Replace pump pressure Yes Stop burner and check that pressure No Replace pump drops and stops at some positive value Yes Reconnect nozzle line and test fire No Check for nozzle problem burner Check for ignition problem 1555 mm Bl col INI o zieolz olz olgslol zo o 4 9 9 a4 o o 3 Check combustion air supply 4 No Check for contaminated fuel Yes v Yes Set CO and smoke levels No Check system for blockages and Yes Allow system to complete several cycles ES 101 IV 3 Yes v Check inlet for air leak high vacuum Correct inlet line Yes Replace nozzle Yes Repair or replace ignition system Yes Reset to proper settings Yes Have tank pumped and refilled FUEL PUMP TROUBLESHOOTING
54. m 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 automatically operate
55. or Kerosene Mounting in any position except upside down I 3 SPECIFICATION ORDERING INFORMATION 1653 3 625 008 pa 2 7 8 MAX 045 1 Pressure Gauge _ inlet Port 4 51 64 p Port 1 8 NPTF 1 4 NPTF Nozzle Port 1 8 NPTF npon QUUD Bleeder Vue Z 1 4 NPTF Two Stage Models Flange Mount Nozzle Strainer Model RPM Rotation Port amp Nozzle Special Number Rating at Features Location 100 psi BIVA 8212 1725 R H R H 3 gph B2VA 8216 3450 R H R H 3 gph B2YA 8916 3450 R H R H 7 gph 3 gph at 200 psi B2VA 8416 3450 R H R H 3 gph Solenoid dumping fuel unit B2VA 8241 3450 R H R H Boost pump 20 gph at 10 20 psi B2VA 8242 2850 R H R H 2 25 gph Also apply to 8 model numbers shown on fuel unit For example 8212 6 etc Viewed from shaft end 1 4 MODEL B 8200 TWO STAGE HIGH CAPACITY HIGH PRESSURE NOT PICTURED AND MODEL B 8800 TWO STEP TWO STAGE Two pipe installations up to 17 hg Vacuum e Lift or gravity feed applications with 10 psi maximum inlet return pressure Adjustable manual or automatic high low firing High efficiency burner applications Capacities to 23 gph A Pressure adjustable 100 to 200 psi low fire 200 300 psi high fire e For no 2 fuel oil For other fuels consult factory Two bolt flange mounting in any position except upside down SPECIFICATIONS ORDERING I
56. port e 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 e Use a non hardening thread sealing compound Prefill prime the pump on long runs to reduce dry running time e Start 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 READ OPERATING PRESSURE NOZZLE PORT 1 8 OPTIONAL INLET 1 4 1 15 BYPASS PLUG INSERT FOR 2 PIPE SYSTEM USE 5 32 ALLEN WRENCH RETURN 1 6 REGULATE PRESSURE EASY FLOW AIR BLEED VALVE 00 NOT READ OPERATING PRESSURE RETURN 1 4 RETURN LINE INLET PORTS 1 4 USE EITHER PORT REGULATE PRESSURE BY PASS PLUG INSERT FOR TWO PIPE SYSTEM NEW EASY FLOW AIR BLEED VALVE AND GAGE PORT e f NOZZLE PORT 1 6 RETURN PORT 1 4 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 DO NOT USE CHECK FILTER VALVES QN GRAVITY FEED SYSTEMS 3 4 INCHES RETURN ABOVE INLET FIGURE 7 NOTES FOR FIGURE 7 1 H vertical distance from top of tank to centerline of pump 2 H must not exceed 27 feet to be within manufacturer
57. r fittings Dope with good quality thread sealer Retighten Leak at pressure adj screw or nozzle plug etes Washer may be damaged Replace with washer or o ring Blown seal single pipe system Check to see if by pass plug has been left in unit Replace fuel unit Blown seal two pipe system Check for kinked tubing or other obstructions in return line Replace fuel unit Seal leaking iie med oos Replace fuel unit GOV T T P B00 Tighten cover screws or replace damaged gasket NOISY OPERATION Bad coupling alignment Loosen fuel unit mounting screws slightly and shift fuel unit in different positions until noise is eliminated Retighten mounting screws Air in inlet line Check all connections Use only good flare fittings Tank hum on two pipe system and inside tank Install return line hum eliminator in return line PULSATING PRESSURE Partially clogged strainer or filter Remove and clean strainer Replace filter element Air leak in intake line Tighten all fittings Air leaking around cover Be sure strainer cover screws are tightened securely Check for damaged cover gasket FUEL PUMP TROUBLESHOOTING GUIDE CAUSE REMEDY LOW OIL PRESSURE Defective gage ecce Check gage
58. tem to provide the proper oil supply to the fuel units See Boost Pumps or Transfer Pumps page II 23 TWO PIPE TANK ABOVE OR BELOW FUEL UNITS INLET MANIFOLD RETURN MANIF NOT RECOMMENDED FIGURE 11 Line Sizing The manifolds or supply lines must be sized to accommodate the total gear set capacity not firing rate or all units connected to the manifold A B C D as shown above See Line Sizing page 11 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 ao TP 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 II 23 CHECK VALVES OTHER VALVES AND THERMAL EXPANSION Check Valves A properly installed fuel oil heating s
59. 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 S LI EASY FLOW STUTNTT ET AIR BLEED VALVE e B 8800 READ OPERATING R PRESSURE PRESSURE GAGE Ns PORT 1 8 INLET 1 47 X 1 16 BY PASS iacu INSERT FOR 2 PIPE SYSTEM b USE 5 32 ALLEN WRENCH FIGURE 2 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
60. ven if they are two stage pumps MODELS AND SELECTIONS BOOST PUMP Includes Pump Delivery Item Pump Rotation GPH O 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 8 150 psi Max Adapter for 48N Motor P N 134462 11 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 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 GPH Total 5 15 GPH required Select a BB1020M which will supply 20 GPH 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
61. w ratings With today s high efficiency furnaces and boilers it is extremely important to check these parameters when the initial installation is made and also during later service calls to assure that high efficiency operation is being maintained It is also important to check fuel unit pressure and vacuum levels during trouble calls to help differentiate pump problems from system problems VACUUM TEST e FOR FUEL UNITS AND INLET LINES FUEL UNIT SINGLE PIPE SYSTEM INLET PORT 1 4 NPTF _ PRESSURE ADJUSTMENT EASY FLOW BLEED amp GAGE PORT 1 8 NPTF FIGURE 1 VACUUM GAGE LOCATION FOR SINGLE PIPE SYSTEM Step 1 Remove inlet line from fuel unit and install vacuum gage in the inlet port see Figure 1 If unit has been running dry pour oil into pump prior to testing Step 2 Turn burner ON and open bleed Step 3 When vacuum reaches 15 in hg close bleed port Step 4 Turn burner OFF Pump should hold vacuum level for five minutes NOTE If fuel unit cannot attain 15 in hg or hold that vacuum level for five minutes it should be repaired or replaced FUEL UNIT TWO PIPE SYSTEM INLET PORT 1 4 NPTF N PRESSURE ADJUSTMENT EASY FLOW BLEED amp GAGE PORT 1 8 NPTF RETURN PORT FIGURE 2 VACUUM GAGE LOCATION FOR TWO PIPE SYSTEM Step 1 Remove inlet line from fuel unit and install vacuum gage in the inlet port see Figure 2 Step 2 Remove return line Step 3 Turn burner ON
62. ystem 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 absorb pressure increases
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