Service manual

ManualsBrandsModine Manufacturing ManualsBurnerPOR

INSTALLATION AND SERVICE MANUAL

oil-fired unit heaters

model POR

➀

4-522.5

5H75804

Inspection on Arrival

1. Inspect unit upon arrival. In case of damage, report

immediately to transportation company and you local Modine

sales representative.

2. Check rating plate on unit and motor to verify that power

supply and motor specification requirements meet available

electric power at the point of installation.

3. Inspect unit received for conformance with description of

product ordered (including specifications where applicable).

October, 2010

THIS MANUAL IS THE PROPERTY OF THE OWNER.

PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.

WARNING

Improper installation, adjustment,

alteration, service or maintenance can

cause property damage, injury or death,

and could cause exposure to substances

which have been determined by various

state agencies to cause cancer, birth

defects or other reproductive harm. Read

the installation, operating and maintenance

instructions thoroughly before installing or

servicing this equipment.

FOR YOUR SAFETY

WHAT TO DO IF YOU SMELL GAS:

1. Open windows.

2. Do not try to light any appliance.

3. Do not touch any electrical switch; do

not use any phone in your building.

4. Immediately call your gas supplier.

CAUTION

To prevent premature heat exchanger

failure do not locate ANY oil-fired units in

areas where chlorinated, halogenated or

acid vapors are present in the atmosphere.

FOR YOUR SAFETY

The use and storage of gasoline or other

flammable vapors and liquids in open

containers in the vicinity of this appliance

is hazardous.

IMPORTANT

The use of this manual is specifically

intended for a qualified installation and

service agency. All installation and service

of these units must be performed by a

qualified installation and service agency.

➀ This manual is for models with Beckett Clean Cut Burner.

Summary of content (20 pages)

PAGE 1
4-522.5 5H75804 October, 2010 installation and service manual oil-fired unit heaters model POR ➀ FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.
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special precautions / table of contents Special Precautions THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE, EFFICIENT AND TROUBLE-FREE OPERATION. iN ADDITION, PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW. FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS, PERSONAL INJURY, OR DEATH. THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES. HAZARD INTENSITY LEVELS 1.
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si (metric) conversion factors / unit location SI (Metric) Conversion Factors 3. In multiple unit installations, arrange units so that each supports the air stream of the next unit, thus creating circulatory air movement in the area. See Figure 3.1. A large portion of the heated air should be directed toward the side of the building exposed to prevailing winds. 4. When locating units, it is important to consider that the exhaust vent piping must be connected to the outside atmosphere. 5.
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installation Combustion Air Requirements Figure 4.1 - Suspension Methods For complete combustion, 14-1/2 lbs. of air is required for each pound of No. 2 fuel oil. Lack of combustion air can cause erratic burner operation, noisy combustion, fuel odors and soot deposits on heat exchanger walls resulting in lowered efficiency and high fuel consumption.
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installation Wiring Venting - continued 5. If it is necessary to have an excessively high stack or if the stack is located such that it is susceptible to updraft conditions caused by wind, then oversized barometric dampers should be installed. In extremely windy locations, a Breidert type vent cap is recommended. 6. For the best venting, the chimney should be as close to the unit as possible. Keep flue pipes as straight as possible, avoiding sharp bends.
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installation Figure 6.1 - Single Unit Wiring Diagram 115V/60HZ/1Ø Wiring Legend FACTORY FIELD WIRE NUT FUSED DISCONNECT SWITCH (BY OTHERS) FAN & LIMIT CONTROL FAN MOTOR FAN LIMIT FAN SWITCH BL W BK BK LIMIT CONTROL BURNER MOTOR R GROUND VALVE FIELD WIRING JUNCTION BOX (ON HEATER) BK VALVE BK W W V PRIMARY CONTROL T USE COPPER CONDUCTORS ONLY W OR BK T VIOLET W IGNITOR EQUIPMENT GROUND GR BURNER MOTOR IGNITOR BL/W tr PRIMARY CONTROL Y Y LOW VOLT. THERMOSTAT T LOW VOLT.
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installation Piping Piping Selection Figure 7.1 can be used to approximate system piping requirements for two pipe systems. Determine the total lift in feet from the bottom of the supply tank to the fuel unit and subtract from 20 feet. This is the reserve available in feet of oil for piping losses. Determine the total equivalent length of piping by adding the total straight lengths to the equivalent length of straight pipe for each elbow and tee per Table 7.1.
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INSTALLATION Multiple Unit Supply To save piping, oil tanks, and provide flexibility to extend pipe supply lines to multiple-unit installations, a centralized oil distribution system may be installed with a booster pump, oil safety valves, and vacuum breaker. Figures 8.1 and 8.2 illustrate typical loop and pressurized oil supply systems. In each of these systems the unit heater is installed as in a one-pipe system. Figure 8.
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UNIT COMPONENTS / ACCESSORIES Figure 9.1 - Cutaway View of Oil-Fired Unit Heater 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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operation Operating Sequence Prior to Operation Although this unit has been inspected and fire-tested at the factory, the following procedures should be performed to assure proper on-site operation: caution Start-up and adjustment procedures should be performed by a qualified oil serviceman. The operation of Modine oil-fired unit heaters is governed by a primary control which operates the burner, and a fan and limit switch which controls the circulating air fan dependent on the heat exchanger temperature.
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operation Initial Start-Up 1. Adjust room thermostat above room temperatures. 2. Open shut-off valves at tank and in oil supply line to the burner. 3. Turn on power to the unit. If burner does not start immediately, push reset buttons on burner motor and primary control. 4. For units installed on a single pipe system, vent air from fuel unit and oil supply lines immediately after the burner motor starts. Vent air by opening bleeder valve on fuel unit until oil appears clear (no foam), then close tightly.
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DIMENSIONS / PERFORMANCE DATA Figure 12.1 - Oil-Fired Unit Heater Dimensions Table 12.1 - Outline Dimensions (inches) Approx. Shipping Model A B C D E F G H J K L M Y Wt. Lbs.
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service instructions Service Instructions To Service Burner Assembly 1. Disconnect electric power to unit. caution 2. Remove fasteners on hinged ignitior on top of the unit and swing back giving access to the inside of the burner housing, the nozzle, cad cell, and blower wheel. Service procedures should only be performed by a qualified oil serviceman. 3. Clean blower wheel and combustion air openings with vacuum cleaner or air hose, if required. Routine Unit Maintenance 4.
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service instructions Burner Adjustments F. caution 1. Do not attempt to start the burner when excess oil or oil vapor has accumulated in the combustion chamber or when the heat exchanger is very hot. Test the flue gas for carbon dioxide (CO2) content. Zero the CO2 analyzer and insert probe into flue pipe and draw sample of the flue gas into analyzer. The concentration of CO2 should be 11.5 to 12.5%. CO2 levels above 12.
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service instructions Fuel Unit Service Fire Pot Service A Beckett two stage, 3450 RPM fuel unit is supplied on all Modine oil unit heaters. Two stage fuel units are intended for high lift applications, up to 15 inches Hg. (Mercury) of inlet vacuum or the equivalent of 20 feet of vertical lift. For high lift applications, it is recommended that a two pipe oil supply system be used. Burners are shipped with the bypass plug removed. This plug must be installed for such applications.
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service & troubleshooting warning When servicing or repairing this equipment, use only factory-approved service replacement parts. A complete replacement parts list may be obtained by contacting Modine Manufacturing Company. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not approved by the factory will be at the owner’s risk. Table 18.
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service & troubleshooting Oil Burner Assembly (Continued) Remedy Problem B. Burner motor operates but no oil delivered at nozzle. 1. Oil level below intake line inside supply tank. 1. Fill tank with oil and bleed air from the line. 2. Clogged strainer. 2. Remove and clean strainer. 3. Clogged nozzle. 3. Remove and clean or replace nozzle. 4. Air leak in the intake line. 4. Tighten all fittings in the intake line. Tighten unused intake port plug in the fuel unit.
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commercial Warranty Seller warrants its products to be free from defects in material and workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use of materials substituted under emergency conditions for materials normally employed.