Document 3RwKD7ZrEd61549xaw73zjRa

' '\ i .1 T.J -f i ' iiV ~r `in11 pUJ*1a\> t> v t~ .1U wv? INSIALUniCN iKSTRUCTIOMS $M5 PLUMBING Sc HEATING P.O. BOX 2003 NEV,' BRUNSVi'ICK, N.J. 08S03 PLAINTIFF'S $ EXHIBIT 37 PART NO. 30,10 (1 07814 u. GENERAL INFORMATION This manual is to be used in conjunction with the appropriate PFA-3 boiler manual. The boiler should be assembled, tested, and the boiler controls installed before the burner is unpacked and serviced for installation. All electrical and oil lines should be run adjacent to the boiler-burner instal lation. It is important that the serviceman and installer have the following instruments available for proper testing, adjustments, and servicing the burner: CO2 Test Instrument Smoke Tester Draft Gauge (Inclined tube . 0 to 1.0 inch) Oil Pressure Gauge Oil Vacuum Gauge Multi-Meter Flame Mirror The burners covered by this book have been specifically designed and tested for the boiler-burner units involved. At the rear of this manual are specific charts showing "Air Handling Data", "Burner Data", and various parts data. For proper burner operation the dimensions shown should be strictly adhered to. AIR FOR COMBUSTION It is necessary to have sufficient outside air for combustion to be supplied at all times to the Boiler Rocm. A permanent opening or duct should be provided such that the boiler input will not exceed 5000 Btuh/square inch of free area. The air inlet opening should be located at a point where it cannot be covered with snow or where it cannot be obstructed by any other means. Movable louvers should not be used. Never depend on an open door that can be closed for the air inlet, or rely on cracks under doors or around loose windows. _o _ 07815 FUE L SYSTEM All Burners are furnished with two-stage fuel units. Two-pipe systems are recommended. Refer to Fuel Unit Literature for proper vacuum, pipe sizes, etc. Suggested piping is illustrated below. FUEL-UNIT ABOVE TANK. TWO-PIPE SYSTEM FUEL-UNIT BFLOW TANK, TWO-PIPE SYSTEM Air vtnl obova maw laval 3- - NciU lnl*f Rtfurn tin* 07816 PREPARATION OF BURNER FOR INSTALLATION ON BOILER 1. Insert proper nozzle. (See "Nozzle Data" in charts of this manual.) 2. Check nozzle settings as shown in this manual. 3. Check electrode settings as shown in this manual. 4. Be sure all parts and settings agree with those shown in this manual. 5. Set drawer assembly to middle position on side of housing. 6. Burner is now ready for installation on boiler mounting plate. ELECTRICAL POWER CONNECTION Check burner, this manual, and wiring diagrams for the proper power supply to be connected to burner and controls. Note that, all burners are factory wired, eliminating field wiring as much as possible. START -UP AND FINAL ADJUSTMENTS 1. Make sure that flue damper in PFA-3 boiler is in full open position. (To be adjusted later if required.) 2. CAUTION Make sure there is water in the boiler and that there is oil in the oil line to prevent burn-out of Fuel Unit. 3. Connect oil lines to burner. 4. Connect electrical power wiring to burner and boiler controls. 5. Set air adjustments on burner to half open position. (These adjustments are temporary and will probably have to be changed to achieve proper smoke and CO2 readings. 6. Turn on power to burner. 7. Set limit and operating controls to desired settings. Burner should start. 8. Check smoke characteristics immediately . Adjust air to get No. 2 smoke or less. 9. Check oil pressure, .Should be 100 P.S.I. A_ 07817 / $- - N 1 10. Check CO reading (should be 12% 11. Check Out Operation of: Limit Control Operating Control Low Water Cut-Off Ignition Characteristics Burner Safety Circuit Re-check CO2 and Smoke Readings SERVICE TIPS The following information has been compiled to assist the installer and serviceman in locating and correcting service problems with our "LC" series burners. These burners are equipped with 3450 r.p.m. motors and pumps, one-stage firing, and with flame retention. * All of the models can be fired ?/iih draft or with pressure in .the firebox. (See boiler installation manual for maximum allowable pressure in the firebox.) ''- * ' A forced draft burner supplies all the air for combustion' and can be. fired in a boiler with natural draft, induced draft or with no draft. ' '.? Pressure firing is a term used when there is pressure in the firebox during the burner operation. The pressure is produced by the resistance through the boiler or furnace and the combustion air supplied by the burner. AIR FOR COMBUSTION If lack of combustion air is suspected, close the door to the boiler or furnace room and operate the burner for at least 30 minutes. If the flame appears to become gassy and tends to snuff out, insufficient combustion air is the cause and corrective measures must be taken to provide the proper amount of air. BLOWER WHEELS (FANS) - VIBRATION If undue vibration is detected in the burner, it could be caused by the blower wheel being out of balance. Check to determine if any foreign matter has been drawn into the burner and lodged in the blower wheel. If not, replace the blower wheel. Remove the motor from the burner and run it vvitnout the blower wheel to determine if there is any undue vibration. Replace the motor if the operation is not smooth. When installing a new blower wheel in the burner, it is very important that it be secured tightly to the motor shaft. -o 07818 / The replacement blower wheel must be located on the motor shaft so that the set screws bear on the center of the flat on the 1/4 H. P. motors. Make sure that the set screws on blower wheels are securely tightened. There should be adequate clearance on both sides of the blower wheel in the housing. The blower wheels used in the burners are dynamically balanced for operation at 3450 r.p.m. and any replacement should be an exact duplicate of the original. DRAFT The burners are designed for firing against pressure in the firebox, but operate just as satisfactorily ir. a natural draft installation. It is important that tbs vent or ohirrmey bo located so as to be free of downdrafts. Forced draft burners can operate with back pressure in the boiler and flue pipe, but strong surges of down draft can cause tire fire to become smoky and erratic. After a shut-down the heat in the combustion area could damage the burner if it is forced back through tiro burner by down-drafts, it may be necessary' to increase the height of the vent or chimney above the building and in some instances install a dutch cap or similar appliance to prevent downdrafts. FUEL SYSTEM The burners can be installed with a single line if no lift from the oil tank is involved. If a long single line is used, it should be large enough in diameter so that the vacuum reading on the fuel unit is no more than 10 inches. If the oil tank is below the level of the burner, use a two-line system. If two or more burners are piped to a common suction line, each burner must have its own check valve. If the pressure gauge on the fuel unit shews the 100 p.s.i. cannot be obtained, the fuel unit should be replaced. The quick cut-off pumps used should never be adjusted above 100 p.s.i. A pressure gauge and a vacuum gauge should be used if a fuel unit problem is suspected. If the pressure is excessive, such as 125# to 150#, check the flame base at the flame retention cup. Excessive pressure may cause the flame to lift away'from the spinner. The pressure should be maintained at 100#. 07819 tefer.to the fuel unit manufacturers data lor the proper vacuum -'or h:**, . installation, " the vacuum reads higner than the calculated vacu - mauufa.. :v .. instructicus) check for restrictions in the oil liiVi. .. sively long' closed tank valve, kinked copper tubing, plugged cD fro: ?a oil II . r d.ersized oil line, excessive oil lift or a restiie,hi.; or foe id-" - . vi vacuum reads low, look for air leaks in the sucticvju ~ wias. yah -j fir. .kgs . unit. Qn a gravity flow installation, no vacuum will he _sa` --a eu 'he hr . re except where there are restrictions caused by a closed var:.. p.-.. .god : ii filter, kinked, undersized, or excessively long suction line.' . ' All restrictions must be eliminated and undersized or excessively long lines replaced with lines of a greater diameter so that the vacuum reading will be no more thaii 10 inches. A singing sound in she fuel unit may indicate air in the suction line. Excessively high vacuum can also cause noise in the fuel unit. Air in the suction line can cause delayed lighting. This condition will in time coat the photocell with carbon and safety shut-downs may result. If it is suspected that the oil is returning to the tank after shut-down, inspect for leaks in the suction line and check valve, if the check valve is not seating properly and there is a slight air leak in the suction line, the oil will flow back to the oil tank. On the next start up of the burner, there will be a delay in the oil delivery while che ^irnp is lifting the oil from the tank. Repair any air leaks and replace the check valve if necessary. ... IGNITION PROBLEMS Hard (rough) lighting can be caused by ignition problems. Check the transformer for adequate spark. Check for a spark by momentarily short circuiting the transformer across the terminals by use of a screwdriver with an insulated handle. A 3/4" long spark should be obtained. If there is no spark or if the spark was weak (less than 1/2 inch), replace the transformer. Check the spark gap with the dimensions in the installation manual. With standard control systems the spark should appear immediately when the burner starts. If a delay is detected, check the power supply to the burner. When a condition of tins type is suspected, the best check is to have a voltage recorder connected to the burner for a period of 48 hours. This will indicate any voltage drop during that period. Voltage drops are usually caused by undersized wiring or a long run from the burner to the source of power. If delayed ignition is not corrected, it could cause an explosion. 07820 Cl. ;ck the drawer asscmhly for possible high voltage leaks in the insulators. If in doubt, change the electrode assemblies. Check the electrode springs and , points for adequate clearance to the ground. Check for carbon on the electrode . points. Ched: all dimensions on the drawee assembly according to the dimensions shown in the: manual and reart if necessary. If the cup is not correctly positioned in^relation t' :k.. and cone hard lighting could occur. This is usually caused when the cup is posk-oned too far back inside the end cone. To correct this condition, loosen the screw that locks the drawer assembly in place and move the assembly forward in steps of 1/16 of an inch until the lighting is smooth. Be sure to tighten the set. screw after making this adjustment and check the electrode springs from the electrodes to the transformer, making sure there is adequate clearance to a ground and there in >v..< possibility of a short circuit. If the fire is clean with no smoke while hi operation, but the heating unit continues to become coated with : oot, check tor short cycles cn the burner. Short cycling will eventually cause hard lighting due to carbon on the spinner and nozzles. Under these conditions the limit, control on the heating unit should be set with a greater differential. INSTRUMENTS In most forced draft unii.v it ir. impossible to view the flame satisfactorily so instruments must be used to properly adjust the flame. . Do not attempt to obtain a higher percentage of CO2 than a clean fire will give. Keeping the heating surface of the unit clean is more important than securing a higher percentage el CO.-.. Set the flame at no more than #2 on the Bacharach scale. NOZZLES Use only the nozzles recommended for they are of the proper type, capacity and spray angle, and these nozzles should give the best performance in each burner and unit combination endec normal conditions. However, because the great variation in fuel oils in different localities, normal conditions do not always apply. Nozzles will not always deliver the gallons per hour or the spray angle v-rit.--. which thev art: marked, and hi some instances nozzles other than those ftirr.iehe-. r. ; c.'-iequipment could give better performance. 07821 The nozzles used should give smooth lighting and be able to produce a CO2 reading of 10.5 to 12.5 percent with no.more than a #2 smoke. Do not attempt to installthe nozzle through the end cone. It is impossible to get a tight joint between the nozzle and the adapter unless two wrenches are used. Remove the drawer assembly from the burner and then remove the cup before installing the nozzle. 9- - liU IWN C. IV Ui* J. 1.1. i W` ' Boiler Number Burner Model No. fc Spec. No. "A" I. D. Of End Cone "B" Nozzle To Back of Cup "C" From Face of Cup To End Cone PFA-34 PFA-35 PFA-36 PFA-37 LC334-A3/1171 LC 3 34-A/1172 LC 5 34-A/1173 LC534-A/1173 3,f 3-1/4" 3-3/16" 3-9/16" 1/4" 1/4" 1/4" 1/4" 3/16" to 1/4" 1/16" to 1/4" 1/16" to 1/4" 1/16" to 1/4" * * CUP EXTENDS IN FRONT OF END CONE ON PFA-34 BOILERS Boiler Number Burner Model No. & Spec. No. "D" Burner Flange To End of Air Tube Electrode Settings "E" Back of Cup To Electrode Points ripti Centerline Nozzle up To Electrodes "G" Spark Ga- PFA-34 PFA-35 PFA-36 PFA-37 LC334-A3/1171 LC334-A/1172 LC534-A/1173 LC534-A/1173 2" 2" 2" 2" 1/32" 1/32" 1/32" 1/32" 1/4" 1/4" 1/4" 1/4" 1/8" 1/6" 1 / X v* 1/3" 07823 IR ITAN? !Nf DATA Boiler No. PFA-34 PFA-35 PFA-36 PFA-37 Burner No. & Spec. No. Bci'ov Rating' gp:i LC334-A3/1>.71 LC334-A/1172 LC534-A/1173 LC534-A/1173 2, a5 3.30 3.25 4.50 Eu? Cone Data I. D. Parc No, 3" 3-1/4" 3-S/16" 3-9/16" C51571 C61681 C516S1 C51691 E-iip Data 0. D. Part No. 2-5/8" 2-5/8" 2-5/8" 2-5/8" A40752 A40752 A40752 A40752 Boiler No. PFA-34 PFA-35 PFA-36 PFA-37 Burner No. & Spec. No. Stabilizer in 1\oD LC 3 34 -A3 /1171 LC 3 34-A/1172 LC534-A/'li73 LCuS ^-A/1173 A4I131 A411C1 A41131 A4116L Disc Data O. D. Part No, Nozzle Data Qty. Size Spray Used G.P.1I. Angle 7v> 2-1/4" S40SC4-3 2-1/4" S409C4-3 2-1/4" S4C904-3 2-1/4" S40D04-3 I 1 l i 2.50 3.25 4.00 4.50 70 45 45 45 rK p P P Boiler Number PFA-34 PFA-35 PFA-36 PFA-37 BURNER RATING CAPACITY CHART Burner No. & Spec. No. Gallons Per Hour Mia. Max. LC334-A3 LC324-A LC534-A LC534-A 2.00 2.00 3.00 3.00 4.00 5.00 6.00 6.00 TRANSFORMER Allanson Mfg. Corp. - Niagara Falls. New York Manufacturer Burner Model Sunray Fart Ns. Name Fart No. LC334-A3 LC334-A LC534-A Mil 1072 Allanson 452 Type Burner 07824 TWO -STAGE FUEL UNITS FOR OIL BURNERS Sundstran Hydraulics - Rockford, Illinois Burner M del Sunray Part No. Manufacturer Name Part No. LC334-A3 LC334-A LC534-A P40072 Sundstrand H3BA200 ______ Shaft DIA. FLAT 7/16" 1-3/1G" MOTORS FOR OIL BURNERS Marathon Electric Mfg. Corp, Wausau, Wisconsin Burner Model LC334-A3 LC334-A LC534-A Sunray Part No. MFRS . Part No. H. P. Frame Voltage and Cycles Type Shaft DIA. FLAT M40061 48S34S3B 1/4 48-6 split 115 -60 phase 1/2" 1-3/8" American-Standard Boiler No._____ PFA-34 PFA-35 PFA-36 PFA-37 BURNER MOUNTINGS PARTS INFORMATION Burner Model No. And Spec. No. LC334-A3/1171 LC334-A/1172 LC534-A/1173 LC534-A/1173 Air Tube Part No. Welded Flange & Air Tube Assembly Part No. A51232-7-3 A51242-7 -3-1/4 A51262-7-3-9/16 A51262-7-3-9/16 - 12 - 07825 iUTlON TO INSTALLERS AND OWNERS The heat transfer surface of this boiler has been carefully designed to give optimum performance and reliability. However, the presence of contaminants such as scale or lime, sediment and boiler sealing compounds in the section waterways may cause premature failure of the sections. If leaks occur in the system and are undetected or neglected, fresh water replaces the water lost through the leaks. Nearly all water contains dissolved minerals ("lime"). As water is heated in the boiler, the minerals are deposited, mostly at the bottom of the sections directly above the fire. No appreciable amount of lime is deposited in a system with no leaks; but when water is hard and makeup water must be added frequently and in large amounts, boiler waterways may be coated with a thick layer of lime within days or a few weeks of operation. Lime is an insulator, which causes over heating of boiler metal: if deposition ox lime is not halted, the boiler will fail. To stop lime deposition, step system leaks. Leaks may occur occasionally in any system. These leaks are usually of such a nature that they can be prevented or corrected by good workmanship. Every effort should be made to correct them without the use of boiler sealing compounds. If compounds are used, they should be used as sparingly as possible, and never in excess of manufacturers recommendations. Following use, the boiler must be flushed out thoroughly, or serious damage is likely to result. Sediment which may accumulate in the boiler should be flushed out in accordance with recommended maintenance practices. Excessive use of water should be avoided because of the danger of lime and corrosion buildup. Glycol anti-freeze is sometimes added to system wama- to protect against freezup. Although American Standard can not recommend this practice, we realize that glycol anti-freeze will occasionally be used. Heat transfer through glycol is poorer than through water: use no more than 50 percent glycol in the system. With any proportion of glycol, radiator- output will be lower then with pure water at the same temperature. It is always better, when possible, to drain the system rather than add anti-freeze? neither the heating system^orpiumbing system water will freeze so long as the heating system continues to operate; and the plumbing system is not protected against freezeup when the heating system is off, whether or not the heating system contains anti-freeze. Cast iron is highly resistant to corrosion. However, some propellants used in aerosol cans break down into poison g as ana corrosive gas, at high temperatures. If aerosol mixtures are used near boilers, the aerosol will enter the boiler flame and will be heated. Continued use of aerosol cans near heating system boilers can result in severe boiler heating surface corrosion and possible danger to health. The installer oi this boiler is responsible for shox^ing to the owner operator the location cf all et.ergcncy shutoff devices, and instructing him in the use of each. 07826 CONSUMER PROTECTION - WfcEEAKTY American-Standard products normally reach owners or consumer-users through an Industry channel of distributors and plumbing and heating contractors. Experience has bhown that claims of defects in our products generally relate to abuse or to other damage which occur after our sale and are not our responsi bility. Since determining proper responsibility requires local inspection, our warranty (set forth below) extends only to our direct buyers; distributors are best equipped to obtain the facts underlying claims, to place responsibility where it belongs and to recommend /handle repair or replacement. American-Standard warrants only to its distributors and ocher direct Buyers Chat it will furnish by freight a replacement for, or at its option repair, any product of its manufacture or part or portion thereof, proved to its satisfaction to be defective in material or vorloianship under normal use and service within one year after installation. THEBE IS HO OTHER WARRANTY, EXPRESS OR IMPLIES, INCLUDING NO IMPLIED WARRANTY 0? MERCHANTABILITY OR IMPLIED WARRANTY FOR FITNESS FOR A PARTICULAR PURPOSE AND AMERICAN-STANDARD WILL NOT BE RESPONSIBLE FOR ANY DAMAGES WHATSOEVER, NOR FOR LABOR OR TRANSPORTATION EXPENSES RELATING TO SUCH REPLACEMENT OR SUCH REPAIR, NOR WILL IT BE HELD RESPONSIBLE FOR WARRANTY ADJUSTMENTS COSTING MORE THAN THE PRICE OF THE PRODUCT TO ITS DISTRIBUTORS AND OTHER DIRECT BUYERS. Goods of other manufacturers sold by American-Standard are not warranted unless accompanied by an express written warranty, but the Seller will endeavor to secure for its direct Buyers Che benefits of-warranties extended by such other manufacturers for such goods. American-Standard Is proud of Its record for product quality and for fairness in handling warranty matters; and, if an ultimate user of our products should feel our warranty system described above does not work fairly in his case, he should write the Office of the President, Director of Consumer Affairs, U. S. Plumbing/ Heating, American-Standard, AO West 40th Street, New York, N. Y. 10018. WMgreMAAAS. Araaesfi. T&EKSStfS NO.______ CATS O? ij^STAilATlGMt 07827