Waste Oil Fired Boiler 280-480 Installation, operation and service instructions 120v Manual
Table of Contents Table of Contents Important Information Notice Burner & Pump Specifications Product Description Inspect Shipment Before Install Boiler Room Air Requirment Venting Installation Fuel Supply Lines Boiler Assembly & Wiring Boiler Assembly & Installation Oil Burner Technology Oil Burner Components References (Nozzle|Electrode|Burner & Pump) Boiler Start-up
Impor t ant In for mat ion Waste oil contains various unknown materials and may also contain random amounts of gasoline or other volatile fuels. Specific safety and handling precautions should be considered when cleaning, maintaining and operating waste oil boilers. It is recommended to use a filter or some kind of strainer when pouring waste oils into the storage tank(s). This will increase chances of catching any particulates prior to the pump filter(s) to insure a cleaner fuel source.
Notice To insure the best performance, optimal efficiencies and heat output of the heating unit, it is recommended and necessary to become familiar with your unit and the procedures needed with initially starting, running, cleaning and maintaining the heating unit. It is important to remember when burning used or dirty oils that contaminants could be present. Because of various contaminates, be aware of needing to change filters when needed. Keep the chamber and heat exchanger(s) passageways clean.
Burner & Pump Specifications BURNER ASSEMBLY Performance Ratings Voltage Cycles Total Operating Amperage (Burner Only) Total Operating Amperage (Burner & Oil Pump) Electrical Operating Consumption (Burner Only) Electrical Operating Consumption (Burner & Oil Pump) Weight Oil Primary Oil Valve Pre-Heater Block Pre-Heater Controller Board Igniter Transformer Burner Motor Amp Amp Watts Watts Lbs Amp Amp Amp Amp Amp Amp 120v 60Hz 8.4 10.5 970 1,212 36.5 0.2 0.075 4.2 0.011 0.3 3.
CENTERLINE OF BURNING PLATE SPECIFICATIONS - DIMENSIONS TABLE 1 2 - 1/2" M.P.T SUPPLY CONNECTION O B S E R VAT I O N PORT 9 - 3/8" F 36" 29- 1/2" 17" 20" 4" 33" L FRONT Boiler Model RIGHT OIL GPH C. O. PORTS 2 - 1/2" F.P.T RETURN CONNECTION REAR APPROX. DRY WEIGHT LBS. Vent Connect DIA" I-B-R VENT DIA" DIM" L WATER CONTENT GAL. F MHB280 2.0 1301 10 8 42 22.2 MHB360 2.5 1654 10 10 52 28.5 MHB480 3.0 1831 10 10 57 31.
Product Description The MHB Series boilers are a three pass Scotch Marine design, with fully water backed heat transfer surfaces. Boilers are designed for use in forced hot water heating systems up to 75 PSI water working pressure. They may be used with burners firing gas or oil. Boiler-Burner units operate with a positive pressure overfire and may be vented using a conventional chimney with a balanced draft or pressurized vent systems.
Inspect Shipment Any claims for damage or shortage must be filed immediately against the carrier by the consignee. No claims for variances from, or shortage in orders, will be considered unless presented within 7 days after receipt of goods. Boiler shipment comes on two separate pallets. NOTE : Burner, when ordered, is shipped separately 1. Wood pallet with: A. Boiler block with baffles installed in flue passages. 2. Wood pallet with shrink wrapped boxes: A. Box of jacket parts. B.
Before Install CODE REQUIREMENTS: Installation must comply with all state, local and utility codes. When required, the installation must conform to A.S.M.E. safety code for controls and safety devices for automatically fired boilers No. CSD-1. RULES FOR SAFE INSTALLATION AND OPERATION: 1. Read this owner's manual and the rules for safe operation carefully.
Boiler Room Air Requirment WARNING Failure to provide an adequate supply of fresh air for combustion will result in hazardous operating conditions. Do not use an exhaust fan in the boiler room. 1. To ensure safe, efficient operation, the boiler system must be supplied with sufficient air for combustion and ventilation. (See Fig. 2) 2. Unless properly controlled, avoid the use of forced ventilation, since it can create an undesirable pressure differential between boiler room and air source. 3.
FIG. 1 | TYPICAL BOILER ROOM LAYOUT F As Required F Boiler Vent Connection 2 - 1/2 Boiler Supply Connection 2 B CL CL 4 - 1/2" 33" L 33" 4 - 1/2" VENT CONNECTION DIA" BOILER MODEL F L DIMENSIONS" MHB280 10 42 MHB360 10 52 MHB480 10 57 Notes: 1. CL Dimensions as per job specs, and applicable codes. 2. B Dimensions of burners other than shown, consult crown.
FIG. 3 | CHIMNEY OR VENT SYSTEM The MorrHeat boilers operates with positive pressure throughout the boiler furnace and flue passages. The over-fire pressure will vary according to boiler size. Consult local building codes for proper installation of vent system relative to the fuel being burned. See burner manufactures draft recomendation. FORCED DRAFT BALANCED DRAFT Boiler breech & stub vent operate at positive pressure. Entire system must be gas tight .
Venting Installation 1. When installing the vent pipe, be sure all connections are fastened correctly to insure no leaks and proper draft is achieved. Minimum draft through the unit is, -.02- with draft meter. Draft up the stack must be -.04 to -.06 inches of water column when checking a draft meter for proper draft readings. 2. If proper or desired draft isn’t easily achieved, a third party draft inducer or power vent may be needed to prevent back draft from occurring (not provided). 3.
Fuel Supply Lines • Use only 3/8” ID copper tubing with flare fittings from the tank to the fuel pump assembly and the fuel pump assembly to the heating unit. Ferrule fittings are not recommended and Teflon tape is not needed. Using a Teflon tape or liquids that dry on the threads increases the potential of creating a piece or flake of the material that could block passageways.
FIG. 13 | BOILER CONTROLS AND ACCESSORY LOCATION SUPPLY MANIFOLD KEY 1. Probe Type LWCO 2. Modulating Aquastat tapping 3. Press Temp/Gauge 4. Manual Reset Limit 1 Relief Valve in Top of Rear Section Burner Service Switch 2 1 2 4 L400BA Hi-Limit In Top of Rear Section 3 4 3 Supply Manifold Transition Piece with Quadrant Locking Damper "MH" Boiler Supply Manifold Return Flow 1. Install relief valve, tridicator and L4008A operating high limit as shown in Fig 13. 2.
Boiler Assembly & Wiring ATTENTION - Disconnect source before installing burner or servicing, can cause severe injury or death. All wiring should be done in accordance with rules of the National Electrical Code ANSI/NFPA - 70 latest edition and any State or Local codes having jurisdiction. 1. Before Any Wiring Is Done - Check burner voltage/cycle/phase. It must be compatible with the electricity furnished at job site. 2. Wiring diagram is found in burner instruction manual.
Single Zone Wiring 1. 120 Volt Wiring - The boiler should be provided with its own 20A branch circuit with fused disconnect. All 120 volt connections are made inside teh L8148A aquastat relay as follows (also see Fig. 31 or 32): • Hot ("black") - Terminal "L1" • Neutral ("white") - Terminal "L2" • Ground ("Green" or bare) - Ground screw on case of L8148A 2. Thermostat Wiring - Follow thermostat manufacturer instructions.
Example 1. Example 2.
MorrHeat - Most Heat In The Industry - Rev 3/18/2019 19
Fig. 35 Wiring Diagram, Zone Wiring Using Honeywell V8043F Valves (Factory Boiler Wiring Not Shown - Fig 33 | Fig 34) Fig.
FIG. 8 | TYPICAL OIL BURNER PIPING DIAGRAMS CAUTION: All field piped components must be mounted in the proper location and proper direction of oil flow. RETURN BEND (NOT LESS THAN 2 FT. FROM NEAREST BUILDING OPENING) 1-1/4" VENT PIPE CAUTION: Oil supply pressue to Burner Pump must not exceed 3 PSI per NFPA Code. DO NOT USE TEFLON TAPE WALL MOUNTED TANK GAUGE PLAIN CAP OR LOOK FILL CAP (NOT LESS THAN 5 FT.
Boiler Assembly & Installation All boilers are shipped with the boilers sections assembled and hydrostatically tested at the factory. 1. Postion boiler on proper load bearing concrete pad on floor. 2. Attach supply manifold as shown in Figure 10. FIG. 10 | SUPPLY MANIFOLD ASSEMBLY Boiler Supply Port Flange Gasket 12MM X 50MM Stud 12MM X Washer Supply Manifold 12MM Washer FIG.
Oil Burner Technology MorrHeat’s waste oil burner technology improves the efficiency of the oil burn process by continuously burning the waste oil with no interuptions. The waste oil enters into the Oil Pre-Heater Block and is pre-heated to a specific temperature setpoint. Then compressed air from the air compressor is infused with the oil prior to spraying out the nozzle by breaking up the oil particles into a finer mist or spray.
Oil Burner Components • Igniter Transformer: Supplies high voltage to the electrodes generating electrical arc igniting the oil. Transfers the high voltage from the igniter transformer to the electrodes. • Solenoid Oil Valve: Opens when burner is running and closes when burner is not running eliminating bleed back of oil out of the Pre-heater block. • Air Band: Adjusts amount of air introduced into the combustion chamber.
• Electrodes: Provides continuous high voltage electrical arc from electrode to electrode igniting the waste oil as it is being sprayed out of the nozzle. • Nozzle: Low-pressure nozzle. (3 pc. and cleanable) • Flame Cone: Flame cone forces the flame into a swirl pattern improving the flame for a complete burn. • Burner Motor: Multitask motor turns the burner blower and integrated air creates combustion and atomization air at the same time.
References (Nozzle|Electrode|Burner & Pump) Nozzle Assembly When cleaning, inspect all three pieces thoroughly. Electrode Adjustment 3/8 from tip/center of nozzle flush with the Electrodes.
Boiler Start-up & Adustments 1. Close manual air vents (if used) and automatic air vents. Attach the hose to boiler drain on return connection and run to drain or to outdoors. Open drain cock and close shutoff valve on the boiler supply pipe. 2. HEATING ONLY - SINGLE ZONE SYSTEME --Open manual valve in cold water feed line and set the fill valve to fast fill. Allow water to flow through the system and out the hose until there is a steady flow of water through the hose with no air bubbles.
Filling Boiler 1. Fill boiler and system in accordance with job specification. System pressure should be set to have 5 PSI pressure at the highest point in the heating system. Boiler pressure gauge will indicate pressure relative to the height of water column from the boiler to the hightest point, plus the additional 5 PSI. Example - To calculate cold fill pressure: Highest point in system above boiler is 40'; 40 + 2.31 = 17.32 (1 PSI = 2.31 Ft. W.C.) Add 5 PSI to 17.32 = 22.
Burner Startup - All Fuels Warning DO NOT start or operate burner unless boiler and heating system pumps are ON and boiler has minimum system water flow of 1.8 GPM for each 100,000 BTU/HR, of Gross boiler output. Refer to Table 2. Consult Burner Manufacturer's Instruction Manual for proper start-up procedure All Fuels - General Start Up A thoroughly qualified burner technician should be employed to provide the initial burner start up, as well as any subsequent servicing.
Prevention Water Treatment Generally, no water treatment will be required. Care should be taken to ensure that the system does not lose water from leaks or continual relief valve operation since continual make-up water will reduce boiler life. Freeze Protection Where freeze protection is required to use antifreeze made especially for hydronic systems such as inhibited Propylene Glycol. DO NOT use automotive type antifreeze. Follow antifreeze manufacturer's directions for quantity.
Initial Start Procedure 1. Make sure the heating unit and all components have been properly and securely installed. 2. Check that all electrical connections and hook-ups are properly wired and connected. 3. It is recommended prior to priming the fuel pump and bleeding the air to pre-fill the fuel filter to help speed up the process. For a secondary check you can always pressurize the fuel lines to eliminate any potential leaks in the line or fittings. Consistent fuel supply to the burner is very important.
Maintenance IT IS RECOMMENDED THAT YOUR FACILITY GETS ON A REGULAR MAINTENANCE SCHEDULE AND OR SET REMINDERS OF CLEANING AND MAINTENANCE OF THE HEATING UNIT, TANK, OIL FILTER, AIR FILTERS AND ALL OTHER WORKING COMPONENT AND CONSUMABLES THAT MAY NEED ATTENTION OR REPLACED BEFORE OR DURING SEASON.
Maintenance Continued... Periodic observation of the Heating Plant is advised to insure safe efficient operation. 1. Check control operation and setting 2. Check for odors or soot deposit marks. Door seal may need adjusting or vent connections may require additional sealing. 3. Observe burner operation for excessive noise or vibration. 4. Check for water leaks. Cleaning Tips Boiler which operate only for heating, need only be cleaned at the end of each heating season.
Attention 1. Remove smoke pipe and flue collector at back of boiler 2. Disconnect burner fuel lines as needed to open front door. 3. Remove all flue baffles. 4. Using the cleaning brush, scrub all fireside surfaces in combustion chamber, flue passages and flue collector area. 5. Remove residue and vacuum clean. 6. Check condition of flue baffles and replace as needed. 7. Check front door and flue collector rope seals, replace as needed. 8. Re-assemble and put boiler into operation as needed.
Troubleshooting NO HEAT: 1. Check burner power switch and make sure power is available to the whole control system. 2. If included in the system, check low-water, cutoff and/ or manual reset high limit. 3. Check room thermostat(s) and zone valves or pump relays (if used). 4. Make sure there is oil in the tank. 5. Inquire if reset button on burner oil primary control has been tripped. If the reset button continues to trip them DO NOT ATTEMPT TO START BURNER.
Troubleshooting Continued... ▲ Most likely || ▶ Less likely || ▼ Least Likely Problem 1. Boiler shuts off 2. Loss of prime overnight 3.Fails to Start 4. Reduced air pressure and can’t increase 5. Hard starting (Diminished flame) Cause ▲ ▲ ▶ ▼ Manual reset Vacuum air leak in air line Plugged filter or tank empty Plugged pump screen ▲ Vacuum leak ▲ Inadequate fuel supply ▶ No pressure ▶ No pre-heat ▶ Auto start circuit not functioning ▶ No arc ▶ No air pressure ▲ Gauge may be bad.
6. Boiler cycles frequently, without set temperature being reached ▲ Boiler over firing ▶ High limit safety switch bad ▼ Temperature setting wrong ▲ Investigate and locate reason for over firing. I.e nozzle eroded, pump not functioning properly, decrease pump motor speed. ▶ Replace high limit fan safety switch ▼ Check temperature setting and adjust as necessary. 7. Boiler rumbles and ▲ Pump setting wrong excessive heat blow back from flame vision port ▼ Draft incorrect. If proper draft can't be achieved.
Jacket Attachment 1. Screw the (4) extension setscrews (043) into the four outer holes in teh corners of the rear sections. Securely tighten the setscrews and other fastening bolts of the flue outlet cover (022). 2. Place teh large wraparound insulation mat (040) over boiler block (aluminum foll side facing out). 3. Place smaller piece of insulation on top of wraparound insulation. This will provide double thick insulation top of the boiler block. 4. Remove flue collector clean-out covers (062). 5.
FIG.
Parts List 002 003 004 005 006 Hinge Pin Adjusting Pin Anchor Rod Nipple Bolt M 10x40 008 009 010 012 013 Rear Section Middle Section Front Section Boiler door, complete (013-017, 049) Insulation mat for boiler door 344x344 014 016 017 019 022 Insulation mat for boiler door 583x745 Insulation block for boiler door Pack 20x15 Aquastat well Flue gas cover with flue connection 023 Hose coupling nipple 1/4" 025 Sight glass with seal 026 Sight glass and measing tube cap 026A Sight glass nipple 1-1/4" 027 B
Exploded View 026 048 025 030 028A 027 049 012 024 028 023 031 032 002 013 017 014 016 010 028 047 005 003 004 019 005 004 009 022 043 008 056 006 053 054 056 053 051 062 062 056 046 052 170 100 41 MorrHeat - Most Heat In The Industry - Rev 3/18/2019
Warranty Information - 10 Year MorrHeat warrants the materials and workmanship will be free of defects for the duration of the warranty specified. Warranty is valid from the date of delivery and warranty card must be sent in to MorrHeat within 30 days of delivery date. MorrHeat is not responsible for damaged goods. Please check your shipment for any damages.
Warranty Card REMINDER: Warranty coverage is specific to the materials and workmanship of the unit and does not cover additional labor and freight charges unless written authorization is provided. Warranty assures and covers welds when maintained and used properly but does not cover stress cracks caused by excessive heat or over fire. Bad draft, back draft or simply too much fuel and too large of flame are a direct cause of an over fire or over heated unit.
