thor “frost buster” operating manual€¦ · thor “frost buster” operating manual model...

Thor “Frost Buster” Operating Manual Model LD5030

Warning- Use of this equipment creates hot surfaces and contains hot liquids. Fluid operating temperatures may rise to 185 degrees Fahrenheit. Be aware and use caution when operating or working around this equipment! Boiler compartment contains burning fuel and flame. Fuel tank contains flammable liquid (Winter Blend Diesel.) Smoking is not allowed in or around this equipment. Use caution at all times when operating the hose reel! Do not allow possible entanglement with hose!

STARTUP

Step 1: Read and understand all instructions before proceeding. *Consult Boiler Operating Manual for Proper Operation of Boiler Step 2: Check fluid level in reservoir. The fluid level should appear above the red and white label shown in Fig 1. Add a mixture of 30% propylene glycol and 70% water ONLY until fluid level rises to the indicator.

Fig 1 1

Step 3: Seasonally check the level of lubricant in the reel drive motor (Fig 2) by removing the access plug and filling with 80/90W Gear Oil. Step 4: Check for adequate fuel in the burner reservoir (Fig 3.) Fill with Winter Blend Diesel Only. Step 5: Unroll hose spreading over the area to be heated (Fig 4.) The hose is 3000 feet long and is made of three 1000-foot sections connected to one another. To facilitate more effective warming, each section of hose may be disconnected from the loop and connected to the auxiliary circuit located just under the reel. The connectors are quick couplers and snap together when the outer ring of the coupler is retracted (Fig 5 & Fig 5A.) The second and third hoses may then be used to make three continuous loops.

DO NOT CONNECT OR DISCONNECT HOSES UNTIL FLUID HAS COOLED TO ROOM TEMPERATURE AND THE MACHINE HAS BEEN SHUT OFF!

Note: The hose may be laid out in a symmetrical pattern over the area to be heated. Spacing’s of 12-24” are common for thawing. Spacing of up to 48” may be adequate for concrete curing. Be careful to spread the hose evenly and do not leave any areas open so as not to receive the necessary heat. 3000 feet of hose spaced at 24” will cover approximately 6,000 sq. feet. Be careful to protect hose from abrasion, stretching, and from coming into contact with anything that may cut or rupture it.

Fig 2

Fig 3

2

Fig 4

Fig 5 Fig 5A

Step 6: All six (6) valves on the system must be open to allow fluid flow.. Valves are open when handles are in alignment with tubing. Valve one and six are at the bottom of the reservoir (Fig 6) and valve two is on the side of the reservoir (Fig 7.) Valves one and two should be open at all times except for service of the boiler.

Fig 6 Fig 7

Valve three is above the fluid pump (Fig 8), valve four is at the back of the reservoir (Fig 9), and valve five is on the overflow line above the line pressure gauge (Fig 10.) These valves must all be open for proper operation although no damage should occur if system is operated inadvertently.

3

Step 7: Adjust desired temperature of fluid to be circulated by adjusting thermostat (Fig 11.) Use a flat tip screwdriver to turn dial to desired setting. 180 Degrees Fahrenheit is the maximum setting for heating. Lesser temperatures may be desirable for concrete curing or other uses. These are factory preset for ground thawing. Step 8: System is designed to operate on a 30 Amp 110/120Volt Circuit. Connect supplied cord to correct power source. Step 9: Turn on Boiler with switch (Fig 12.) Allow Boiler to reach operating temperature. (Boiler has been factory preset to the maximum recommended temperature at 180 Degrees Fahrenheit.) The fluid from the reservoir will be circulated continuously through the reservoir and boiler.

Fig 11

4

Fig 8

Fig 9

Fig 10

Fig 12 Step 10: After hose is positioned and you are ready to start heating, turn on the fluid circulation pump with Pump Switch (Fig 13.)

Fig 13

WARNING– DO NOT HANDLE HOSE WITH PUMP TURNED ON!

Step 11: Adjust line pressure. Pressure should NOT exceed 100 PSI. Read the pressure gauge found near the rear of the pump and adjust using the bypass regulator (Fig 14.) Turning the regulator handle clockwise will increase the pressure in the hose and counter-clockwise will decrease the pressure.

Fig 14 5

Note– Hose pressure will vary because of length of hose being used, number of bends in the hose, and other factors, so check and adjust line pressure with each use. Step 12: Visually check hose, fittings, and system for leaks. Step 13: Check fluid flow by reading flow meter (Fig 15.) The indicator inside the glass will indicate the GPM flowing through the hose. Normal flow is about 3 GPM for 3000 feet of hose in one circuit or 12-16 GPM for 3000 feet of hose in 3-1000 foot circuits. If the flow is inadequate check the hose for kinks. Step 14: Cover hose with insulating blankets to contain heat being careful to protect hose from damage. Step 15: Monitor fuel and fluid levels periodically as the unit is operating.

Keep unauthorized personnel away!

SHUT-DOWN

Step 1: Turn off Boiler with switch (see Fig 12.) Step 2: Turn off the fluid circulation pump with Pump Switch (see Fig 13.) Step 3: Shut the three (3) valves on the system to stop fluid flow. Valves are closed when handles are in perpendicular with tubing. Valve three is about the fluid pump (see Fig 8), valve 4 is at the back of the reservoir (see Fig 9), and valve five is on the overflow line about the line pressure gauge (see Fig 10.) Step 4: After hose and fluid has cooled sufficiently, roll up hose by first turning on the reel drive motor (Fig 16.) Apply rearward pressure on the reel control lever to begin winding the hose. Hose should be positioned and fed onto the reel as it is wrapped (Fig 17.) Do not attempt to drag long lengths of hose as damage to the hose may occur. Control the speed and power of the reel by adding or removing pressure to the reel handle.

Fig 15

6

Fig 16

Fig 17

If using three lengths of hose, disconnect connections on the first loop of hose when it is fully wrapped, then disconnect the second hose from the auxiliary circuit and connect the hoses together. Continue wrapping the second loop until fully wrapped, then disconnect the third hose from the auxiliary circuit and connect second and third hoses together. Continue wrapping. Inspect hose for damage as it is returned to the reel. Repairs to the hose may be made by removing the damaged section and reconnecting the hose with a 5/8” Gates Sure-Grip Hose Clamp available from your Thor supplier or from most auto parts stores. Caution– As the reel becomes fuller, it becomes heavier and has more momentum. Slow the wind speed as the drum fills with hose. Keep all electrical covers and all shields in place at all times. Keep hands and feet away from moving parts. NO SMOKING in or around Frost Buster. 7

FB0308

MSDS - Material Safety Data SheetProduct Name: Harvey Heat -100

Wednesday, October 25, 2006Page 1 of 7

MSDS No.: 016850

016850016852016860016861016862016863016864016870016871

Part Numbers Covered:

1. Basic Information:

Manufacturer: William H. Harvey Company

Address: 4334 South 67th Street

City, ST Zip: Omaha, NE 68117-1019

Last Update: 10/24/2006

Chemical State: SolidGasLiquidX

Chemical Type: MixturePure X

1

0 0

0

1

0

X

Information Telephone Number: (800)228-9681

Emergency Telephone Number: (800)424-9300

Emergency Contact: CHEMTREC

Contact: Information Telephone Number

Expiration Date:

2. Ingredients:

OtherACGIHOSHA

SARAIARCEHS

SUB Z

313

LimitsTLVPEL% RangeChemical NameCAS No. NTP

Trade Secret

7758-11-4 Dipotassium Phosphate NE NI NE1.0 -2.0

57-55-6 Propylene Glycol NE NI NE65.0 - 70.0

Hazard Category:

3. Hazardous Identification:

PHYSICAL HAZARDS:Aqueous solutions may produce flammable vapors.Slightly combustible liquid.

ACUTE HEALTH EFFECTS (Short Term):No inhalation hazard identified from data available;Slight eye irritant;No ingestion hazard identified from data available;No skin irritation hazard identified from data available;No skin irritation hazard identified from data available;

CHRONIC HEALTH EFFECTS:No chronic health effects are expected from anticipated conditions of normal use of this material unless aeroso is generated.

Hazardous Identification Information:

ReactivePressureFireChronicAcute



MSDS No.: 016850

Eye Contact, Skin Contact, Inhalation, Ingestion.

Route(s) of Entry:

4. First Aid Measures:

Not expected to present an acute health hazard upon short term exposure.

No chronic health effects are expected from anticipated conditions of normal use of this material unless aeroso is generated.

Health Hazards (Acute and Chronic):

INHALATION:Not a primary route. No significant signs or symptoms indicative of any adverse health hazard are expected to occur as a result of inhalation exposure.

EYE CONTACT:Primary route. May cause minor eye irritation.

SKIN ABSORPTION:Not a primary route. No significant signs or symptoms indicative of any health hazard are expected to occur as a result of skin absorption exposure.

SKIN IRRITATION:Not a primary route. No significant signs or symptoms indicative of any health hazard are expected to occur as a result of skin skin exposure.

INGESTION:Not a primary route. No significant signs or symptoms indicative of any health hazard are expected to occur as a result of ingestion.

Signs and Symptoms:

This material or its emissions may aggravate pre-existing eye disease.

Medical Conditions Generally Aggravated by Exposure:

EMERGENCY FIRST AIDCall toll free: 1-800-740-5015

INHALATION:Not expected to present a significant inhalation hazard under anticipated conditions of normal use. If overcome by vapors, remove victim to fresh air and give oxygen or artificial respiration if needed. Get immediate medical attention.

EYE CONTACT:In case of eye contact, immediately flush with plenty of water for 5 minutes. Remove contacts if present and continue flushing with water while holding eyelids open with thumb and index finger for 15 minutes. Seek medical attention if irritation develops or persists.

SKIN CONTACT:Not expected to present a significant skin hazard under anticipated conditions of normal use. Wash off skin with clean water and soap.

INGESTION:Not expected to present a significant ingestion hazard under anticipated conditions of normal use. If large amounts are ingested, induce vomiting and get immediate medical attention.

Emergency and First Aid Procedures:

Other Health Warnings:

NI



MSDS No.: 016850

Upper Explosive Limit: ~ 17.4

5. Fire Fighting Measures:

Flash Point: ~ 228º F Lower Explosive Limit: ~ 2.4

Fire Extinguishing Media: Carbon dioxide, dry chemical, alcohol type foam, water spray, water fog.

F.P. Method: PMCC

Prevent human exposure to fire, fumes, smoke, and products of combustion. Evacuate nonessential personnel. Liquid may form slippery film. Firefighters should wear full face, self contained breathing apparatus and impervious protective clothing. Water or foam may cause frothing. Use water to cool containers exposed to fire.

Notify authorities if liquid enters sewers or public waters.

Special Fire Fighting Procedures:

Unusual Fire and Explosion:

None known.

6. Accidental Release Measures:

Steps to be Taken in Case Material is Released or Spilled:

Prevent flow to sewers and public waters as it may contaminate said water. Restrict water usage to prevent slip/fall hazard. Soak up smal spill with inert solids. Dike and recover large land spills. Use suitable disposal containers. On water, material is soluble and may float or sink. May biodegrade Contain/collect rapidly to minimize dispersion. Notify appropriate authorities if product enters any waterway.

Wear protective equipment when handling. Use only with adequate ventilation. Do not get in eyes. Do not breathe vapor or mist. Do not swallow.

Keep container closed when not in use. Store in a cool dry place. Store in accordance with nfpa requirements. Keep out of reach of children

Precautions to be Taken:

7. Handling and Storage:

Other Precautions:

Do not reuse product containers and dispose of in accordance with all federal, state and local regulation. Since emptied container contains product reisdues (vapor or liquid), all labeled hazard precautions must be observed.

Adequate ventilation is required to minimize exposure or to maintain exposure levels below OSHA/ACGIH requirements.

Ventilation Requirements:

8. Exposure Controls/Personal Protection:

Personal Protective Equipment:

Eyes: Chemical goggles, always wear eye protection when working with chemicals. Do not wear contact lenses when working with chemicals

Skin: Clean body covering clothing, impervious gloves

Inhalation: If exposure limits are exceeded, or if exposure may occur, use a NIOSH/MSHA respirator approved for your conditions of exposure. Refer to the most recent NIOSH publications concerning chemical hazards, or consult your safety equipment supplier. Respiratory protection programs must be in compliance with OSHA requirements in 29 CFR 1910.134. For emergencies, a NIOSH/MSHA approved positive pressure breathing apparatus should be readily available.



MSDS No.: 016850

9. Physical and Chemical Properties:

Specific Gravity (H20 = 1): 1.03400 Vapor Density (AIR = 1): ~2.6

Vapor Pressure (mm Hg.): ~.22 @ 68ºFEvaporation Rate (Butyl Acetate = 1): .005

Melting Point: -60º F (freeze point)Boiling Point: ~ 230º F

Other Information: NI

Appearance and Odor: Clear Opal Yellow Liquid / Almost OdorlessSolubility In Water: Complete

Stable

Stability:

10. Stability and Reactivity:

Strong alkalis, strong oxidizing agents.

Conditions To Avoid: Heat, sparks, open flame.

Incompatibility (Materials to Avoid):

Carbon monoxide, carbon dioxide, miscellaneous organic compounds, some possibly toxic

Decomposition/By Products:

Hazardous Polymerization:

Not expected to occur.

11. Toxicological Information:

SKIN: Based largely or completely on information for similar material(s), i.e., propylene glycol, LD50 for skin absorption in rabbts is >10,000 mg/kg.

INGESTION: Based largely or completely on information for similar material(s), i.e., propylene glycol., the oral LD50 for rats is 20,000 - 34,000 mg/kg.

MUTAGENICITY: Based largely or completely on information for similar material(s), i.e., propylene glycol., in-vitro mutagenicity studies were negative, and animal mutagenicity studies were negative.

12. Ecological Information:



MSDS No.: 016850

MOVEMENT & PARTITIONING: Based largely or completely on information for similar material(s), i.e., propylene glycol. Bioconcentration potential is low (BCF less than 100 or Log Pow less than 3). Log octanoll water partition coefficient (log Pow) is -0.92. Henry Law Constant (H) is 1.2E-8 atm.m3/mole.

DEGRADATION & TRANSFORMATION: Based largely or completely on information for similar material(s) i.e., propylene glycol. Biodegradation under aerobic static laboratory conditions is high (BOD20 OR BOD28/ThOD greater than 40%). Biodegradation is expected to be achievable in a secondary wastewater treatment plant. 5-day biochemical oxygen demand (BOD5) is 1.16 p/p. 200-day biochemical oxygen demand (BOD20) is 1.45 pip. theoretical oxygen demand (THOD) is calculated to be 1.68 pip. Inhibitory concentration CICSO) in OECD Activated Sludge Respiration Inhibition Test (OECD Test No. 209) is greater than 1 grn/L. Degradation is expected in the atmospheric environment within minutes to hours.

ECOTOXICOLOGY: Based largely or completely on information for similar material (s), i.e., propylene glycol. Material is practically non-toxic to aquatic organisms on an acute basis (LC50 greater than 100 mg/L in most sensitive species).

Acute LC50 for fathead minnow (Pimephales promelas) is 4,600-54900 mg/L

Acute LC50 for guppy (Poecilia reticulata) is greater than 10000 mg/L,

Acute LCSO for water flea Daphnia magna is 4850-34400 mgIL

Acute LC50 for rainbow trout (Oncorhynchus mykiss) is 44mLIL (about 44000 mgIL)

13. Disposal Considerations:

Material that cannot be used or chemically reprocessed should be disposed of at an approved facility in accordance with any applicable regulation under the Resource Conservation and Recovery Act (RCRA). Dispose of material in accordance with all federal, state and local regulations. Local regulations may be more stringent than federal or state.

14. Transport Information:

This product is not regulated by DOT.This product is not regulated by IMDG.This product is not regulated by IATA.

15. Regulatory Information:



MSDS No.: 016850

Federal Toxic Substance Control Act (TSCA) The following is the Toxic Substances Control Act (TSCA) Chemical Substance Inventory Status of the components of this material listed in Section 2 - Ingredients:

CHEMICAL CAS NO. STATUS Propylene Glycol 57-55-6 Listed - Non ConfidentialDipotassium Phospate 7758-11-4 Listed - Non Confidential

Superfund Amendments and Reauthurization of 1988 (SARA), Title III -Section 302/304 Requires emergency planning based on 'Threshold Planning Quantities' (TPQs), and release reporting based on Reportable Quantities (RQs) of 'Extremely Hazardous Substances' (EHS) listed in Appendix A of40 CFR 355. There are no components of this material with known CAS numbers which are on the EHS list.

-Section 311 & 312 Based upon available infmnation, this material and/or components are not classified as any of the specific health and/or physical hazards defined by Section 311 & 312. -Section 313 This material does not contain any chemical components with known CAS numbers that exceed the De Minimis reporting levels established by SARA Title IIJ, Section 313 and 40 CFR 372.

Comprehensive Environmental Response, Compensation and Liability Act (CERCLA) No chemicals in this material with known CAS numbers are subject to the reporting requirements ofCERCLA.

OSHA Regulations 'Chemical-specific' U.S. Occupational Safsty and Health Administration (OSHA) regulations (1910.1002 to 1910.1050) presented under 29 U.S. Code of Federal Regulations (CFR) 1910 do not apply to this material or its components.

Other EPA Regulations No additional infirmation available

Department of Transportation (DOT) Other than the normal shipping instructions and infirmation given in this MSDS, there is no other specific U.S. Department of Transportation (DOT) regulations governing the shipment of this material.

State Regulations:

California Safe Drinking Water and Toxic Enforcement Act of 1988 - Proposition 65 This material is not known to contain any chemicals currently listed as carcinogens or reproductive toxins under Califirnia Proposition 65 at levels which would be subject to the proposition.

California South Coast Air Quality Management District (SCAQMD) Rule 443.1 (VOC's) A Volatile Organic Compound (VOe) is any volatile compound of carbon excluding methane, carbon monoxide, carbonic acid, metallic carbides or carbonates, ammonium carbonate, 1, I, l-trichloroethane, methylene chloride, (FC-23), (CFC-I 13), (CFC- 12), (CFC-II), (CFC-22), (CFC-114), and (CFC-l 15).By this definition, this is a VOC material.

Massachusetts Right to Know Substances List (MSL) [105 CMR 670.000] Extraordinarily Hazardous Substances (MSL-EHS) must be identified when present in materials at levels greater than state specified criterion. The criterion is>=O.OOOI%. Hazardous Substances (MSL-HS) on the MSL must be identified when present in materials at greater than the state specified criterion. The criterion is>= I %. Components with CAS numbers present in this material, at levels specified in Section 2 - Ingredients, do not require reporting under the statute.

New Jersey Registration The New Jersey, Registry 3, Registration law does not apply to this material, as none of its components are trade secrets.

Pennsylvania Right to Know Hazardous Substance List Hazardous Substances (P A-HS) must be identified when present in materials at levels greater than the state specified criterion. The criterion is >= 1 %. Components with CAS numbers in this material at a level which could require reporting under the statute are: CHEMICAL CAS NO.



MSDS No.: 016850

Propylene Glycol 57-55-6 Special Hazardous Substances (P A-SHS) must be identified when present in materials at levels greater than the state specified criterion. The criterion is >= 0.01%. Environmental Hazards (pA-BI·I) must be identified when present in material at levels greater than the state specified criterion. The criterion is >= 0.01 %. Components with CAS numbers in this material, at levels specified in Section 2 - Ingredients, do not require reporting under the statute.

Regulatory Advisory :If you reformulate or further process this material, you should consider re-evaluation of the regulatory status of the components listed in this sheet.

16. Other Information:

ABBREVIATIONS:

~ = Approximately< = Less Than> = Greater ThanACGIH = American Conference of Governmental Industrial HygienistsAIHA = American Industrial Hygiene AssociationC = Degrees CelciusDeg= DegreesEPA = Environmental Protection AgencyF = Degrees FarenheitHMIS = Hazardous Materials Information SystemIARC = International Agency for Research on CancerNA = Not ApplicableNDA = No Data AvailableNE = Not EstablishedNFPA = National Fire Protection AssociationNI = Not IndicatedNIOSH = National Institure of Occupational Safety and HealthNTP= National Toxicology ProgramOSHA = Occupational Safety and Health Administration

The information in this MSDS was obtained from sources which we believe are reliable. However, the information is provided by the William H. Harvey company without any warranty, expressed or implied regading its correctness. Some information presented and conclusions drawn herein are from sources other than direct test data on the substance itself. This MSDS was prepared and is to be used only for this product. If the product is used as a component in another product, this MSDS information may not be applicable. Users should make their own investigations to determine the suitability of the information or products for their particular purpose.

The conditions or methods of handling, storage, use, and disposal of the product are beyond our control and may be beyond our knowledge. For this and other reasons, the William H. Harvey company does not assume responsibility and expressly disclaims liability for loss, damage or expense arising out of or in any way connected with handling, storage, use or disposal of the product.

Table 1: WATER BOILER PARTS LIST, P, PT AND PPT

ITEM DESCRIPTION QTY TR-20 TR-30 TR-40 TR-50 TR-60 TR-70

1A Casting subassembly water, extended boss less plate 1 4307121 4307131 4307141 4307151 4307161 43071711B Casting subassembly water, solid front

(NO provision for tankless) 1 4307021 4307031 4307041 4307051 4307061 43070712 Burner mounting door assy (Incl. items 3, 6, 6A, 40 & 41) 1 432910000 432910000 432910000 432910000 432910000 4329100004 Target wall 1 430029 430029 430029 430029 430029 430029

4A Blanket, insulation 1 — — — — 430059 4300605 Bolt 3/8-16 1 480119 480119 480119 480119 480119 480119

5A Washer flat 3/8nom 1 430117 430117 430117 430117 430117 4301177 Hex nut 3/8-16 steel 3 400328 400328 400328 400328 400328 4003288 Washer flat 3/8 nom. steel 3 400322 400322 400322 400322 400322 4003229 Blank plate, tankless 1 430031 430031 430031 430031 430031 430031

10 Gasket 1/8 thick 1 430071 430071 430071 430071 430071 43007111 Hex cap nut 3/8-16 steel 6 432735 432735 432735 432735 432735 432735

11A Stud 3/8-16 x 1-1/4 18-8 stainless steel interrupted thread 6 432736 432736 432736 432736 432736 43273611B Washer flat 3/8 stainless steel 6 432761 432761 432761 432761 432761 432761

12 Flue collector (TR-30/TR-40 add item 12B) 1 430032 432708 432709 430035 430036 43003712A Flue collector sealant 1 430147 430147 430147 430147 430147 43014712B Rope Seal (Hinged Flue Collector) 1 — 480064 480065 — — —

13 Carriage bolt 1/4-20 x 2-1/2 long 1 430108 430108 430108 430108 430108 43010813A Wing nut 1/4-20 1 400147 400147 400147 400147 400147 40014713B Washer 1/4" 1 909783071 909783071 909783071 909783071 909783071 909783071

14 Clean out door plate 1 430019 430019 430019 430019 430019 43001915 Observation door 1 400114400 400114400 400114400 400114400 400114400 40011440016 Self tapping screw, 1/4-20 x 3/4 long hex slotted hd. 3 480049000 480049000 480049000 480049000 480049000 48004900017 Stud 3/8-16 x 1-3/8 steel interrupted thread 3 430107 430107 430107 430107 430107 43010718 Jacket, insulated top 1 432530 432531 432532 432533 432534 43253519 Jacket, Insulated side 2 435122 435123 435124 435125 435126 43512720 Jacket, insulated rear 1 432537 432537 432537 432537 432537 43253721 Jacket, insulated front, water “PT & PPT” 1 435098 435098 435098 435098 435098 435098

21A Jacket, insulated front, water “P” 1 432529 432529 432529 432529 432529 43252921B Jacket, front (lower) 1 430512 430512 430512 430512 430512 430512

22 Emblem - Slant/Fin 1 401041 401041 401041 401041 401041 40104124 Sheet metal screw #8 x 1/2A Treuss Head Philips 22 970107000 970107000 970107000 970107000 970107000 97010700025 Relief valve - H.W. 30 psi Conbraco or Watts 1 400103 400103 400103 400103 400103 40010326 Nipple 3/4 x 2 long (for relief valve) 1 400225 400225 400225 400225 400225 40022527 Drain valve 3/4 Nibco #74 1 400201 400201 400201 400201 400201 40020128 Reducing bushing 1-1/2 NPT x 3/4 NPT 1 902179321 902179321 902179321 902179321 902179321 90217932129 Tridicator (0-75 psi) 1 910373061 910373061 910373061 910373061 910373061 91037306130 Control, hi limit Hon. L4080B1253 or W/R11B83-1 1 — — — — — 410699

30A Control, high/low limit L4081A (PT) 1 — — — — 410529 41052930B Control, hi limit-circ. Hon L8148A (P) (Obsolete) 1 400096 400096 400096 400096 400096 —30C Control, hi limit-circ. Hon L7248L1006 (P) 1 400096 400096 400096 400096 400096 —30D Control, hi-lo limit-circ. Hon L8124C1094 (PT) (Obsolete) 1 400095 400095 400095 400095 — —30E Control, hi-lo limit-circ. Hon L7224C1004 (PT) 1 400095 400095 400095 400095 — —30F Control, Hydrostat Plus, hi-lo/high limit 1 430424 430424 430424 430424 430424 430424

31 Well 1/2 NPT x 1-1/2" (without tankless P) 1 410569 410569 410569 410569 410569 41056931 Well 1/2 NPT x 3" (with tankless PT & PPT) 1 430150 430150 430150 430150 430150 43015031 Well 1/2 NPT x 3" for use with Hydrostat Plus 1 430425 430425 430425 430425 430425 43042532 Thermostat - 24V Hon. T822D1537 1 — 400101 400101 400101 400101 40010133 Primary control, Honeywell R7184B Beckett burner 1 430672 430672 430672 430672 430672 N.A.

33A Primary control, GeniSys 7505B1500 Beckett burner 1 430675 430675 430675 430675 430675 N.A.33B Primary control R7184B Carlin burner 1 430668 430668 430668 430668 430668

34 Burner assembly: Beckett 1 430661 430662 430663 430664 — —34A Burner assembly: Carlin 1 430631 430633 430635 430638 430654 43065634B Burner assembly: Riello 1 — 4301533 4301543 4301553 — —34C Burner assembly: Carlin EZ-LF Pro 1 — 432843000 — — — —

35 Tankless heater assy. (optional) 1 430072 430073 430074 430074 430075 43007536 Gasket, Beckett burner 1 — 430172 430172 430172 — —

36A Gasket, Carlin burner 1 430173 430173 430173 430173 430173 43017337A Circulator, Taco 007 1 7902022 7902022 7902022 7902022 7902022 790202237B Circulator, Grundfos UP-15-42F 1 7902021 7902021 7902021 7902021 7902021 790202137C Circulator, B&G NRF-22 1 7902023 7902023 7902023 7902023 7902023 790202337D Circulator, Taco 0010 1 — — — 430102 430102 —

38 Pin retainer 2 480016 480016 480016 480016 480016 48001639 Screw, pin retainers 4 480049 480049 480049 480049 480049 48004942 Junction box 1 480071100 480071100 480071100 480071100 480071100 48007110043 Switchplate cover 1 432753 432753 432753 432753 432753 43275344 Screw 2 480049 480049 480049 480049 480049 48004945 Switch 1 432752 432752 432752 432752 432752 43275246 Ground Screw 1 650666 650666 650666 650666 650666 65066647 “L” Baffle 1 430885000 430885000 430885000 – –48 “T” Baffle

x –430886020 430886020 430886020 430886020 430886020

(x=1) (x=2) (x=3) (x=4) (x=5)

PUBLICATION NO. TR-10PL rev.CPrinted in U.S.A. 1013 • Part No. 432267500

Replacement Parts are available from Slant/Fin Corporation100 Forest Drive, Greenvale, NY 11548

OIL-FIRED WATER AND STEAM BOILERS/NO. 2 OILINTREPID(See exploded view pg. 4)

BOILER REPLACEMENT PARTS LIST

Table 2: STEAM BOILER PARTS LIST, PZ AND PZT (SEE EXPLODED VIEW PG. 3)

ITEM DESCRIPTION QTY TR-30 TR-40 TR-50 TR-60 TR-701 Casting subassembly steam, less plate 1 4320331 4320341 4320351 4320361 43203712 Burner mounting door assy (Incl. items 3, 6, 6A, 51, 52) 1 432910000 432910000 432910000 432910000 4329100004 Target wall 1 430029 430029 430029 430029 430029

4A Blanket Insulation 1 430106 430105 430104 430059 4300605 Bolt 3/8-16 1 480119 480119 480119 480119 480119

5A Washer flat 3/8 nom. 1 430117 430117 430117 430117 4301177 Hex nut 3/8-16 steel 3 400328 400328 400328 400328 4003288 Washer flat 3/8 nom. steel 3 400322 400322 400322 400322 4003229 Blank plate, tankless steam 1 430021 430021 430021 430021 430021

10 Gasket 1/8 thick 1 430070 430070 430070 430070 43007011 Hex cap nut 3/8-16 steel 12 432735 432735 432735 432735 432735

11A Stud 3/8-16 x 1-1/4 18-8 stainless steel interrupted thread 12 432736 432736 432736 432736 43273611B Washer flat 3/8 stainless steel 12 432761 432761 432761 432761 432761

12 Flue collector (TR-30/TR-40 add item 12B) 1 432708 432709 430035 430036 43003712A Flue collector sealant 1 430147 430147 430147 430147 43014712B Rope Seal (Hinged Flue Collector) 1 480064 480065 — — —

13 Carriage bolt 1/4-20 x 2-1/2 long 1 430108 430108 430108 430108 43010813A Wing nut 1/4-20 1 400147 400147 400147 400147 40014713B Washer 1/4" 1 909783071 909783071 909783071 909783071 90978307114 Cleanout door plate 1 430019 430019 430019 430019 43001915 Observation door 1 400114400 400114400 400114400 400114400 40011440016 Self tapping screw, 1/4-20 x 1 long hex slotted hd. 3 400217 400217 400217 400217 40021717 Stud 3/8-16 x 1-3/8 steel interrupted thread 3 430107 430107 430107 430107 43010718 Jacket, insulated top 1 432531 432532 432533 432534 43253519 Jacket, insulated side 2 435123 435124 435125 435126 43512720 Jacket, insulated rear 1 432537 432537 432537 432537 43253721AB Jacket, insulated front, steam (top + breakaway piece) 1 432528 432528 432528 432528 43252821C Jacket, front (lower) 1 430512 430512 430512 430512 43051222 Emblem - Slant/Fin 1 401041 401041 401041 401041 40104124 Sheet metal screw #8 x 1/2A Treuss Head Philips 22 970107000 970107000 970107000 970107000 97010700025 Safety valve Conbraco 13-501 or Watts 315 1 400107 400107 400107 400107 40010726 Water gauge set 1/2 NPT 1 402036 402036 402036 402036 40203627 Glass - 5/8 dia. x 5-3/4 long 1 430132 430132 430132 430132 43013228 Rod - 3/16 dia. x 7-3/4 long 2 430134 430134 430134 430134 43013429 Pressure gauge - 30 psi 2-1/2 1 910374051 910374051 910374051 410374051 91037405130 Pressuretrol PA404A1009 1 400117 400117 400117 400117 40011731 Siphon - 1/4 NPT 1 400222 400222 400222 400222 40022232 Tee - 1/4 x 1/4 x 1-1/4 brass 1 400223 400223 400223 400223 40022333 Nipple - 1/4 x 2-1/2 long 1 400224 400224 400224 400224 40022434 Nipple - 1/4 x close brass 1 400240 400240 400240 400240 40024035 Elbow - 1/4 x 90 deg. brass 1 400232 400232 400232 400232 40023236 Drain valve 3/4 1 400201 400201 400201 400201 40020137 Reducing bushing - 1-1/2 NPT x 3/4 NPT 1 902179321 902179321 902179321 902179321 90217932138 Plug square hd. - 1-1/2 NPT (skimmer tapping) 1 902342051 902342051 902342051 902342051 90234205139 Thermostat - 24V Hon T822D1537 1 400101 400101 400101 400101 N.A.40 Primary control, R7184B Carlin burner 1 430668 430668 430668 430668

40A Primary control, Honeywell R7184B Beckett burner 1 430672 430672 430672 400119 N.A.40B Primary control, GeniSys 7505B1500 Beckett burner 1 430675 430675 430675 430675 N.A.

41 Burner assembly, see #34 Table 1 1 — — — — —42 Tankless heater assy. (optional) 1 430080000 430080000 430080000 430080000 43008000043 Control, low limit Honeywell L4006A2049(optional) 1 410527 410527 410527 410527 41052744 Well 1/2 NPT x 1-1/2" (PZ) 1 410569 410569 410569 410569 41056944 Well 1/2 NPT x 3" (PZT) 1 430150 430150 430150 430150 43015045 Plug 3/4 (for alternate L.W.C.O.) 1 902340051 902340051 902340051 902340051 90234005146 Low water cut-off M&M PS 801-120 (optional) 1 430130 430130 430130 430130 43013047 Low water cut-off M&M 67 (standard) 1 400116 400116 400116 400116 40011648 Gasket, Beckett burner 1 430172 430172 430172 — —

48A Gasket, Carlin burner 1 430173 430173 430173 430173 43017349 Pin retainer 2 480016 480016 480016 480016 48001650 Screw, pin retainers 4 480049 480049 480049 480049 48004953 Junction box 1 480071100 480071100 480071100 480071100 48007110054 Junction box cover 1 432753 432753 432753 432753 43275355 Screw 2 480049 480049 480049 480049 48004956 Switch 1 432752 432752 432752 432752 43275257 Ground screw 1 650666 650666 650666 650666 65066658 “L” Baffle 1 430885000 430885000 – – –59 “T” Baffle

x430886020 430886020 430886020 430886020 430886020

(x=1) (x=2) (x=3) (x=4) (x=5)

DETAIL OF CLEAN OUT ANDOBSERVATION DOOR ASSEMBLY

Figure 3

Figure 4

STEAM BOILER (exploded view)Refer to Table 2 for detailed description of parts

Figure 2

2

2A 2C 2B

2D

2E

2F

BURNER DOOR ASSEMBLY DETAIL

ITEM 2. P/N 432910000 BURNER DOOR ASSEMBLY DETAILDESCRIPTIONPART NUMBERQTYITEM

BURNER DOOR - MACHINED43051040012AINSULATION - BURNER DOOR43001800012BFIBERGLASS ROPE 5/1640325100012CROLL PIN - UPPER HINGE 48001700012DROLL PIN - LOWER HINGE48001800012ECLEAR 5005 SEALANT73092900012F

©Slant/Fin Corp. 2013

SLANT/FIN CORPORATION, Greenvale, N.Y. 11548 • Phone: (516) 484-2600FAX: (516) 484-5921 • Canada: Slant/Fin LTD/LTEE, Mississauga, Ontario

www.slantfin.com

DETAIL OF OBSERVATION DOOR ASSEMBLY

Figure 3Figure 4

WATER BOILER (exploded view)Refer to Table 1 for detailed description of parts

Figure 1

2

2A 2C 2B

2D

2E

2F

BURNER DOOR ASSEMBLY DETAIL

ITEM 2. P/N 432910000 BURNER DOOR ASSEMBLY DETAILDESCRIPTIONPART NUMBERQTYITEM

BURNER DOOR - MACHINED43051040012AINSULATION - BURNER DOOR43001800012BFIBERGLASS ROPE 5/1640325100012CROLL PIN - UPPER HINGE 48001700012DROLL PIN - LOWER HINGE48001800012ECLEAR 5005 SEALANT73092900012F

RESIDENTIAL BURNERS

Potential for Fire, Smoke and Asphyxiation Hazards

To the Homeowner or Equipment Owner:Please read and carefully follow all instructions provided in this manual regarding your responsibilities in caring for your heating equipment.Contact a professional, qualifi ed service agency for installation, start-up or service work.Save this manual for future reference.

Incorrect installation, adjustment, or misuse of this burner could result in death, severe personal injury, or substantial property damage.

To the Professional, Qualifi ed Installer or Service Agency:Please read and carefully follow all instructions provided in this manual before installing, starting, or servicing this burner or heating system.The Installation must be made in accordance with all state and local codes having jurisdiction.

2

To the Owner:

Thank you for purchasing a Beckett burner for use with your heating appliance. Please pay attention to the Safety Warnings contained within this instruction manual. Keep this manual for your records and provide it to your qualifi ed service agency for use in professionally setting up and maintaining your oil burner.

Your Beckett burner will provide years of effi cient operation if it is professionally installed and maintained by a qualifi ed service technician. If at any time the burner does not appear to be operating properly, immediately contact your qualifi ed service agency for consultation.

We recommend annual inspection/service of your oil heating system by a qualifi ed service agency.

Daily – Check the room in which your burner/appliance is installed. Make sure:

Air ventilation openings are clean and unobstructedNothing is blocking burner inlet air openingsNo combustible materials are stored near the heating applianceThere are no signs of oil or water leaking around the burner or appliance

Weekly Check your oil tank level. Always keep your oil tank full, especially during the summer, in order to prevent condensation of moisture on the inside surface of the tank.

Remainder of manual to be used ONLY BYQUALIFIED SERVICE TECHNICIANS▼ ▼

ContentsGeneral Information ....................................................3

Hazard Defi nitions ........................................................................3

Inspect/Prepare Installation Site ................................6Inspect Chimney or Direct Vent System ........................................6Combustion air supply ...................................................................7Clearances to burner and appliance .............................................7Combustion chamber — Burner retrofi tting ...................................7

Prepare the Burner ......................................................8Low Firing Rate Baffl e ...................................................................8Burner fuel unit ..............................................................................8Attach air tube (if not already installed) .........................................8Nozzle and Pump Pressure ..........................................................8Install burner nozzle (if not already installed) ................................8Check/adjust electrodes ................................................................9Servicing nozzle line assembly .....................................................9

Mount Burner on Appliance .......................................9Mounting options ...........................................................................9Mounting dimensions ....................................................................9Check/Adjust ‘Z’ Dimension - ‘F’ heads ...................................... 10Installing the Oil Tank and Supply System ................................. 12

Wire burner ................................................................13Burner packaged with appliance ................................................ 13Burner installed at jobsite ........................................................... 13Special wiring required with covered burners ............................ 13

Burner Controls .........................................................14GeniSys Model 7505 Control ..................................................... 14Features ..................................................................................... 14Wiring ......................................................................................... 14Reset Button Operation .............................................................. 16Wire Burner ................................................................................ 18

Start Up Burner/Set Combustion .............................18Cad Cell Resistance Measurement ............................................ 18Resetting From Restricted or Hard Lockout ............................... 18Startup / Checkout ..................................................................... 19Check Safety Features ............................................................... 19Set combustion with instruments ............................................... 19

Perform Regular Maintenance..................................20Shutting the Burner Off .............................................................. 20

Replacement Parts ....................................................22Limited Warranty Information ..................................24

3AFG Burner Manual

This manual contains information that applies to both AF and AFG burners. These burners may appear to be basically identical, but there are differences in design and performance. Please

review the comparison chart below:

Feature AF AFG Static Pressure Capability Conventional - Low range Enhanced - Medium range Blower Wheel Design Standard strip Special tablock Inlet Airfl ow Design Standard inlet bell Special airguide UL Air Tube Combinations “F” Series ONLY “F” or “M” Series Igniter Gaskets Baseplate/Barrier Optional, as specifi ed Required, always specifi ed Low Firing Rate Baffl e Not required Required, per specifi cation

General InformationSection: General Information

Hazard Defi nitions

Within the boundaries of the hazard warning, there will be information presented describing consequences if the warning is not heeded and instructions on how to avoid the hazard.

Indicates a hazardous situation, which, if not avoided, will result

in death or serious injury.

Indicates a hazardous situation, which, if not avoided, could

result in death or serious injury.

Indicates a hazardous situation, which, if not avoided, could

result in minor or moderate injury.

Intended to bring special attention to information, but not related to

personal injury or property damage.

Owner’s Responsibility

Incorrect installation, adjustment, and use of this burner could result in severe personal injury, death, or substantial property damage from fi re, carbon

monoxide poisoning, soot or explosion.Contact a professional, qualifi ed service agency for the installation, adjustment and service of your oil heating system. This work requires technical training, trade experience, licensing or certifi cation in some states and the proper use of special combustion test instruments.

Please carefully read and comply with the following instructions:

Never store or use gasoline or other fl ammable liquids or vapors near this burner or appliance. Never attempt to burn garbage or refuse in this appliance.Never attempt to light the burner/appliance by throwing burning material into the appliance. Never attempt to burn any fuel not specifi ed and approved for use in this burner.Never restrict the air inlet openings to the burner or the combustion air ventilation openings in the room.

Figure 1. Burner label location

4

Section: General Information

Do NOT Alter the Original Burner Design

Tampering with or altering the burner design could seriously impair performance, resulting in loss of static pressure, damage to the system components, reduced air volume, heavy smoke, fl ame impingement, appliance sooting, hot gas puff-back, and asphyxiation or fi re hazards. Maintain the design to its original confi guration. Only use parts specifi ed for AF or AFG Burners.Do NOT remove the air guide from the AFG chassis.Do NOT use ‘M’ Series air tube combinations on AF Burners.

Never try to convert an AF to an AFG or vice versaAny design alteration will:

Void UL ListingVoid manufacturer’s warrantiesSeriously impact burner performanceGreatly increase your liability risk

Impaired Burner Performance and Fire Hazard.

Do NOT operate the burner beyond specifi cations outlined in the following Table.

For applications beyond these limits, consult Beckett Technical Service at 1-800-645-2876.NOTE: Some packaged appliances with burners may be agency listed as a unit to operate beyond these limits. Consult the appliance manufacturer’s specifi cations and agency approvals for verifi cation.

Table 1 – Burner Specifi cationsCapacity(Note 1)

‘F’ Head (AF & AFG)Firing rate range: 0.40 – 3.00 GPH Input: 56,000 – 420,000 Btu‘L1’ Head (AFG Only)Firing rate range: 0.40 - 1.10 GPH Input: 56,000 – 154,000 Btu/h‘L2’ Head (AFG Only)Firing rate range: 0.50 - 1.00 GPH Input: 70,000 – 140,000 Btu/h‘V1’ Head (AFG Only)Firing rate range: 0.75 - 2.75 GPH Input: 105,000 – 385,000 Btu/h

Certifi cations/Approvals

UL listed to comply with ANSI/UL296 and CSA-B140.0

Fuels USA: No. 1 or No. 2 heating oil only (ASTM D396)Canada: No. 1 stove oil or No. 2 furnace oil only

DO NOT USE GASOLINE, CRANKCASE OIL, OR ANY OIL CONTAINING GASOLINE.

Electrical Power supply: 120 volts AC, 60 Hz single phaseOperating load: 5.8 Amps maxMotor: 1/7 hp, 3450 rpm, NEMA 48M frame PSC rotation CCW when facing shaft endIgnition: Continuous duty solid-state igniter

Fuel pump Outlet pressure: Note 2

Air tube ATC code: See Table 2

Dimensions(with cover)

Height (maximum): 12.5 inchesWidth (maximum): 15 inchesDepth: 9.25 inchesAir tube diameter: 4.00 inches

Ambient Operat-ing Temperature

+32o F. (0 C.) Minimum+115o F. (+46 C.) Maximum(See above Warning)

Moisture 5% to 95% RH, non-condensing and non-crystallizing

Note 1: Approval agency listed rating for these burners is 0.40 to 3.00 gph. However, the fi ring rate range is limited by the specifi c air tube combination being used. Refer to Table 2.Note 2: See appliance manufacturer’s burner specifi cations for recommended pump discharge pressure.

If the residence is unattended in severely cold weather, burner primary control safety lockout, heating system component failures, power outages or other electrical system failures could result in frozen plumbing and water damage in a matter of hours. For protection, take preventive actions such as having a security system installed that operates during power outages, senses low temperature and initiates an effective action. Consult with your heating contractor or a home security agency.

Frozen Plumbing and Water Damage Hazard

5AFG Burner Manual

Table 2 – Air Tube Combination (ATC) codes

Firing Rate (gph) (min-max)

HeadStatic

plate size (inches)

VenturiATC Codes for usable air tube lengths

(‘A’ in inches; See Figure 3.)

4-1/2 5 5-3/8 6-5/8 7 7-1/4 9 10-1/2 13 160.50-0.75 F0 3-3/8U None AF44XR - AF53XR AF65XR - AF72XR AF90XR AF104XR AF130XR A160XR

0.75-1.25 F3 2-3/4U None AF44XN - AF53XN AF65XN - AF72XN AF90XN AF104XN AF130XN AF160XN

0.85-1.35 F4 2-3/4U None AF44WH - AF53WH AF65WH - AF72WH AF90WH AF104WH AF130WH AF160WH

0.85-1.65 F6 2-3/4U None AF44YB - AF53YB AF65YB - AF72YB AF90YB AF104YB AF130YB AF160YB

1.10-2.00 F12 2-3/4U None AF44XO - AF53XO AF65XO - AF72XO AF90XO AF104XO AF130XO AF160XO

1.65-2.50 F22 2-3/4U None AF44XP - AF53XP AF56XP - AF72XP AF90XP AF104XP AF130XP AF160XP

2.50-3.00 F31 None None AF44XS - AF53XS AF65XS - AF72XS AF90XS AF104XS AF130XS AF160XS

0.50-1.10 L1 3-3/8U 8hole - AFG50MB - - AFG70MB - AFG90MB - - -

0.50-1.00 L2 2-3/4U 8hole AFG50MP - - AFG70MP - AFG90MP - - -

0.75-2.75 V1 2-3/4U 8hole - AFG50MD - - AFG70MD - AFG90MD - - -

0.40-0.75 F0 3-1/2U None AF44WG - AF53WG AF65WG - AF72WG AF90WG AF104WG AF130WG A160WG

Section: General Information

Please read and understand the manual supplied with this equipment. This equipment must be installed, adjusted and put into operation only by a qualifi ed individual or service agency that is:

Licensed or certifi ed to install and provide technical service to oil heating systems.Experienced with all applicable codes, standards and ordinances.Responsible for the correct installation and commission of this equipment.Skilled in the adjustment of oil burners using combustion test instruments.

The installation must strictly comply with all applicable codes, authorities having jurisdiction and the latest revision of the National Fire Protection Association Standard for the installation of Oil-burning Equipment, NFPA 31 (or CSA-B139 and CSA-B140 in Canada).Regulation by these authorities take precedence over the general instructions provided in this installation manual.

Incorrect installation, adjustment, and use of this burner could result in severe personal injury, death, or substantial property damage from fi re, carbon monoxide poisoning, soot or explosion.

Professional Service Required

Special Requirements

THE INSTALLATION OF A BURNER SHALL BE IN ACCORDANCE WITH THE REGULATIONS OF AUTHORITIES HAVING JURISDICTION.For recommended installation practices in the U.S. refer to the latest edition of NFPA 31. (CSA-B139 and CSA-B140 in Canada.Concealed damage — If you discover damage to the burner or controls during unpacking, notify the carrier at once and fi le the appropriate claim.When contacting Beckett for service information — Please record the burner serial number (and have available when calling or writing). You will fi nd the serial number on the silver label located on the left rear of the burner. Refer to Figure 1.

○

○

○

○

6

Carefully inspect the chimney or exhaust vent system.Make sure it is properly sized and in good working condition. Follow the instructions supplied by the appliance manufacturer.The installation must strictly comply with all applicable codes, authorities having jurisdiction and the latest revision of the National Fire Protection Association Standard NFPA 31 for the installation of chimneys and vent sizing, (or CSA-B139 and CSA-B140 in Canada).Regulation by these authorities take precedence over the general instructions provided in this installation manual.

Fire, Smoke & Asphyxiation Hazard

piece of broken tile wedged in the chimney should be removed.No other appliance connection should be made to the same fl ue pipe.The fl ue pipe should have an upward pitch toward the chimney of at least 1/4” per foot of length. It should fi t tightly and should not project into the chimney.Any leakage between tiles, around clean-out doors, or around the vent pipe should be sealed.

Insulated stainless steel chimney liners

The new designs of high effi ciency oil furnaces and boilers in conjunction with fl ame retention oil burners are more effi cient. One result of increased effi ciency is lower fl ue gas temperatures. As fl ue gases rise in the chimney, they will cool and condense when they reach the dew point. The condensation will mix with the sulphur in the fl ue gases creating sulphuric acid. The acid will attack the chimney mortar, brick and clay liners causing corrosion, deterioration and blockage of the chimney. Eventually the blockage could prevent exhausting the fl ue gases. Instead, the fl ue gases could vent out the barometric damper into the living space.

Therefore, it is strongly recommended that an approved insulated stainless steel liner be installed.

For those installations not requiring a chimney, such as through-the-wall vented appliances, follow the instructions given by the appliance and power venter (if used) manufacturers.

5.

6.

7.

○

Inspect Chimney or Direct Vent System

Starting with minimum gph fi ring rate, the minimum size recommended is 6” fl ue pipe with 8” X 8” inside chimney, unless specifi ed otherwise by the appliance manufacturer.A chimney fl ue shall extend at least 3 feet above the highest point at which the chimney comes in contact with the roof, and not less than 2 feet above the highest roof surface or structure within 10 feet horizontally of the chimney. Refer to Figure 2.Any accumulation of soot or debris in chimney offsets should be removedAny obstructions such as a protruding joint or a

1.

2.

3.

4.

Section: Inspect/Prepare Installation Site

Figure 2 – Chimney Design - Above the Roof

NOTE: Correct chimney design is shown by dotted lines. Incorrect chimney design, as shown by the solid lines, may result in down-drafts.

Inspect/Prepare Installation Site

7AFG Burner Manual

Combustion air supply

Do not attempt to install outside air piping to the burner without using the outside air kit and instructions.

Failure to comply could result in impaired combustion, appliance soot-up, puffback of smoke, and fi re or asphyxiation hazards.

Follow the Outside Air Kit Instructions Exactly

Appliance located in confi ned space

The confi ned space should have two (2) permanent openings: one near the top of the enclosure and one near the bottom of the enclosure. Each opening shall have a free area of not less than (1) one square inch per 1,000 BTU’s per hour of the total input rating of all appliances within the enclosure. The openings shall have free access to the building interior, which should have adequate infi ltration from the outside.

Exhaust fans and other air-using devices

Size air openings large enough to allow for all air-using devices in addition to the minimum area required for combustion air. If there is any possibility of the equipment room developing negative pressure (because of exhaust fans or clothes dryers, for example), either pipe combustion air directly to the burner or provide a sealed enclosure for the burner and supply it with its own combustion air supply.

Direct air supply and sidewall venting

Some AFG burners are equipped with combustion air boots to allow use of outside air for combustion.When sidewall venting appliances, carefully follow appliance and power venter instructions for installation and wiring.

○

○

Outside air kit applications

Refer to separate instruction sheet supplied with AF/AFG outside air kit for installation. This optional kit allows combustion air to be piped directly to the burner (Beckett part number 51747).

Clearances to burner and applianceProvide space around burner and appliance for easy service and maintenance.Check minimum clearances against those shown by the appliance manufacturer and by applicable building codes.

○

○

Combustion chamber — Burner retrofi ttingVerify that the appliance combustion chamber provides at least the minimum dimensions given in Table 3.

Chamber Dimensions (inches)Firing Rate

(GPH)

Round I.D.

RectangularHeight

Floor to

nozzleWidth Length

0.50 8 7 8 12 5-60.75 9 8 9 12 5-61.00 10 9 10 12.5 5-61.25 11 10 11 12.5 5-61.50 12 11 12 13 6-72.00 14 12 15 13.5 6-72.50 16 13 17 14 7-83.00 18 14 18 15 7-8

Table 3. Chamber Dimensions

Section: Inspect/Prepare Installation Site

The burner cannot properly burn the fuel if it is not supplied with a reliable combustion air source.Follow the guidelines in the latest editions of the NFPA 31 and CSA-B139 regarding providing adequate air for combustion and ventilation.

Failure to provide adequate air supply could seriously affect the burner performance and result in damage to the equipment, asphyxiation, explosion or fi re hazards.

Adequate Combustion and Ventilation Air Supply Required

When retrofi tting appliances that have unlined stainless steel combustion chambers, protect the chamber by lining the inside surfaces with a ceramic fi ber blanket, such as a wet-pac or other suitable refractory material.Some steel chambers may not require liners because the appliance was designed and tested for use with fl ame retention burners. Refer to the manufacturer’s instructions.

Failure to comply could result in damage to the heating equipment and result in fi re or asphyxiation hazards.

Protect Steel Combustion Chamber From Burnout

8

Table 4. AFG Reduced Firing Rates (with LFRB)

Burner head type Low Firing Rate Baffl e installedF0 up to 0.65 gph

F3 or L1 up to 0.85 gphF4 or F6 up to 0.90 gph

V1 up to 1.00 gph

Prepare the BurnerLow Firing Rate Baffl eThe AFG Low Firing Rate Baffl e (LFRB) reduces the air fl ow and pressure. The LFRB is sometimes used for fi ring rates under 1.00 gph as listed in Table 4. Refer to the appliance manufacturer’s instructions. Do not omit the LFRB when specifi ed. Omitting the baffl e when specifi ed or installing the baffl e when not specifi ed could result in impaired burner performance.

Burner fuel unitVerify that the burner fuel unit is compatible with the oil supply system. For more details, refer to the pump manufacturer’s instructions provided with the burner.

Attach air tube (if not already installed)If using a fl ange and gasket, slide them onto the air tube. Then attach the air tube to the burner chassis using the four sheet metal screws provided. Refer to Figure 4 for details.

Nozzle and Pump Pressure

Install burner nozzle (if not already installed)Remove the plastic plug protecting the nozzle adapter threadsPlace a 3/4” open-end wrench on the nozzle adapter. Insert the nozzle into the adapter and fi nger tighten. Finish tightening with a 5/8” open-end wrench. Use care to avoid bending the burner head support legs or electrodes. If you remove the head to replace the nozzle (type “L1”/“L2” or “V1” heads), carefully reconnect the head to the nozzle adapter, making sure that the head support makes contact with the nozzle adapter shoulder. Refer to Figure 5 or 6.

1.

2.

Section: Prepare the Burner

Use only nozzles having the brand, fl ow rate (gph), spray angle and pattern specifi ed by the appliance manufacturer.

Follow the appliance manufacturer’s specifi cations for the required pump outlet pressure for the nozzle, since this affects the fl ow rate.

Nozzle manufacturers calibrate nozzle fl ow rates at 100 psig.When pump pressures are higher than 100 psig, the actual nozzle fl ow rate will be greater than the gph stamped on the nozzle body. (Example: A 1.00 gph nozzle at 140 psig = 1.18 gph)

Securely tighten the nozzle (90 torque inch pounds). For typical nozzle fl ow rates at various pressures refer to Table 5.

Incorrect nozzles and fl ow rates could result in impaired combustion, under-fi ring, over-fi ring, sooting, puff-back of hot gases, smoke and potential fi re or asphyxiation hazards.

Correct Nozzle and Flow Rate Required

Table 5. Nozzle Flow Rate by SizeNozzle fl ow rate U. S. gallons per hour of No. 2 fuel oil when pump pressure (psig) is:

Nozzle size

(rated at 100 psig)

125 psi 140 psi 150 psi 175 psi 200 psi

0.40 0.45 0.47 0.49 0.53 0.560.50 0.56 0.59 0.61 0.66 0.710.60 0.67 0.71 0.74 0.79 0.850.65 0.73 0.77 0.80 0.86 0.920.75 0.84 0.89 0.92 0.99 1.060.85 0.95 1.01 1.04 1.13 1.200.90 1.01 1.07 1.10 1.19 1.271.00 1.12 1.18 1.23 1.32 1.411.10 1.23 1.30 1.35 1.46 1.561.20 1.34 1.42 1.47 1.59 1.701.25 1.39 1.48 1.53 1.65 1.771.35 1.51 1.60 1.65 1.79 1.911.50 1.68 1.77 1.84 1.98 2.121.65 1.84 1.95 2.02 2.18 2.331.75 1.96 2.07 2.14 2.32 2.482.00 2.24 2.37 2.45 2.65 2.832.25 2.52 2.66 2.76 2.98 -2.50 2.80 2.96 - - -

9AFG Burner Manual

If the nozzle is already installed, remove the nozzle line assembly to verify that the nozzle size and spray pattern are correct for the application (per appliance manufacturer’s information). Verify that the electrode tip settings comply with Figure 3.If the nozzle is not installed, obtain a nozzle from the manufacturer, having the capacity and spray angle specifi ed in the appliance manufacturer’s information. For conversions or upgrades, when information is not available for the application:

Refer to Table 6 to select the mid-range nozzle spray angle for the head type being used.Fire the burner and make sure the combustion is acceptable and the fl ame is not impinging on chamber surfaces.If a shorter fl ame is needed, select a wider spray angle. If a longer fl ame is needed, select a narrower spray angle.Either hollow or solid spray patterns may be used. If combustion results are not satisfactory with the selected spray pattern, try the other pattern.

3.

4.

○

○

○

○

points up. Pull the nozzle line assembly toward you and remove assembly from burner.To replace the nozzle assembly, reverse the above steps.

Mount Burner on ApplianceMounting options

Bolt the burner to the appliance using the factory-mounted fl ange or an adjustable fl ange.

Mounting dimensionsWhen using the Beckett universal adjustable fl ange, mount the air tube at a 2° downward pitch unless otherwise specifi ed by the appliance manufacturer.Verify that the air tube installed on the burner provides the correct insertion depth. See Figure 7.The end of the air tube should normally be ¼” back from the inside wall of the combustion chamber. Never allow the leading edge of the head assembly to extend into the chamber, unless otherwise specifi ed by the heating appliance manufacturer. Carefully measure the insertion depth when using an adjustable fl ange. Verify the insertion depth when using a welded fl ange.

7.

1.

1.

2.

3.

Table 6. Nozzle Spray AnglesRecommended nozzle spray angles

“F” head 70° or 80° nozzle“L1” & “L2” head 45°, 60°, or 70° nozzle

“V1” head 45°, 60°, or 70° nozzle

Figure 3. – Electrode Tip AdjustmentStandard Dimensions for F, L1, and V1 Heads.

The Dimensions shown below are for use with L2 heads and M series air tube combinations ending with an ‘N’ suffi x (example: AFG70MDAQN)

Check/adjust electrodesCheck the electrode tip settings. Adjust if necessary to comply with the dimensions shown in Figure 3. To adjust, loosen the electrode clamp screw and slide/rotate electrodes as necessary. Securely tighten the clamp screw when fi nished.

Servicing nozzle line assemblyTurn off power to burner before proceeding.Disconnect oil connector tube from nozzle line.Loosen the two screws securing igniter retaining clips and rotate both clips to release igniter baseplate. Then tilt igniter back on its hinge.Remove splined nut.“F” head air tube. - Remove nozzle line assembly from burner, being careful not to damage the electrodes or insulators while handling. To ease removal of long assemblies (over 9 inches), rotate assembly 180° from installed position after pulling partially out of tube.“L1”, “L2”, and “V1” head air tubes. - Slide nozzle line assembly forward (further into air tube) so the head clears the venturi opening. Then rotate the nozzle line assembly 90° so the nozzle line end

1.2.3.

4.5.

6.

Section: Mount Burner on Appliance

10

Figure 4. Check/Adjust ‘Z’ Dimension for ‘F’ Heads


Make all adjustments exactly as outlined in the following information.

Incorrect Adjustments could cause combustion problems, carbon deposition from fl ame impingement, heavy smoke generation and fi re hazard.

Adjust the ‘Z’ dimension to the required specifi cation.

Check/Adjust ‘Z’ Dimension - ‘F’ headsThe important ‘Z’ dimension is the distance from the face of the nozzle to the fl at face of the head (or heat shield, if applicable). This distance for F heads is 1-⅛” (1-⅜” if the air tube has a heat shield). The “Z” dimension is factory set for burners shipped with the air tube installed. Even if factory set, verify that the “Z” dimension has not been changed.

Use the following procedure to adjust the “Z” dimension, if it is not correct:

1.

2.

Turn off power to the burner. Disconnect the oil connector tube from the nozzle lineSee above fi gure. Loosen the splined nut from the nozzle line. Loosen the hex head screw securing the escutcheon plate to the burner housing. Place the end of a ruler at the face of the nozzle and, using a straight edge across the head, measure the distance to the face of the head. A Beckett T501 gauge may also be used.Slide the nozzle line forward or back until this dimension for F heads is 1-⅛” (1-⅜” to the face of the heat shield, if applicable). Tighten the hex head screw to secure the escutcheon plate to the burner chassis. Then tighten the splined nut and attach the oil connector tube.

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Recheck the “Z” dimension periodically when servicing to ensure the escutcheon plate has not been moved. You will need to reset the “Z” dimension if you replace the air tube or nozzle line assembly. The Beckett Z gauge (part number Z-2000) is available to permit checking the F head “Z” dimension without removing the burner from the appliance.

3.

1-3/8”

1-1/8”

Burner Dimensions

For usable length A (inches)Dimension (inches) F Head L1 Head L2 Head V1 Head

H(nozzle to head), +1/32 N/A 1/4 7/32 1/4

L(Total tube length) A+1/2 A+1/2 A+1/2 A+1/2

R(electrode length), + 1/4 A+2-1/4 A+1-1/8 A+1-1/8 A+1-1/8

S(adapter to static plate), + 1/16 (Note 1) 1-3/8 1-3/8 1-3/8

Q(nozzle line length), A+ 15/16 A+ 3/16 A+ 3/16 A+ 3/16

Z(F head-no heat shield)

(F head-with heat shield)(L1 head w/straight shroud)

(L1/L2/V1 head w/conic shroud)

1-1/81-3/8N/AN/A

N/AN/A

1-3/81-3/4

N/AN/AN/A

1-3/4

N/AN/AN/A

1-3/4

Note 1: 1-3/8 for dimension A less than 4”; 1-5/8 for dimension A from 4” through 4-1/2 “, 2-13/32 for dimension A greater than 4-1/2”.

11AFG Burner Manual

V1 Adjusting Plate Setting

AFG with V1 HeadBurner Firing Rates

0 0.75-1.00

1 1.00-1.50

2 1.50-1.75

3 1.75-2.00

4 2.00-2.25

5 2.25-2.50

6 2.50-2.75

Table for initial adjusting plate settings for V1 Head Set head position adjusting plate (V1 head only)

After setting “Z” dimension, loosen head adjusting plate hex head screw and nozzle line splined nut. Move the nozzle line assembly until the burner reference indicator lines up with the head adjusting plate setting number given in Table shown below.

Tighten the hex head screw and splined nut. (DO NOT loosen the acorn nut when setting head position.) Refer to the manufacturer’s instructions for OEM settings.

The position of the head affects air fl ow volume and pattern. For most applications, the burner will perform satisfactorily with the air adjustment plate setting of Table shown below.

If combustion results indicate the need for change, adjust the head position adjusting plate forward or back one position at a time to optimize combustion.

1.

2.

3.

4.


Figure 6. Check/Adjust ‘Z’ Dimension - V1 Heads

V1 heads (see Table below and Figure above for dimensions) See fi gure above. The important “Z” dimension is the distance from the leading edge of the head to the end of the air tube. This distance for V1 heads is 1-¾”. The “Z” dimension is factory set for burners shipped with the air tube installed. Even if factory set, verify that the “Z” dimension has not been changed.

1.


2.

Turn off power to the burner. Disconnect the oil connector tube from the nozzle line.See fi gure above. Loosen the splined nut from the nozzle line. Loosen the hex head screw securing the head adjusting plate to the burner housing. Loosen the acorn nut. Move the head adjusting plate until the “0” lines up with the reference indicator on the housing, and retighten the hex head screw. Place the end of a ruler at the leading edge of the head and, using a straight edge across the end of the air tube, measure the distance to the end of the tube. A Beckett T501 gauge may also be used. Slide the nozzle line forward or back until this dimension is 1-¾” for V1 heads. Tighten the acorn nut. Tighten the hex head screw to secure the head adjusting plate to the burner chassis. Then tighten the splined nut and attach the oil connector tube.

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Recheck the “Z” dimension periodically when servicing to ensure the escutcheon plate has not been moved. You will need to reset the “Z” dimension if you replace the air tube or nozzle line assembly.

3.

Figure 5. Check/Adjust ‘Z’ Dimension - L1 & L2 Heads

L1/L2 heads (see Table 7 and Figure 3 for dimensions)

See fi gure above. The important “Z” dimension is the distance from the leading edge of the head to the end of the air tube. This distance for L1 & L2 heads is 1-3/8” if the tube has a straight shroud or 1-3/4” if the air tube has a conic shroud. The “Z” dimension is factory set for burners shipped with the air tube installed. Even if factory set, verify that the “Z” dimension has not been changed.

1.


Turn off power to the burner. Disconnect the oil connector tube from the nozzle line. Refer to fi gure. Loosen the splined nut from the nozzle line. Loosen the hex head screw securing the escutcheon plate to the burner housing. Place the end of a ruler at the leading edge of the head and, using a straight edge across the end of the air tube, measure the distance to the end of the tube. A Beckett T501 gauge may also be used. Slide the nozzle line forward or back until this dimension is 1-3/8” for L1 & L2 heads if the tube has a straight shroud, or 1-3/4” if the air tube has a conic shroud. Tighten the hex head screw to secure the escutcheon plate to the burner chassis. Then tighten the splined nut and attach the oil connector tube.

Recheck the “Z” dimension periodically when servicing to ensure the escutcheon plate has not been moved. You will need to reset the “Z” dimension if you replace the air tube or nozzle line assembly.

2.

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3.

12

Installing the Oil Tank and Supply System

Fuel supply level with or above burner

Figure 7. – Mounting Burner in Appliance

SK8745

Tilt down 2°

If space between burner air tube and opening

exceeds 1/2 inch, pack burner opening with

ceramic fiber refractory.

Figure 8. – Inside Tank Gravity Feed System

Figure 9. – Outside Buried Tank-Lift System

Note: to determine the proper fuel line size, refer to the fuel pump manufacturer’s instructions provided with the burner. Refer to Figure 8 or Figure 9 for typical installation layouts. Fuel Line Valves and Filter

Install two high quality, oil duty rated, fusible handle design shutoff valves in accessible locations on the oil supply line. Locate one close to the tank and the other close to the burner, upstream of the fi lter for service access.

Install a generous capacity fi lter inside the building between the fuel tank shutoff valve and the burner, locating both the fi lter and the valve close to the burner for ease of servicing. Filter should be rated for 50 microns or less.


Oil Leak and Fire Hazard

Install the oil tank following applicable standards in the U.S. by referring to the latest edition of NFPA 31 or CSA-B139 & CSA-B140 in Canada, and all authorities having jurisdiction.

Never use Tefl on tape on fuel oil fi ttings. Tape fragments can lodge in fuel line components and fuel unit, damaging the equipment and preventing proper operation.Use oil-resistant pipe sealant compounds.

Damage to the pump could cause impaired burner operation, oil leakage and appliance soot-up.

Do Not Use Tefl on Tape

To further protect the fuel supply system and reduce nozzle orifi ce

plugging with fi ring rates below 0.75 gph, a dual fi ltration system can be installed. This typically consists of a 50 micron primary fi lter, located near the fuel tank and a secondary fi lter rated for at least 10 microns located near the burner.

The burner is shipped without the by-pass plug installed.Install the by-pass plug in two-pipe oil supply systems ONLY.

Failure to comply could cause Immediate pump seal failure, pressurized oil leakage and the potential for a fi re and injury hazard.

Do Not Install By-pass Plug with 1-Pipe System

13AFG Burner Manual

The burner may be equipped with a single-stage fuel unit for these installations. Connect the fuel supply to the burner with a single supply line if you want a one-pipe system (making sure the bypass plug is NOT installed in the fuel unit.) Manual bleeding of the fuel unit is required on initial start-up. If connecting a two-pipe fuel supply, install the fuel unit bypass plug.

Fuel supply below the level of the burner

When the fuel supply is more than eight feet below the level of the burner, a two-pipe fuel supply system is required. Depending on the fuel line diameter and horizontal and vertical length, the installation may also require a two-stage pump. Consult the fuel unit manufacturer’s literature, included with the burner, for lift and vacuum capability.

Fuel line installation

Continuous lengths of heavy wall copper tubing are recommended. Always use fl are fi ttings. Never use compression fi ttings.Always install fi ttings in accessible locations. Proper routing of fuel lines is required to prevent air cavitation and vibration.

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Wire burner Burner packaged with appliance

Refer to appliance manufacturer’s wiring diagram for electrical connections.

Burner installed at jobsiteRefer to Figures 11a and 11b, for typical burner wiring, showing cad cell primary controls. Burner wiring may vary, depending on primary control actually used. Refer to the appliance manufacturer’s wiring diagram prior to connecting the burner wiring. All wiring must be in accordance with the latest revision of National Electric Code NFPA 70 and all local codes and regulations. In Canada, all wiring is to be in accordance with the Canadian Electrical Code, Part 1.

The 7505 primary control with valve-on delay (pre-time) and burner motor-off delay (post-time) requires a constant 120 volts AC power source supplied to the BLACK wire on the control. The RED wire goes to the appliance limit circuit. Please note that other control manufacturers may use different wire colors for power and limit connections.

Special wiring required with covered burnersThe mounting plate is not a conduit connection point. Pass conduit and attached connector through the opening in the mounting plate and attach it directly to the burner-mounted 4x4 electrical box.

If attaching a burner cover to a previously installed burner, attach the mounting plate and then slide the conduit into the “J” shaped conduit slot.

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Section: Wire Burner

The oil supply inlet pressure to the burner cannot exceed 3 psig. Insure that a pressure limiting device is installed in accordance with the latest edition of NFPA 31. Do NOT install valves in the return line. (NFPA 31, Chapter 8.)Gravity Feed Systems: Always install an anti-siphon valve in the oil supply line or a solenoid valve (RWB Part # 2182602U) in the pump/nozzle discharge tubing to provide backup oil fl ow cut-off protection.

Damage to the fi lter or pump seals could cause oil leakage and a fi re hazard.

Oil Supply Pressure Control Required

Disconnect electrical power before installing or servicing the burner.Provide ground wiring to the burner, metal control enclosures and accessories. (This may also be required to aid proper control system operation.)Perform all wiring in compliance with the National Electrical Code ANSI/NFPA 70 (Canada CSA C22.1)

Electrical shock can cause severe personal injury or death.

Electrical Shock Hazard

14

Burner ControlsGeniSys Model 7505 Control

Wiring

Figure 10 - 7505 Control

FeaturesThermostat / Operating and Limit Control CompatibleWelded Relay ProtectionLimited RecycleLimited Reset3 Status LightsValve-On Delay / Motor-Off Delay (Field programmable with 52067 GeniSys Display)15 Second Lockout TimeInterrupted or Intermittent Duty IgnitionTechnician Pump Priming ModeDisable FunctionCommunication Ports

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Section: Burner Controls

The control can malfunction if it gets wet, leading to accumulation of oil or explosive oil vapors.Never install where water can fl ood, drip or condense on the control.Never use a control that has been wet - replace it.

Can cause severe injury, death, or property damage.

Fire or Explosion Hazard

Follow the appliance manufacturer’s wiring diagrams and note all required safety controls.Typical safety controls include high temperature or pressure limits, low water cutoffs, pressure relief valves and blocked fl ue sensing switches.Verify all limit and safety controls are installed and functioning correctly, as specifi ed by the manufacturer, applicable safety standards, codes and all authorities having jurisdiction.Ensure that the appliance is free of oil and oil vapor before starting or resetting the burner.

All heating appliances must have HIGH LIMIT protection to interrupt electrical power and shutdown the burner if operating or safety controls fail and cause a runaway condition.

Explosion, Fire, Scald, and Burn Hazard

Incorrect Wiring Will Result in Improper Control Operation

GeniSys wiring label colors may not match the wire colors of the burner or other manufacturers’ controls.The GeniSys Control should be wired according to the appliance manufacturer’s instructions.

Display Module:Permanent device for programming and diagnostics

Alarm Module:For adding isolated low voltage alarm contacts to the base control. See Alarm Module Instructions for specifi cations.

Contractor’s Tool:Hand-held device for programming and diagnostics

Cad CellConnections

Wiring Connections

Communication Port 2

Reset Button with Red Light

Communication Port 1Thermostat Terminals

Green LightYellow Light

Optional Components:

15AFG Burner Manual

the igniter remains on for 10 additional seconds to ensure fl ame stability. Run: The fl ame is sustained until the call for heat is satisfi ed. The burner is then sent to Motor-Off Delay, if applicable, or it is shut down and sent to Standby.Recycle: If the fl ame is lost while the burner is fi ring, the control shuts down the burner, enters a 60 second recycle delay, and repeats the ignition sequence. The control will continue to Recycle each time the fl ame is lost, until it reaches a pre-set time allotment. The control will then go into Hard Lockout instead of recycle. This feature prevents excessive accumulation of oil in the appliance fi ring chamber.Motor-Off Delay: If applicable, the oil solenoid valve is turned off and the control delays turning the motor off for the set motor-off delay time before the control returns to standby.Pump Prime: The igniter and motor are on with the oil solenoid valve energized for 4 minutes. During Pump Prime mode, the cad cell is disregarded, allowing the technician to prime the pump without having to jumper the cad cell.

6.

7.

8.

9.

Typical Burner Sequence of Operation for GeniSys 7505 Control.Refer to the appliance manufacturer’s wiring diagram for actual specifi cations.

Standby: The burner is idle, waiting for a call for heat. Valve-On Delay: The igniter and motor are on while the control delays turning on the oil solenoid valve for the programmed time.Trial For Ignition: The oil solenoid valve is energized. A fl ame should be established within the factory set trial for ignition time (lockout time).Lockout: The control has shut down for one of the following safety reasons:

The trial for ignition (lockout) time expired without fl ame being established.

The cad cell detected fl ame at the end of the Valve On Delay state.

To reset the control from lockout click the button 1-second.

NOTE: A recurrence of the above failure modes or a failed welded relay check could cause the control to enter a Hard Lockout state that must be reset only by a qualifi ed service technician. To reset from Hard Lockout, hold the reset button for 15 seconds until the yellow light turns on.

Ignition Carryover: Once fl ame is established,

1.

2.

3.

4.

a.

b.

5.

2

1

3

5

68

4

7

Standby

Motor-off delay

Valve-on delay Trial forignition

Ignition carryover

Run

Lockout

Recycle

9Pumpprime


16

Figure 11a. – Interrupted ignition, valve-on delay only (no motor-off delay)

Figure 11b. – Interrupted ignition, valve-on delay and motor-off delay

SAFETY ANDOPERATING

LIMITS

LIMIT

L1

L2 (VLV)VALVE

L2

MOTORL2 (MTR)

L2 (IGN)IGNITER

CADCELL

MOTOR

IGNITER

W

R

80

7060

50

5070

80

60

OIL VALVE

CAD CELL

THERMOSTAT

TR

TW

TR-TWJUMPER

TR-TW TERMINALSLOCATED ON OPPOSITE

SIDE OF CONTROL

L1L2SAFETY AND

OPERATINGLIMITS

LIMIT

L1

L2 (VLV)VALVE

L2

MOTORL2 (MTR)

L2 (IGN)IGNITER

CADCELL

MOTOR

IGNITER

W

R

80

7060

50

5070

80

60

OIL VALVE

CAD CELL

THERMOSTAT

TR

TW

TR-TWJUMPER

TR-TW TERMINALSLOCATED ON OPPOSITE

SIDE OF CONTROL

L1L2

LIMIT L1 - LIMIT JUMPER

Table 2 - Reset Button Operation

If the burner is in the below state:

Pushing the reset button will:

Button Click(press < 1 second)

Button Hold(press > 1 second)

Button Hold (press 15+ seconds)

Lockout Reset from Soft Lockout Reset from Restricted (Hard) Lockout

Valve-on Delay, Trial for Ignition, Ignition Carryover

Go to Pump Prime (see “Priming the Pump” above)

Disable the Burner:Any time the burner is running, press and hold the reset button to disable the burner. The burner will remain off as long as the button is held.

Enables Pump Priming: After the reset button has been held for 15 seconds, the button can then be clicked during the next ignition sequence to enter Pump Prime mode.

Run (igniter is shut off) No action

Motor-Off Delay,Standby No action

Pump Prime No action Exit Pump Prime mode and return to Standby

Table 3 - Status Lights

Light Color On Continuously FlashingRed Restricted (Hard) Lockout Soft Lockout

Green Flame Sensed during normal operation (Could be stray light during standby) Recycle

Yellow Control is in Pump Prime mode orReset button currently held for 15+ seconds. N/A

Reset Button OperationTable 2 explains what action the control will take when the reset button is pressed for different lengths of time during the various burner operating states.


17AFG Burner Manual

RECYCLE. If the fl ame is lost while the burner is fi ring, the control shuts down the burner, enters a 60 second recycle delay, and then repeats the above ignition sequence. If fl ame is lost three times in a row, the control locks out to prevent cycling with repetitious fl ame loss due to poor combustion.BURNER MOTOR-OFF DELAY. The fuel valve is closed and the burner motor is kept on for the selected motor-off delay time before the control returns the burner to standby.

7.

8.

Figure 10 - Typical Burner Wiring & Burner Sequence of Operation for R7184P Control.Refer to the appliance manufacturer’s wiring diagram for actual specifi cations.

STANDBY. The burner is idle, waiting for a call for heat. When a call for heat is initiated, there is a 3-10 second delay while the control performs a safe start check.VALVE-ON DELAY. The ignition and motor are turned on for a 15 second valve-on delay.TRIAL FOR IGNITION (TFI). The fuel valve is opened. A fl ame should be established within the 15 second lockout time.LOCKOUT. If fl ame is not sensed by the end of the TFI, the control shuts down on safety lockout and must be manually reset. If the control locks out three times in a row, the control enters restricted lockout. IGNITION CARRYOVER. Once fl ame is established, the ignition remains on for 10 seconds to ensure fl ame stability before turning off. If the control is wired for intermittent duty ignition, the ignition unit stays on the entire time the motor is running.RUN. The burner runs until the call for heat is satifi ed. The burner is then sent to burner motor off delay, if applicable, or it is shut down and sent to standby.

1.

2.

3.

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6.

Feature Interrupted ignition

Limited reset, Limited recycle

Valve-ondelay

Burner motor off delay

AlarmContacts

R7184A YES YES — — —R7184B YES YES YES — —R7184P YES YES YES YES Optional

Control System Features


61351

18

Make connections to the control’s terminals as shown in Figures 11a and 11b. Refer to the label on the underside of the control for wiring details.Note: Motor-off delay on a 7505P will be disabled if the safety and operating limits as shown in Figures 11a and 11b interrupt power to the control terminal L1.Connect thermostat leads to the TR and TW terminals on the control or jumper the TR and TW terminals on the control, as directed by the appliance wiring diagram.

- Thermostat anticipator Current: 0.1 amp - Thermostat voltage: 24 volts AC

Note that if the thermostat short cycles or operates improperly, it may require an isolation relay for proper operation. The Beckett A/C Ready Kit (part no. 51950U) provides this function. Wiring instructions are included with the A/C Ready Kit.

Start Up Burner/Set Combustion

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Some Thermostats Are Polarity Sensitive. Reversed polarity

could cause erratic cycling of the burner control.Connect the wire from the RH or R terminal on the thermostat to the TR terminal on the control. Connect the wire from the W terminal on the thermostat to the TW terminal on the control.

Open the shutoff valves in the oil supply line to the burner.Close air band and partially open air shutter. This is an initial air setting for the pump bleeding procedure only. Additional adjustments must be made with instruments.

1.

2.

Set the thermostat substantially above room temperature.Close the line voltage switch to start the burner. If the burner does not start immediately you may have to reset the burner primary control.Initiate a call for heat.After the burner starts, press and hold the reset button for 15 seconds until the yellow light turns on. This indicates that the button has been held long enough.Release the reset button. The yellow light will turn off and the burner will start up again.At burner start up, click the reset button while the igniter is still on. This will transition the control to a dedicated Pump Prime mode, during which the motor, igniter, and valve are powered for four minutes. The yellow light will be on.Bleed the pump until all froth and bubbles are purged. If desired, terminate the call for heat or hold the reset button for at least one second to exit Pump Prime mode and return to Standby.At the end of 4 minutes, the yellow light will turn off and the control will automatically return to standby mode. If prime is not established during the four minute pump prime mode, return to step 8 to re-enter Pump Prime mode. Repeat steps 8 through 10 until the pump is fully primed and the oil is free of bubbles.Terminate the call for heat, and the control will resume normal operation.

Cad Cell Resistance MeasurementIf the Beckett 7505 control is equipped with the GeniSys Display Module, part 52067U, the cad cell resistance can be selected and read on the LCD screen. Also, the GeniSys Contractor Tool, part 52082U, can be used for this purpose.If these are not available, the cad cell leads can be unplugged from the control and the resistance measured with a meter in the conventional way. Conduct these tests with fl ame present.

Flame Detection Range

Normal = 0 to 1600 ohms

Limited = 1600 ohms to lockout

Resetting From Restricted or Hard LockoutIf the control continues to lockout without a satisfi ed call for heat, or fails the motor relay check, the control enters Hard (restricted) Lockout in order to limit accumulation of unburned oil in the combustion chamber.To reset, hold the button down for 15 seconds until the red light turns off and the yellow light turns on.

3.4.

5.6.

7.

8.

9.

10.

11.

12.

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Section: Start-up Burner/Set Combustion

Wire Burner

Do not allow oil to spray into a hot combustion chamber while bleeding air from the pump.Install a gauge in the nozzle discharge port tubing or fully open the pump bleed valve to prevent oil spray from accumulating in the combustion chamber during the air bleed procedure.Ensure that all bubbles and froth are purged from the oil supply system before tightening the pump bleed valve.Ensure that the appliance is free of oil and oil vapor before starting or resetting the burner.

Failure to prime the pump properly could result in unstable combustion, hot gas puff-back and heavy smoke.

Hot Gas Puff-Back and Heavy Smoke Hazard

19AFG Burner Manual

Always verify the control functions according to all specifi cations before leaving the installation site. Replace the control if it does not operate as specifi ed.

Startup / Checkout

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○

If the burner or control fails any of the following tests, recheck control wiring. If the burner or control still fails any tests, replace the control.

Check Safety FeaturesSafe Start Check

Place a jumper across the cad cell terminals.Refer to the steps for “Start up burner/set combustion” and have the system call for heat.Burner must not start. Verify that the green light is on continuously and that the control remains in Standby mode.End the call for heat and remove the cad cell jumper.

Simulate Flame Failure and Ignition Failure

Refer to the steps for “Start up burner/set combustion” and have the system call for heat.After fl ame is established and the burner igniter turns off, close the hand valve in the oil supply line.At fl ame loss, the control will enter Recycle

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1.2.

3.

4.

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1.

2.

3.

mode. Verify that the green light is fl ashing. The control will remain in Recycle for 60 seconds.After the 60 second recycle period, the control will try to restart the system.After the 15 second lockout time, the control will lock out the burner and the reset button will fl ash. Verify that the burner motor and igniter are off and that the burner oil solenoid valve (if used) is not energized.Open the hand valve in the oil line.Click the reset button and verify that the red light in the reset button shuts off and that the burner lights.End the call for heat.

Before leaving the installation, verify that all thermostat and boiler/furnace control wiring is correct. Consult heating appliance manual for directions.

Set combustion with instruments

4.

5.

6.7.

8.

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Allow the burner to run for approximately 5 to 10 minutes.Set the stack or over-fi re draft to the level specifi ed by the appliance manufacturer.

Natural Draft Applications; typically over-fi re draft is -0.01” or -0.02” w.c.

Direct Venting; typically may not require draft adjustment.

High Effi ciency/Positive Pressure Appliances; also vary from traditional appliances (see manufacturer’s recommendations).

Follow these four steps to properly adjust the burner:

Step 1: Adjust the air shutter/band until a trace of smoke is achieved.

Step 2: At the trace of smoke level, measure the CO2 (or O2) . This is the vital reference point for further adjustments. Example: 13.5% CO2 (2.6% O2)

Step 3: Increase the air to reduce the CO2 by 1.5 to 2 percentage points. (O2 will be increased by approximately 2.0 to 2.7 percentage points.) Example: Reduce CO2 from 13.5% to 11.5% (2.6% to 5.3% O2).

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2.

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3.

Section: Start-up Burner/Set Combustion

Do not attempt to start the burner when excess oil has accumulated in the appliance, the appliance is full of vapor, or when the combustion chamber is very hot. Do not attempt to re-establish fl ame with the burner running if the fl ame becomes extinguished during start-up, venting, or adjustment.Vapor-Filled Appliance: Allow the unit to cool off and all vapors to dissipate before attempting another start. Oil-Flooded Appliance: Shut off the electrical power and the oil supply to the burner and then clear all accumulated oil before continuing.If the condition still appears unsafe, contact the Fire Department. Carefully follow their directions. Keep a fi re extinguisher nearby and ready for use.

Failure to follow these instructions could lead to equipment malfunction and result in heavy smoke emission, soot-up, hot gas puff-back, fi re and asphyxiation hazards.

Explosion and Fire Hazard

Oil-Burning Equipment shall be connected to fl ues

having suffi cient draft at all times to ensure safe and proper operation of the burner.

20

Step 4: Recheck smoke level. It should be Zero. This procedure provides a margin of

reserve air to accommodate variable conditions.

If the draft level has changed, recheck the smoke and CO2 levels and readjust the burner if necessary.

Once combustion is set, tighten all fasteners on air band, air shutter and head adjusting plate or escutcheon plate.Burner equipped with cover - Reinstall the cover and repeat Steps 2 and 4. If CO2 increases (O2 decreases), remove the cover and adjust the air setting so the CO2 (O2) with cover on meets requirements of Step 3.Start and stop the burner several times to ensure satisfactory operation. Test the primary control and all other appliance safety controls to verify that they function according to the manufacturer’s specifi cations.

Perform Regular Maintenance

4.

5.

6.

replacing any that are cracked or chipped.

Check electrode tip settings. Replace electrodes if tips are rounded.

Inspect the igniter spring contacts. Clean or replace if corroded.

Clean the cad cell grid surface, if necessary.

Make sure Low Firing Rate Baffl e is in place if required for the burner application. Omitting the baffl e can result in unacceptable burner combustion.

Inspect all gaskets. Replace any that are damaged or would fail to seal adequately.

Inspect the combustion head and air tube. Remove any carbon or foreign matter. Replace all damaged units with exact parts.

Clean the blower wheel, air inlet, air guide, burner housing and static plate of any lint or foreign material.

If motor is not permanently lubricated, oil motor with a few drops of SAE 20 nondetergent oil at each oil hole. DO NOT over oil motor. Excessive oiling can cause motor failure.

Check motor current. The amp draw should not exceed the nameplate rating.

Check all wiring for secure connections or insulation breaks.

Check the pump pressure and cutoff function.

Check primary control safety lockout timing.

Check ignition system for proper operation.

Inspect the vent system and chimney for soot accumulation or other restriction.

Clean all fl ue passages and fl ue pipe. Replace corroded or damaged pipes.

Clean the appliance thoroughly according to the manufacturer’s recommendations.

Check the burner performance. Refer to the section “Set combustion with test instruments”.

It is good practice to make a record of the service performed and the combustion test results.

Shutting the Burner Off

□

□

□□

□

□

□

□

□

□

□□□□

□

□

□

□

Replace the oil supply line fi lter. The line fi lter cartridge must be replaced to avoid contamination of the fuel unit and nozzle.

Inspect the oil supply system. All fi ttings should be leak-tight. The supply lines should be free of water, sludge and other restrictions.

Remove and clean the pump strainer if applicable.

Verify the nozzle is the one originally specifi ed by the appliance manufacturer and replace the nozzle with one having the exact specifi cations from the same manufacturer.

Clean and inspect the electrodes for damage,

□

□

□□

□

Section: Perform Regular Maintenance

DO NOT TAMPER WITH THE UNIT OR CONTROLS - CALL YOUR SERVICE PERSONNEL.To ensure continued reliable operation, a qualifi ed service technician must service this burner annually.More frequent service intervals may be required in dusty or adverse environments.Operation and adjustment of the burner requires technical training and skillful use of combustion test instruments and other test equipment.

Tampering with or making incorrect adjustments could lead to equipment malfunction and result in asphyxiation, explosion or fi re.

Annual Professional Service Required

Always keep the fuel oil supply valve shut-off if the burner(s)

is shut down for an extended period of time.

Turn off all electric power to the burner. Note: There could be more than one disconnect switch.

21AFG Burner Manual

Figure 12. Blower wheel assemblyReplace the blower wheel:

Turn off all power to the burner before servicing.Disconnect the burner motor wires.Remove the bolts securing the motor to the burner housing.Remove the motor and blower wheel.Remove the existing blower wheel.Referring to the fi gure below, slide the new blower wheel onto the shaft.

Use a feeler gauge to set the wheel-to-motor gap, as shown below. (AF = 0.125 +1/64 inch, AFG = 0.030 +1/64 inch)Slide blower wheel toward motor until it contacts feeler gauge.Rotate the blower wheel until the setscrew is centered on the fl at of the motor shaft. Tighten the setscrew to secure the wheel.

DO NOT use a motor that has endshield openings outside the blower wheel circumference (represented by the dashed line).Install the motor on the burner housing. Tighten screws. Reconnect wires.Restore power, start the burner and perform combustion tests. Refer to the section “Set combustion with test instruments”.

1.

2.3.

4.5.6.

○

○

○

7.

8.

9.

Section: Perform Regular Maintenance

SK9190

Use a Feeler Gauge to set the gap to; AF = 0.125 +1/64 inch AFG = 0.030 +1/64 inch

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USA: P.O. Box 1289 ● Elyria, Ohio 44036Canada: R.W. Beckett Canada, Ltd. ● Unit #3, 430 Laird Road ● Guelph, Ontario N1G 3X7

www.beckettcorp.com

Part Number 6104 BAFG R09, Printed in the U.S.A. 01/11

The R. W. BECKETT CORPORATION (“Beckett”) warrants to persons who purchase its “Products” from Beckett for resale, or for incorporation into a product for resale (“Customers”), that its equipment is free from defects in material and workmanship. To qualify for warranty benefi ts, products must be installed by a qualifi ed service agency in full compliance with all codes and authorities having jurisdiction, and used within the tolerances of Beckett’s defi ned product specifi cations.

To review the complete warranty policy and duration of coverage for a specifi c product, or obtain a written copy of warranty form 61545, please choose one of the following options:

Visit our website at: www.beckettcorp.com/warranty Email your request to: [email protected] to: R. W. Beckett Corporation, P. O. Box 1289, Elyria, OH 44036

NOTE: Beckett is not responsible for any labor cost for removal and replacement of equipment.

THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE, AND PROVIDES EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER REMEDIES, AND IN PARTICULAR THERE SHALL BE EXCLUDED THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT WILL BECKETT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE OF ANY NATURE. Beckett neither assumes, nor authorizes any person to assume for Beckett, any other liability or obligation in connection with the sale of this equipment. Beckett’s liability and Customer’s exclusive remedy is limited to the cost of the product.

1.2.3.

Limited Warranty Information

INSTALLATION INSTRUCTIONS

68-0281-16

L7224A,C; L7248A,C,L Oil and Electric Boiler Electronic Aquastat® Controllers

APPLICATIONThe L7224A,C and L7248A,C,L 2012 Compliant Electronic Aquastat® Controllers provide electronic temperature sensing in a UL limit-rated control with a single sensing probe. The L7224A,C and L7248A,C,L control the circulator, oil or electric burner or contactor, and boiler temperature. The L7224/L7248 is �“Outdoor Temperature Reset�” ready which is enabled when connected to the W8735Y1000 wireless or W8735S1000 wired Outdoor Reset Kit. Outdoor Reset with the L7224/L7248 is intended for all applications except for tankless coil systems for domestic hot water. Compliance to 2012 DOE regulation ensures efficiency is maximized without interfering with domestic hot water demand.

The L7224A,C and L7248A,C,L replace the L8124A, L8124C, L7124A,C, L7148A and L8148A Controllers. The L7224A,C and L7248A,C,L series controls provide status and diagnostic information through an LED display combined with LED lights as well as EnviraCOM�™ communications enabled thermostats and diagnostic tools to enhance the diagnostic process.

L7224/L7248 Aquastat Controllers are intended for use in residential-type applications.

IMPORTANT

Use of Outdoor Temperature Reset on a tank-less coil application requiring a Low Limit setting will result in reduced system effectiveness and efficiency.

SPECIFICATIONSElectrical Ratings:Voltage: 120 Vac, 60 Hz.Power: 7 VA maximum at 120 Vac plus external loads.Thermostat current: 100 mA nominal at 24 Vac.Burner Relay:

7.4 A at 120 Vac Full Load Amperage (FLA); 44.4 A inrush Locked Rotor Amperage (LRA);Less Ignition Load: 360 VA.

Circulator Relay:7.4 A at 120 Vac FLA; 44.4 A inrush LRA.Zone Controller (ZC): 7.4 A at 120 Vac FLA; 44.4 A inrush LRA.

NOTE: All loads combined cannot exceed 2000 VA.

Environmental Ratings:Temperature: -30 °F to +150 °F (-34 °C to +66 °C).Humidity: 0 to 95% relative humidity, noncondensing.

Approvals:Underwriters Laboratories Inc. Component Recognized. Canadian Underwriters Laboratories Inc. Component

Recognized.

2012 DOE Compliance and OperationOperation of this control may delay the burner operation while the residual heat is circulated out of the boiler.

NOTE: This operation may be different than earlier electronic Aquastat® revisions which did not implement thermal purge.

L7224A,C; L7248A,C,L OIL AND ELECTRIC BOILER ELECTRONIC AQUASTAT® CONTROLLERS

68-0281�—16 2

Accessories:W8735Y1000 Wireless Outdoor Reset KitW8735ER1000 Wireless Outdoor Reset ModuleC7089R1013 Wireless Outdoor Temperature Sensor

(requires W8735ER1000)W8735S1000 AquaReset�™ Outdoor Reset Kit (includes

50022037-002 Outdoor Reset Module and C7089U1006 Outdoor Temperature Sensor)

W8735S1008 AquaReset�™ Domestic Hot Water Kit (includes 50022037-005 Domestic Hot Water Module and 32003971-003 Sensor)

W8735S3000 EnviraCOM�™ Alarm ModuleC7089U1006 Outdoor Temperature Sensor (used with the

50022037-002)32003971-003 Temperature Sensor (used with

50022037-005)Sensor (See Table 2).120650 Heat Conductive Compound. 121371AA Sensor Well Clamp.

Table 1. Wells for L7224A,C; L7248A,C,L Controllers.

Table 2. Sensors for L7224A,C and L7248A,C,L Controllers.

INSTALLATION

When Installing this Product...1. Read these instructions carefully. Failure to follow

them could damage the product or cause a hazardous condition.

2. Check the ratings given in the instructions and on the product to make sure the product is suitable for your application.

3. The installer must be a trained, experienced service technician.

4. After installation is complete, check out product operation as provided in these instructions.

5. Set High Limit, Low Limit and Low Limit Differential to the settings recommended by the boiler OEM.

6. Record the maximum High Limit setting from the replaced controller in the text box provided on the cover insert label.

7. Record the High Limit setting at time of installation in the text box provided on the cover insert label.

WARNINGElectrical Shock Hazard.Can cause severe injury, death or property damage.Disconnect power supply before beginning installation to prevent electrical shock or equipment damage.

MountingThe L7224A,C and L7248A,C,L models are available in a well-mount, horizontal position, vertical position, or flush mounted remote from the well versions. Dimensions for the variety of mounting options are shown in Fig. 1. Note that each identity will have only a single mounting option.

Fig. 1. L7224A,C; L7248A,C,L mounting dimensions in inches (mm).

IMPORTANT

Immersion well must fit sensing element and sensor must rest against bottom of well.

Part Number

Spud Sizein. (mm)

Insertion in. (mm)

Insulation in. (mm)

123869A 1/2 (12.7) NPT 3 (76.2) 1-1/2 (38.1)

123870A 3/4 (19.05) NPT 3 (76.2) 1-1/2 (38.1)

Part NumberLength in.

(mm) Application

50001464-001 12 (304.8) Well-mounted controls

50001464-003 24 (609.6) Flush-mounted controls

50001464-004 36 (914.4)

50001464-005 48 (1219.2)

M22147B

3/4(75)

5-11/16(145)

3/8(10)

2-5/8 (67)

7-1/8(181)

6-1/2(166)

3-13/32 (86)

2x 1/4 (7) x 3/8 (9)

1/16 (2)

1-3/16(30)

3-1/32(77)

2-1/16 (53)

1-1/8 (29)

4-1/4 (109)


3 68-0281�—16

New InstallationOrder well assemblies separately; see Table 1 and form no. 68-0040, Immersion Wells and Compression Fittings for Temperature Controllers. Boilers usually have tappings that allow the well to be mounted horizontally so boiler water of average temperature can circulate freely over the well.

1. Turn off all power and drain the boiler, if applicable.2. If no tapping is provided, prepare properly sized and

threaded tapping near the top of the boiler.3. Sparingly coat the well threads with pipe dope.

NOTE: Do not attempt to tighten by using the case as a handle.

4. Install the well in the boiler tapping and tighten securely.

5. Refill boiler and check for water leakage.6. Loosen but do not remove the well clamp screw.7. Fit the case into the well so the clamp on the case

slides over the flange on the well.8. Securely tighten the clamp screw.9. Insert the sensor element into the well until it bot-

toms. See Replacement Sensor Installation section for details. (If necessary, slightly bend the wire inside the case to hold the sensor against the bot-tom of the well.)

10. Turn power ON.11. Set High Limit, Low Limit and Low Limit Differential

to the settings recommended by the boiler OEM. (See OPERATION section.) (See INSTALLATION steps 6 and 7.)

12. On L7248L models, adjust ELL option to match your configuration (see OPERATION section, and Fig. 11 and 13).

IMPORTANT

Best thermal response is obtained with a well that snugly fits the sensor. Insert the sensor until it rests against the bottom of the well. Use a well of correct length and bend the wiring, if neces-sary, to hold the bulb against the bottom of the well.

If the well is not a snug fit on the sensor, use the heat-conductive compound (furnished with TRADELINE® models) as follows: Fold the plastic bag of compound lengthwise and twist it gently. Then snip off end of bag and work the open end of the bag all the way into the well. Slowly pull out the bag while squeezing it firmly to distribute compound evenly in the well. Bend the wiring, if necessary, to hold the sensor against the bottom of the well and to hold outer end of the sensor in firm contact with the side of the well. See Fig. 2. Wipe excess compound from the outer end of the well.

Fig. 2. Position of sensor in immersion well.

Flush-Mounted Aquastat ReplacementTurn off all power and remove the old control. Refer to the cover insert of the old control to identify and tag each external lead as it is disconnected. If the old well is unsuitable for the new installation, remove it and replace it with a suitable new well. If the old well is suitable, use it.

Well-Mounted Aquastat ReplacementTurn off all power and remove the old control. Refer to the cover insert of the old control to identify and tag each external lead as it is disconnected. If the old well is unsuitable for the new installation, remove it and proceed with instructions for new installation. If the old well is suitable, use it.

1. Loosen, but do not remove, the well clamp screw on the side of the control case.

2. Position immersion well clamp snugly over the flange of the adapter and tighten the clamp screw.

3. Insert the sensor into the well as shown in Fig. 2 or 3. (See Replacement Sensor Installation section for details.)

Fig. 3. Circuit board, showing sensor connection and well holes for horizontal mount models.

SENSOR WIRES

IMMERSION WELL CLAMP SCREW

IMMERSIONWELL CLAMP

M16120

HEAT-CONDUCTIVE COMPOUND(OPTIONAL)

CONTROLLER CASE

BOILER

IMMERSION WELL

SENSOR

C1

B1 ZCL2

LINE

C2

ZR L1 B2

T T3 2 1

THERMOSTATTERMINALS

ENVIRACOMTM

TERMINALSSENSOR HOLES

FUSE

M32186

SENSORCONNECTOR

DISPLAY


68-0281�—16 4

Fig. 4. Replacement sensor installation.

Replacement Sensor InstallationTurn off all power and:

1. Carefully disconnect sensor from circuit board by pulling gently on the connector.

2. Gently pull sensor from thermo well and through cir-cuit board by pulling on leadwires.

3. Carefully align replacement sensor with hole in cir-cuit board and guide through Aquastat case and into well. (See Fig. 5).

4. Make sure sensor is fully seated to bottom of well (See Fig. 4). Use a small pencil to measure depth of sensor in well, if necessary.

5. Connect sensor to circuit board by pressing con-nector on sensor unit into mating connector on cir-cuit board (See Fig. 5).

6. For remote sensors (flush-mounted Aquastat Con-trollers) be sure to use 121571AA Clamp (see Accessories) to securely hold sensor in place.

Fig. 5. Circuit board, showing sensor connection and well holes for vertical mount models.

FuseThe 1 Amp fuse located near the transformer is intended to protect the EnviraCOM circuit from incorrect wiring. The Aquastat will continue to function should the fuse blow or be removed though no EnviraCOM communication will be possible on the bus and Err 6 will be displayed. See Table 10.

WIRING

WARNINGElectrical Shock Hazard.Can cause serious injury or death.Disconnect power supply before making wiring connections to prevent electrical shock or equipment damage.

All wiring must comply with local electrical codes and ordinances. Do not exceed the specifications in the Application section when wiring this control. Use wire rated for 194 °F (90 °C) or higher.

IMPORTANT

The terminals on these Aquastat Controllers are approved for use with copper wire only.

Follow the appropriate wiring diagrams shown on the inside of the front cover of the L7224A,C; L7248A,C,L or in Fig. 8�–13.

Refer to Fig. 6 for Connections for the optional Outdoor Reset Module and the Domestic Hot Water (DHW) module. In subsequent wiring diagrams these modules will be displayed with a dotted line signifying that they are optional.

Fig. 6. Wiring the Outdoor Reset Module and the Domestic Hot Water Module.

OPERATION

GeneralThe L7224A,C and L7248A,C,L Oil Electronic Aquastat Controllers are primary safety limit-rated devices designed for use with oil fired boilers with line voltage burners and circulators. Many boilers do not include wiring or control compartments as part of the design, but are provided with an integral, replaceable, immersion well that is the mounting hardware for the Aquastat Controllers. Wiring to the other controls is done through flexible metal conduit.

For boilers that do include a remotely (flush) mounted control, the wiring may be completed with conduit or routed behind the boiler sheet metal.

SENSOR WIRES

M22026

HEAT-CONDUCTIVE COMPOUND(OPTIONAL)

BOILER

IMMERSION WELL

SENSOR

C1

B1

ZC

L2

LIN

E

C2

ZR

L1

B2

T

T 3

2

1

THERMOSTATTERMINALS

ENVIRACOMTM

TERMINALS

DISPLAY

SENSORCONNECTOR

SENSOR HOLES

FUSE

RELAYS

M32187

C1

B1

ZC

L2

LIN

E

C2

ZR

L1

B2

T

T 3

2

1

1 2 3 OT OT

C7089U1006OUTDOORSENSOR

W8735Y1000 OR W8735S1000 OUTDOOR RESET MODULE(W8735S1000 SHOWN)

1 2 3 TS TS

W8735S1008DOMESTIC HOTWATER MODULE

32003971-003TEMPERATURESENSOR

M34961


5 68-0281�—16

A separate electromechanical high-limit is not required in a system that uses this control to meet Underwriters Laboratories Inc. requirements for oil-fired boiler assemblies, UL 726.

On the L7224 models, the High Limit, Low Limit, Low Limit Differential, and Anti Short-Cycle time can be adjusted to the setting recommended by the boiler OEM. On the L7248 models, the High Limit, and Anti Short-Cycle time are also adjustable, see �“Adjusting Settings�”.

The overall range of the High Limit is from 130 °F to 240 °F (54 °C to 116 °C). Select devices may have different ranges. Some models have limited ranges on the High Limit setpoint; this limited range is listed on the device label.

Some models also have a Low Limit and Low Limit Differential adjustment. The range of the Low Limit is from 110 °F to 220 °F (43 °C to 104 °C). Select devices may have different ranges.

The Zr setting can be set to DHW, Zoning, or for tankless coil applications depending on the L7224/L7248.

If an Outdoor Reset Module is installed, the reset curve can be set by entering the minimum outdoor temperature, minimum (boiler) temperature, and maximum outdoor temperature on the 3-digit display. The range of the minimum outdoor temperature is from -40 °F to 40 °F (-40 °C to 4.4 °C) and has a default setting of 0 °F (-18 °C). The range of the maximum outdoor temperature is from 30 °F to 70 °F (-1.1 °C to 21.1 °C) and has a default setting of 40 °F. The range of the minimum (water or boiler) temperature is from 80 °F to 180 °F (26.7 °C to 82.2 °C) and has a default setting of 130 °F. See the �“Outdoor Reset Module�” Installation Instructions (form number 69-2335) for more information on setting the boiler reset curve and all related parameters.

The L7224A,C and L7248A,C,L are designed for use with 24 Vac electronic and electromechanical thermostats or EnviraCOM�™ enabled thermostats, and have screw-type terminals for easy field connection.

Adjusting SettingsTo discourage unauthorized changing of Aquastat settings, a procedure to enter the ADJUSTMENT mode is required. To enter the ADJUSTMENT mode, press the UP, DOWN, and I buttons (Refer to Fig. 5) simultaneously for three seconds. Press the I button until the feature requiring adjustment is displayed:

* Settings available for adjustment on the 3-digit display only if a W8735Y1000 or W8735S1000 Outdoor Reset Kit is installed.

**Settings available for adjustment only when the W8735Y1000 or W8735S1000 Outdoor Reset Kit is NOT installed.

Then press the UP and/or DOWN buttons to move the set point to the desired value, to change between °F and °C, or to enable (On) or disable (Off) the External Low Limit. After 60 seconds without any button inputs, the control will automatically return to the RUN mode.

DisplayIn the RUN mode, the Aquastat will flash �“bt�” (boiler temp) followed by the temperature (i.e., 220), followed by °F or °C.

To read boiler settings, press the I key to read the parameter of interest. For example, press I and High Limit (HL) is displayed, followed by a three-digit number, i.e., 220, followed by °F or °C. Pressing the I button again (on L7224 models) will display the Low Limit (LL) followed by a three-digit number and the corresponding degree designator. See Display Readout, Table 4.

After approximately 60 seconds without any key presses, the display will enter a dim display mode. To return to the bright display mode, simply press any key.

Table 3. Adjustable Features.

Display Definition

HL_ High Limit.

Hdf High Limit Differential.

LL_ Low Limit. (L7224A, C)

Ldf Low Limit Differential (L7224A, C)

ELL External Low Limit (L7248L only)

duu ZR input configured as external Domestic Hot Water (DHW) request (ON/OFF) (L7224A,C/L7248L)

ASC Anti Short-Cycle Timeout (seconds); �“OFF�” is disabled.

otL* Outdoor Temperature Low (minimum) parameter for the outdoor reset curve (°F or °C)

otH* Outdoor Temperature High (maximum) parameter for outdoor reset curve (°F or °C)

btL* Boiler Temperature Low (minimum) parameter for outdoor reset curve

bP* Boost Period (minutes). �“OFF�” is displayed if Boost is inactive

bS* Boost step (°F or °C) shown only if Boost is active (bP=ON)

UUS* Warm Weather Shutdown Temperature (°F or °C)

tPL** Thermal Purging Limit Temperature (°F or °C), �“OFF�” if disabled

tPt** Termal Purging Time Delay (minutes), shown only if tPL is enabled

PC Pump Cycling (ON / OFF)

F-C Temperature units (°F or °C)


68-0281�—16 6

1 Display shows local setting; not the setting as modified by an external enviracom control.

2 Settings are viewable only if the outdoor reset module and out-door temperature sensor are installed and functioning properly.

3 Settings are viewable only if the domestic hot water module and sensor are installed and functioning properly.

OperationThe L7224 and L7248 models can be in any of four operational states: Normal, High Limit, Low Limit and Error. The controller moves back and forth from High Limit to Normal to Low Limit state as part of normal operation. Only devices having High Limit settings are restricted to the High Limit and Normal states. However, the controller will enter the Error state when there is an abnormal condition. The operating states are:

1. Normal: Boiler temperature went below the High Limit setting (minus the Differential) and has not exceeded the High Limit setting; or, the boiler temperature went above the Low Limit setting and

has not gone below the Low Limit setting (minus the Differential); or, ZR input is not powered with 120 Vac (only L7248L with ELL set On).

2. High Limit: Boiler temperature went above the High Limit setting and has not dropped below the High Limit setting (minus the Differential).

3. Low Limit: Boiler temperature went below the Low Limit setting (minus the Low Limit Differential) and has not gone above the Low Limit setting; or, ZR input is powered with 120 Vac (only L7248L with ELL set On).

4. Error: The controller has detected an error condition (e.g., open sensor) and has shut down the burner output. The ZC output is energized. The controller continues to monitor the system and automatically restarts if the error condition clears. Refer toTable 4.

The operating sequence for the L7224/L7248 is shown inTable 6�–9.

High Limit ControllerThe High Limit opens and turns off the burner when the water temperature reaches the setpoint. The High Limit automatically resets after the water temperature drops past the setpoint and through the Differential. The L7248 models have High Limit Differential presets of 15 °F (8 °C). The L7224 models have High Limit Differential presets of 10 °F (6 °C).

Low Limit and Circulator ControllerOn a temperature rise, with the adjustable Differential at the default setting of 10 °F (6 °C), the burner circuit breaks and the circulator circuit makes (assuming no call for heat is present) at the Low Limit setpoint. On a temperature drop of 10 °F (6 °C) below the Low Limit setpoint, the burner circuit makes and the circulator circuit breaks. See Fig. 7.

Fig. 7. Setpoints and differentials.

Anti Short-Cycle FeatureThe Anti Short-Cycle feature allows for field selection of a delay time between burner cycles. Should a call for heat occur following the end of the previous heat cycle and before the Anti Short-Cycle delay time is expired, the circulator will be allowed to run, but the burner will be held off until the time has elapsed. The range of the Anti Short-Cycle time is from OFF to five minutes.

Table 4. Display readout definitions.

Text Description Display

Err Error Code (if one is present)

bT Boiler Temperature

HL High Limit 1

HdF High Limit Differential

LL Low Limit (L7224 only)

Ldf Low Limit Differential (L7224 only)

tt Local Thermostat Status

ttE EnviraCOM Thermostat Status

brn B1 (Burner) output (ON or OFF)

Cir C1 (Circulator) output (ON or OFF)

ZC ZC (Zone Control) output (ON or OFF)

Zr ZR (Zone Request) Call for HEAT (ON or OFF)

ELL External Low Limit Enabled (L7248L only)

duu ZR Configured as Domestic Hot Water Request (L7224, L7248L only)

ASC Anti Short-Cycle Timeout

bSP Boiler Set-Point 2

dhc DHW Module Connected 3 (YES or NO)

ot Outdoor Temperature 2

otL Outdoor Temperature Low 2

otH Outdoor Temperature High 2

btL Boiler Temperature Low 2

bP Boost Period 2

bS Boost Step 2

UUS Warm Weather Shutdown Temperature 2

LOW LIMIT SETTING

HIGH LIMITSETTING

SWITCH BREAKS ON TEMPERATURE RISE. BURNER TURNS OFF. CIRCULATOR OPERATES ON A CALL FOR HEAT.

SWITCH MAKES ON TEMPERATURE FALL.BURNER OPERATES ON A CALL FOR HEAT.

WITH NO HEATING DEMAND, SWITCH BREAKS ON TEMPERATURE RISE.

SWITCH MAKES ON TEMPERATURE FALL, BURNER IS ON TO MAINTAIN MINIMUM WATER TEMPERATURE. CIRCULATOR IS OFF.

M23364

WHEN WATER REACHES LOW LIMIT SETTING, THE BURNER SHUTS OFF OR THE CIRCULATOR PUMP STARTS (WHEN CALLING FOR HEAT).

1

1

10ºF (6ºC) DIFFERENCE

L7224: 10°F (6°C) DIFFERENCEL7248: 15°F (8°C) DIFFERENCE


7 68-0281�—16

NOTE: This feature is blocked if a Domestic Hot Water demand occurs. Domestic Hot Water demands are serviced immediately, without any delay.

NOTE: When the Aquastat is connected to the oil primary and/or thermostat via the EnviraCOM bus, the Anti Short-Cycle time does not apply to recycle events such as loss of airflow or flame. It applies only to loss of demand.

ZR-Domestic Hot Water (DHW) RequestThe ZR terminal can be selected to service an indirect water heater heat request. This parameter is set via the 3 digit display (see Adjusting Settings section of this document). A heat request via the ZR terminal will have priority over all other features such as the Anti Short-Cycle feature or those enabled by the Outdoor Reset Module (See form #69-2335 for more information).

Frost ProtectionThe Frost Protection function protects the boiler and potentially the boiler plumbing from possible damage which may occur should the water in the system begin to freeze. The Frost Protection feature is enabled only in the L7248 (cold start models). The feature default setting is enabled (ON), but can be disabled using the 3-digit display. See �“Adjusting Settings�” on page 5.

When the Boiler temperature drops to the Frost Protection Limit temperature (fixed 40 °F), the burner is forced on. The Circulator and ZC outputs remain in the same state as before the Frost Protection function was enabled. They can be either ON or OFF during the Frost Protection cycle.

When the Boiler temperature reaches the Frost Protection Limit temperature plus a fixed 10 °F differential, the burner is turned off unless requested to stay on due to a different demand.

Thermal Purge OperationThe intent of thermal purge is to insure usable residual heat in the boiler is circulated until it is sufficiently depleted from the system before the burner is allowed to fire. To that end, on a call for heat, the burner is held off while the circulator runs until the boiler temperature drops to the thermal purge temperature or a time delay is exceeded. Both of these parameters are adjustable. When the boiler temperature reaches the thermal purge temperature, the burner is allowed to fire. Thermal purge is only applied to cold start Aquastat models (L7248) and will not interfere with domestic hot water call for heat or boilers equipped with Honeywell outdoor reset accessories. For warm start models where a Low Limit must be set, thermal purge is not applied.

In addition to the thermal purge temperature and thermal purge time delay parameters, two other conditions release the Aquastat from thermal purge in order to maintain comfort in the space:�• The boiler temperature has dropped 10 °F from the

beginning of the thermal purge.�• Boiler temperature is cooling at a rate greater than

5 °F/minute while the circulator is running.The thermal purge feature applies to single zone as well as multi-zone applications.

Thermal Purge SettingsSome thermal purge parameters are configurable using the 3 digit display. See �“Adjusting Settings�” on page 5. Thermal purge may be disabled by setting the thermal purge temperature limit to "OFF".

Thermal Purge and Domestic Hot WaterThe thermal purge feature is automatically disabled whenever there is a call for domestic hot water either from the Zr terminal or from the DHW Module to insure hot water is available in a timely manner. See �“ZR-Domestic Hot Water (DHW) Request�” on page 7.

Pump CyclingThe Pump Cycling feature exercises the system pump for 15 seconds after a non-adjustable five day period of no boiler activity. The Pump Cycling feature default setting is enabled (ON) but can be disabled (OFF) using the 3-digit display. See �“Adjusting Settings�” on page 5.

CHECKOUTPut the system into operation and observe at least one complete cycle to make sure that the controller operates properly. See TROUBLESHOOTING section to use LED to assist in determining system operation.

TROUBLESHOOTINGWhen attempting to diagnose system performance, reference to the LED display can help to identify specific areas not working properly. The LED display will scroll Err, followed by a digit (1-8). Refer to Table 10 and 11 for a description of each error and suggested actions.

Table 5. Thermal Purge Settings.

Parameter name Minimum value Maximum Value Default

Boiler temperature drop Not adjustable Not adjustable 10 °F

Thermal purge temperature limit 120 °F (or OFF) 160 °F 140 °F (L7248)

Thermal purge temperature rate of drop Not adjustable Not adjustable 5 °F/minute

Thermal purge time delay 1 minute 10 minutes 2 minutes


68-0281�—16 8

Fig. 8. L7224A,C; L7248L single heat zone with indirect water tank and circulators. Optional Outdoor Reset Module.

C1

B1

ZC

L2

LINE

C2

ZR

L1

B2

T

T 3

2

1

M32023A

L1(HOT)

SENSOR

LINEVOLTAGE

CIRCULATOR

LINEVOLTAGE

OIL BURNERRELAY

L2

OUTDOOR RESET MODULE IS OPTIONAL. W8735S1000 WIRED OUTDOOR RESET MODULE SHOWN.

FOR BEST PERFORMANCE SET DUU=”ON”.

1

1 2 3 OT OT

C7089UOUTDOORSENSOR

1

W8735Y1000 ORW8735S1000

INDIRECTTANK CIRCULATOR

LINE VOLTAGE INDIRECTTANK AQUASTAT

L1(HOT)

L2

2

2


9 68-0281�—16

* Error condition only available when the Outdoor Reset Module is installed.

Table 6. L7224/L7248 Controller Operating Sequence.

Action System Response

Thermostat calls for heat. Circulator starts when water temperature is above Low Limit setting (if applicable) or above the Thermal Purge Temperature Limit (tPL) if Thermal Purge is enabled. Boiler temperature is checked. Burner starts when water temperature is below High Limit setting minus the differential or at or below the Thermal Purge Temperature Limit (tPL) for cold start boilers if the Thermal Purge Temperature Limit is enabled. If tPL is enabled, the burner may also start if the boiler temperature is cooling at 10 ºF or greater per minute or the Thermal Purge Time Delay (tPt) has expired.If Anti Short-Cycle Time is enabled, the burner does not start until the set Anti Short-Cycle Time between cycles expires after the previous call for heat was satisfied.

Boiler temperature exceeds the High Limit. Burner is turned off. Burner restarts when the water temperature drops below the High Limit setting minus the Differential. If Thermal Purge is enabled, the burner is turned on when either the Thermal Purge Temperature Limit is reached, the Thermal Purge Time Delay has expired or the boiler temperature cooling rate exceeds 10 ºF/minute.

Thermostat is satisfied. Circulator and burner turn off.

Boiler temperature drops below the Low Limit setting minus the differential (if applicable).

Burner is turned on, Circulator is turned off. Burner stops when the water temperature exceeds the Low Limit setting. Power to Zc is removed.

Error condition1-5.

If an error condition is detected, all outputs except ZC are shut down. Burner is off. Control continues to function and restarts when error is corrected.During the error check sequence, the system checks for drift in the sensor and corrosion in the connections.

Error condition 6. EnviraCOM communication is not available.

Error condition 7. The control has reset the High Limit, Low Limit and Differential setting to a default setting and will continue to run at those settings.Performance of the system will be degraded.

Error condition 8. If the error condition is detected, all outputs except ZC are shut down. Burner is off. Control continues to function and restarts when all three user keys have been pressed longer than 60 seconds.

Error condition 9*. System continues to run with no outdoor reset functionality

Error condition 10*. System continues to run with outdoor reset parameters enabled as programmed. Error cleared automatically.

Error condition 11*. System continues to run with boiler temp set to High Limit.

Table 7. L7224/L7248 Controller Operating Sequence with multiple zones connected through the ZR terminal.


Zone Request (ZR) terminal is connected to L1 (Zone calls for heat).

Boiler temperature is checked. Burner starts when water temperature is below High Limit setting or at or below the Thermal Purge Temperature Limit (tPL) for cold start boilers if the Thermal Purge Temperature Limit is enabled. If tPL is enabled, the burner may also start if the boiler temperature is cooling at 10 ºF or greater per minute or the Thermal Purge Time Delay (tPt) has expired. Anti Short-Cycle Time is applied, see Table 6.

Boiler temperature exceeds the High Limit. Burner is turned off. Burner restarts when the water temperature drops below the High Limit setting minus the Differential. If Thermal Purge is enabled, the burner is turned on when either the Thermal Purge Temperature Limit is reached, the Thermal Purge Time Delay has expired or the boiler temperature cooling rate exceeds 10 ºF/minute.

Zone Request input is de-energized (Zones are satisfied).

Burner turns off.

Boiler temperature drops below the Low Limit setting minus the differential (if applicable).

Burner turns on and Zone Control is de-energized. Burner turns off and Zone Control is re-energized when the water temperature exceeds the Low Limit setting.


68-0281�—16 10

.

a Warnings are generated to enunciate the system is not operating optimally, but the Aquastat is still operating and maintaining boiler temperature. In the instance where an Outdoor Reset Module is used, the warnings may indicate a reset curve setting error one or more features is not running optimally, and the Aquastat is reverting to default settings or has stopped running the Outdoor Reset algorithms. The warnings are cleared when the issue(s) is resolved.

b To clear Err 8 condition, depress and hold all three user keys simultaneously for 60 seconds. Err 8 condition clears and display returns to normal. Err 8 condition is designed to catch welded relays on the Aquastat and will normally only occur near end of life for the control. If Err 8 condition has occurred early in the controls life, be sure to check for voltage feedback to B1 when B1 should be off and check current draw on b terminal to be sure oil burner is not draw-ing excessive current. Err 8 condition will keep repeating if B1 fault is not cleared.

Table 8. Controller Operating Sequence with External Low Limit device connected trough the ZR terminal.


Zone Request (ZR) terminal is connected to L1 (External Low Limit call for heat).

Boiler temperature is checked. Burner starts when water temperature is below High Limit setting. Circulator turns off.

Boiler temperature exceeds the High Limit. Burner is turned off. Burner restarts when the water temperature drops below the High Limit setting minus the Differential.

Zone Request input is de-energized (External Low Limit is satisfied).

Burner is turned off.

Table 9. L7224 Controller Operating Sequence with Domestic Hot Water connected trough the ZR terminal.


Zone Request (ZR) terminal is connected to L1 (Domestic Hot Water calls for heat).

Boiler temperature is checked. Burner starts when water temperature is below High Limit setting.

Boiler temperature exceeds the High Limit. Burner is turned off. Burner restarts when the water temperature drops below the High Limit setting minus the Differential.

Zone Request input is de-energized (Domestic Hot Water is satisfied).

Burner is turned off.

Table 10. LED Error Codes.

Aquastat Error Code Cause/Action

EnviraCOM Alarm

Err1 Aquastat sensor fault; check water sensor. 18

Err2 ECOM fault; check EnviraCOM�™ wiring. 18

Err3 Excessive electrical noise or frequency out of range. Hardware fault; replace controller. 18, 58

Err4 B1 fault; check B1 wiring/voltage. 64

Err5 Low Line; check L1-L2, 110 Vac. 59

Err6a Warning: Fuse; check ECOM wires, replace fuse. 92

Err7 Warning: EEPROM, HL, LL, Hdf, Ldf; reset to default values. N/A

Err 8b Repeated B1 fault (voltage present at B1 when output is turned off); check B1 wiring/voltage. 25

Err9a Warning: Outdoor Reset System failure; communication to Outdoor Reset Module lost, Outdoor Reset Module failure, multiple outdoor temperature sensors detected on the bus, or outdoor temperature sensor failure. Check EnviraCOM wiring (1, 2, 3), check sensor wiring.

50, 53, 149

Err 10a Warning: Boost Failure; Boost Mode active at least once per cycle for the last 60 consecutive cycles. Check Outdoor Reset curve settings.

150

Err 11a DHW Module/Sensor failure; communication to DHW Module lost, DHW Module failure, or temperature sensor failure. Check EnviraCOM wiring (1, 2, 3), check sensor wiring.

146, 147, 148

Table 11. Troubleshooting Guide

System Condition

Diagnostic Condition Check Action

Boiler is cold, house is cold.

Display is OFF. 120 Vac System power. Turn system power on.

Display is ON. 24 Vac T-T No 24 V; replace control.

24 V present; disconnect thermostat, short T-T.

Boiler starts, check wiring and thermostat.

120 Vac at B1-B2 �• If no, replace control.�• If yes, check burner and wiring.

Refer to Err on display. �—


11 68-0281�—16

Fig. 9. L7224A,C multizone system with circulator connections.

Boiler is hot, house is cold.

Display is ON. 120 Vac at C1-C2 �• 120 Vac at C1-C2, check wiring to pump.�• Wiring OK, is pump running?�• If not, replace the pump.�• If pump is running, check for trapped air or

closed zone valves.

Boiler below the Low Limit temperature, wait for boiler to go above Low Limit temperature.

�—

Boiler above LL? If yes, check for 120 Vac between ZC and L2.

�• If no 120 Vac, replace control.�• If yes, check zone relays, circulators and

wiring.

ELL setting (L7248L only) �• Set ELL to Off for multizone system (see Fig. 11).

�• Set ELL to On for External Low Limit (see Fig. 13).

Boiler above LL? If yes, check 120 Vac at ZR-L2 (only L7248L with ELL set On)

�• If no 120 Vac, check C1-C2 (see above).�• If yes, check the External Low Limit control.

Boiler is hot, no hot potable water.

Display is ON. Boiler Demand signal from the water heater (either 120 Vac at ZR-L2, or 0 Vac on T-T; depends on installation and �“duu�” setting)

�• 24 Vac on T-T (or 0 Vac on ZR-L2), check wiring to water heater

�• Wiring OK, check the water heater

�“duu�” setting �• Set duu to ON if 120 Vac water heater demand is connected to ZR

�• Set duu to OFF if open/closed water heater demand is connected to T-T

Check DHW Module and DHW Sensor

�• DHW Module not properly connected and/or DHW Sensor improperly positioned

Table 11. Troubleshooting Guide

System Condition

Diagnostic Condition Check Action

M27115

POWER SUPPLY. PROVIDE DISCONNECTMEANS AND OVERLOADPROTECTION AS REQUIRED.

1

CONTROL CASE MUST BE CONNECTEDTO EARTH GROUND. USE GROUNDINGSCREW PROVIDED.

2

C1

B1

ZC

L2

LIN

E

C2

ZR

L1

B2

T

T 3

2

1

SENSOR

LINEVOLTAGE

CIRCULATOR

LINEVOLTAGE

OIL BURNERRELAY

2

LOWVOLTAGETHERMOSTAT

L7224

3

L1 (HOT)L2

1

2

1

4

5

6

ZONE 2LOW VOLTAGETHERMOSTAT

R845A RELAY ZONE 2

ZONE 2CIRCULATOR

TO ADDITIONAL R845A RELAYS FOR OTHER ZONES


68-0281�—16 12

Fig. 10. L7224A,C single zone system with circulator and indirect water tank with EnviraCOM�™ thermostat.

M32025B

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

OPTIONAL FEATURE ON SELECT MODELS.

REFER TO DEVICE LABEL FOR WIRE COLOR CODE.

VALVE IS OPTIONAL ON SPECIFIED MODELS.

1

2

3

C1

B1

ZC

L2

LIN

E

C2

ZR

L1

B2

T

T 3

3

3

2

2

2

1

1

1

SENSOR

LINEVOLTAGE

CIRCULATOR

L7224

3

4

3

35

BURNERMOTOR

IGNITER

VALVE

BURNERMOTOR

IGNITER

VALVE

CADCELL

JUNCTIONBOX

TO REMOTEALARMCIRCUIT

ENVIRACOM™TERMINAL

TH9421C

R7184/R7284

LIMIT

L1

L2

2CADCELL

T

T3

2

1

L1 (HOT) L21

LEGEND SCREW TERMINAL 1/4 IN. (6 MM) QUICK CONNECT TERMINAL

SOLDERLESS WIRE CONNECTION

ENVIRACOM™ TERMINAL 3 IS ALSO THE FIRST THERMOSTAT TERMINAL.

OPTIONAL OUTDOOR RESET MODULE AND OUTDOOR SENSOR. W8735S1000 WIRED OUTDOOR RESET MODULE SHOWN.

DUU MUST BE SET TO “ON” ON THE AQUASTAT.

5

6

1 2 3 OT OT


6

W8735Y1000 ORW8735S1000

7

INDIRECTTANK CIRCULATOR

LINE VOLTAGE INDIRECTTANK AQUASTAT

L2

7

4


13 68-0281�—16

Fig. 11. L7248L multizone system with circulator connections.

M29655A

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.1

CONTROL CASE MUST BE CONNECTED TO EARTH GROUND. USE GROUNDING SCREW PROVIDED.2

3

L1 (HOT) L2

1

2

1

4

5

6

ZONE 2LOW VOLTAGETHERMOSTAT

R845A RELAY ZONE 2

ZONE 2CIRCULATOR

TO ADDITIONAL R845A RELAYS FOR OTHER ZONES

C1

B1

ZC

L2

LINE

C2

ZR

L1

B2

T

T 3

2

1

SENSOR

LINEVOLTAGE

CIRCULATOR

LINEVOLTAGE

OIL BURNERRELAY

2

LOW VOLTAGETHERMOSTAT

L7248L

ELL=OFF


ENVIRACOM TERMINALS.

OPTIONAL DOMESTIC HOT WATER MODULE AND TEMPERATURE SENSOR.

3

4

5

1 2 3 OT OT


W8735Y1000 ORW8735S1000

1 2 3 TS TS

W8735S1008DOMESTIC HOTWATER MODULE


4ENVIRACOMTERMINALS

3

5


68-0281�—16 14

Fig. 12. L7224/L7248 multizone system with Outdoor Reset and Domestic Hot Water Modules (indirect tank applications).

M32024A

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

OPTIONAL FEATURE ON SELECT MODELS.

REFER TO DEVICE LABEL FOR WIRE COLOR CODE.

VALVE IS OPTIONAL ON SPECIFIED MODELS.

ENVIRACOM™ TERMINAL 3 IS ALSO THE FIRST THERMOSTAT TERMINAL.

1

2

3

C1

B1

ZC

L2

LINE

C2

ZR

L1

B2

T

T 3

2

1

SENSOR

LINEVOLTAGE

CIRCULATOR

L7224

3

4

3

35

BURNERMOTOR

IGNITER

VALVE

BURNERMOTOR

IGNITER

VALVE

CADCELL

JUNCTIONBOX

TO REMOTEALARMCIRCUIT

ENVIRACOM™TERMINAL

R7184/R7284

LIMIT

L1

L2

2CADCELL

T

T3

2

1

L1 (HOT) L21

LEGEND SCREW TERMINAL 1/4 IN. (6 MM) QUICK CONNECT TERMINAL

SOLDERLESS WIRE CONNECTION


OPTIONAL DOMESTIC HOT WATER MODULE.

WIRE ONLY THE ENVIRACOM TERMINALS (1, 2, 3) ON OIL PRIMARYIF CONNECTING TO REMOTE DIAGNOSTICS, OTHERWISE CONNECT A JUMPER BETWEEN THE TT TERMINALS.

ZONE PANEL TERMINALS MAY HAVE DIFFERENT LABEL. CHECK PANEL MANUFACTURER SPECIFICATIONS FOR WIRING INSTRUCTIONS.

6

7

8

1 2 3 TS TS


7

W8735S1008

9

MULTI-ZONERELAY PANEL

T T

4

5

1 2 3 OT OT

C7089UOUTDOORSENSOR

6

W8735Y1000 ORW8735S1000

89


15 68-0281�—16

Fig. 13. L7248L External Low Limit connections.

M27113

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOADPROTECTION AS REQUIRED.

1

CONTROL CASE MUST BE CONNECTED TO EARTH GROUND. USE GROUNDING SCREW PROVIDED.

2

W

L1 (HOT)L2

1

B

R

C1

B1

ZC

L2

LIN

E

C2

ZR

L1

B2

T

T 3

2

1

SENSOR

LINEVOLTAGE

CIRCULATOR

LINEVOLTAGE

OIL BURNERRELAY

2

LOWVOLTAGETHERMOSTATL7248L

ELL=ON

L6006LOW LIMITCONTROLLER


Automation and Control SolutionsHoneywell International Inc.

1985 Douglas Drive North

Golden Valley, MN 55422

customer.honeywell.com

® U.S. Registered Trademark© 2013 Honeywell International Inc.68-0281�—16 M.S. Rev. 09-13Printed in United States

183 Water Street • New Haven, CT 06511 • Phone (203) 776-0473 • FAX (203) 773-1019 • www.hydrolevel.com

MODEL 3250-Plus

Temp Limit / LWCO Controlwith Thermal Targeting™

for Water Boilers120 VAC Operating Voltage

PATENT NO. 7,891,572

WARNING Electrical shock hazard. To prevent electrical shock, death orequipment damage, disconnect power supply before

installing or servicing control. Only qualified personnel may install or service this control inaccordance with local codes and ordinances. Read instructions completely before proceeding.

CAUTION To prevent seriousburns, boiler

should be thoroughly cooled before installing orservicing control.

WARNING Frozen pipes/water damage. Central heating systems are prone to shut down as a result of power or fuel outages,safety related fault conditions or equipment failure. Installation of freeze protection monitoring or other precautions

is recommended for unattended dwellings in climates subject to sustain below-freezing temperatures.

Three FunctionDesignTemperature Limit ControlDesigned for cold start and tanklesscoil boilers.Low Water Cut-OffProvides protection against potentiallydangerous low water conditionswhen installed with the HydrolevelElectro-Well™ (see page 2 for details).Boiler Reset Control• Thermal Targeting – On-board micro-

processor adjusts boiler temperaturebased on heating demand.

• Outdoor Reset Ready – Compatible withHydrolevel OS-100 Outdoor Sensor Kit(sold separately) for outdoor reset andwarm weather shut-down functionality.

INSTALLATION INSTRUCTIONSand OPERATING MANUAL

• Saves Fuel – Features Thermal Targeting™ technology andThermal Pre-Purge capability

• Outdoor Reset Ready – Provides Outdoor Reset and Warm WeatherShut-Down capability with the addition of Hydrolevel OS-100 OutdoorSensor Kit (sold separately)

• Universal Design – Replaces common cold-start and triple-actionAquastats*

• Operating Indicators – LEDs, Dynamic Display and Test Button providecontinual and on-demand status checks

• Prioritizes Domestic Hot Water – Gives priority to low limit setting or tocalls from indirect water heater

• Reduces Condensation – Holds circulator off until boiler reaches 125°F• *Aquastat is a registered trademark of Honeywell International, Inc.

2

MOUNTING THE CONTROL

STEP 1 Two mounting positionsare available on the back of the control(Fig. 1). Select which of the two positions(2 knockouts) is best for the location ofthe control. Remove the knockout.

STEP 2 Place control on the well.While holding box against well nut,tighten well clamp screw. (Fig. 2)

BACK OFFUEL SMART HYDROSTAT BOX

FIG. 1 FIG. 3FIG. 2

NOTE: In the case of space restrictions, the Fuel Smart HydroStat control may be mounted in a horizontal orientation without anyloss of function. Hydrolevel recommends vertical mounting, when possible, for proper orientation of LED display.REMOTE MOUNTING KITS are available separately for mounting the Fuel Smart HydroStat control box in a remote location.

Each kit includes mounting hardware and a remote sensor. See page 16 for kit options.

STEP 3 Insert sensor ALL THEWAY into well through the knockout (Aor B) you have chosen. (Fig. 3)

IMPORTANT Make sure that the immersion well or Electro-Well™ is installed in the boiler manufacturer’s designatedtemperature limit control tapping.

NNOOTTEE:: If installing an Electro-Well™, pipe sealing compound should be used. Teflon tape is not recommended.

IMMERSION WELLS

When installed on an Electro-Well™ (sold separately), the Low Water Cut-Offfunction is automatically activated. Heat transfer grease should not be used.NOTE: For proper operation, there must be 1/2" clearance between the cop-per well tube and any furnace within the boiler.

See Electro-Well™ models on page 15.

When installing on a standard immersion well, the LWCO function shouldbe turned off (see page 10 for instructions). A buildup of heat transfergrease or other coatings in older wells can interfere with continuity betweenthe sensor and the well causing a false low water shutdown. Turning off theLWCO function will prevent this from occurring.

Fuel Smart HydroStat can be installed on a Hydrolevel Electro-Well™ or on an existing immersion well already in the boiler.IMPORTANT: The control will only provide low water cut-off protection when installed on an Electro-Well™.

Installing HydroStat with Hydrolevel Electro-Well™

Installing HydroStat with Standard Immersion Well

WIRING

3

STEP 1 Connect 120 VAC Hot to terminal L1. Connect120 VAC Neutral to terminal L2. Disconnect means andoverload protection as required (provided by others).

Select the Diagram thatMatches your System Configuration

on Pages 4, 5 or 6

STEP 2 Connect the burner circuit to B1-B2. (B2 is neutral.)

WARNING Electrical shock hazard. To prevent electrical shock, death or equipment damage, disconnect power supply before installing or servicing this control.

4

Connect thermostat or end switch from zone relay or multi-zonepanel to T-T. Connect circulator to C2-C1. Connect end switchfrom indirect zone relay to ZC-ZR. Move Zone/Indirect Switchdown to I.

SINGLE CIRCULATOR MULTIPLE CIRCULATORS

Connect end switch from heating circulator relays or multi-zonepanel to T-T. Connect end switch from indirect circulator relay toZC-ZR. Move Zone/Indirect Switch to I.

IMPORTANT: When installing with an indirect water heater, the Zone/Indirect Switch must be set in the I position. When set in the I position, calls to ZC-ZR willbypass the Thermal Targeting feature and allow the boiler to fire to the high limit setting to heat the indirect tank. The indirect signal must be separate from allheating zone signals. If you choose not to separate the indirect signal from the heating zones, the Economy Feature should be turned OFF to ensure that theboiler supplies adequate temperature to heat the indirect tank (see page 7).

ZONE/INDIRECTSWITCHPOSITION


Connect thermostat or end switch from zone relay or multi-zone panel to T-T. Connect circulator to C2-C1. MoveZone/Indirect Switch up to Z.

Connect end switch from circulator relay or multi-zone panel toZC-ZR. Move Zone/Indirect Switch up to Z.

STEP 3A: HEATING ONLY – No Indirect Water Heater

STEP 3B: HEATING and Indirect Water Heater

SINGLE CIRCULATOR MULTIPLE CIRCULATORS



NOTE: For proper operation of the boiler reset function, all heating thermostats must input to T-T or ZC-ZR terminals as indicated below. Jumping the T-T terminals and wiring the thermostat to the primary will override the economy feature.

WIRING


� �

� �

CHOOSE � OR � BELOW

CHOOSE FROM � THROUGH BELOW OR ON PAGE 5 OR 6

5

NOTE: The wire from ZR to the hot terminal of the indirect circulator will ensurethat indirect calls will fire to limit and receive priority over heating calls.

MULTIPLE CIRCULATORS — Typical Zone Panel with Priority Zone



SINGLE CIRCULATOR — Multiple Zone Valves including Indirect, No Zone Control Panel

STEP 3B: HEATING and Indirect Water Heater – continued


WIRING


�

�

MORE

NOTE: When using zone valves for both heat and indirect, the calls must be separated in order to prioritize indirect calls. This canbe accomplished by using a general purpose relay as shown above. However, for ease of installation, a zone control panel is rec-ommended (see wiring diagram 7 on next page).

SINGLE CIRCULATOR — Typical Multiple Zone Valve Panel with Indirect

6



MULTIPLE CIRCULATORS — Typical Three Zone Switch Relay

STEP 3B: HEATING and Indirect Water Heater – continued


WIRING


�

NOTE – If a Zone Valve Control Panel has no priority zone: To ensure adequate boiler tempera-ture to satisfy the domestic hot water tank, it may be necessary to turn the Economy Feature off.

NOTE: The wire from ZR to the hot terminal of the indirect circulator will ensurethat indirect calls will fire to limit and receive priority over heating calls.Tacoʼs SR503 combines ZR amd X2.

Zone/Indirect Switch

NOTE: Settings can be checked using the TEST/SETTINGS Button. See page 11 for details.

Setting the High Limit The high limit is factory set at 190°F. To adjust, turn the HITEMP Dial � until the desired setting is displayed. (Settingrange: 100°-220°F)

Setting the Low Limit The low limit is designed to maintain temperature in boilersequipped with tankless coils used for domestic hot water.The low limit is factory set to OFF. Prior to adjusting, removethe jumper (not equipped on all units) �. Then turn the LOTEMP Dial � clockwise until the desired temperature is dis-played. For proper operation, the low temperature limit set-ting should be at least 10° below the high limit setting.NOTE: For cold start operation, the low limit must be turnedOFF. IMPORTANT: If low limit temperature cannot be setabove 140°F, remove jumper �. (Setting range: OFF or110°-200°F).

Setting the Economy FeatureThe Economy Feature is factory set for a 1 zone heating sys-tem. To adjust, turn the ECONOMY Dial � until the numberdisplayed equals the number of heating zones. Do notinclude indirect water heaters in the number of heatingzones. The Economy Feature conserves fuel by reducing

boiler temperature (see “How Thermal Targeting Works” onpage 8). If the heating system is unable to supply neededheat to the house, the ECONOMY Dial should be turned to alower setting (example: In a three zone house, turn the dial to2 or 1). Conversely, if the boiler provides adequate heat,added fuel savings can be achieved by selecting a higher set-ting (example: 4 or 5). If the heating and indirect water heatersignals were not separated when wiring the control, theEconomy Feature should be turned OFF to ensure the boilersupplies adequate temperature to heat the indirect tank.

Setting the Zone/Indirect SwitchSee WIRING on page 4-6.

7

SETTING THE CONTROL

DynamicDisplay

Water Temperatureand Real TimeVerification of

Setting Adjustments.

Low TemperatureLimit Setting

(OFF or 110°-200°F)Factory OFF

High TemperatureLimit Setting (100°-220°F)Factory 190°F

Spade Connectorsfor OS-100 OutdoorSensor Kit

Diagnostic LEDs

�

�

�

Economy Dial(OFF or LO, 1, 2, 3,4, 5, HI)

Differentialsare automaticand will varybased on control settingsand boiler tem-perature.

SETTING

Disables economy function. Will allow boiler to fire until hi-limit temp is reached and re-fire with a 10° subtractive differential.Provides lowest level of fuel savings. Use this setting only ifthe house does not stay warm at higher settings.Recommended setting for single zone systemsRecommended setting for Two zone systemsRecommended setting for Three zone systemsRecommended setting for Four zone systemsRecommended setting for Five zone systemsProvides highest level of fuel savings

Indicator Light(announces heat call)

Jumper �

Test/Settings Button

8

OPTIONAL FEATURES

HOW THERMAL TARGETING WORKS

SYSTEM START-UP

Thermal Targeting technology analyzes thermostat activity and continually evaluates how much heat the house requires. When itis very cold outside, the heat demand is high and the Fuel Smart HydroStat will raise the boilerʼs Target temperature to provideneeded heat to the home. When the outside temperature is milder, the heat demand is lower. During these periods, the FuelSmart HydroStat will lower the boilerʼs Target temperature – saving fuel – while continuing to provide comfort to the house.

At initial start up, with the Economy Feature active, the control establishes a 145°F target temperature. To test the high limitshut-off function, the Economy Dial must be turned to OFF. Once tested, restore the Economy setting. If the heating demand ishigh, the target will increase over time to satisfy the heat load. NOTE: • Smart DHW Priority: During a call from an indirect water heater, the control will de-energize the circulator contacts (C1/C2) to

heat only the indirect tank ensuring an adequate supply of domestic hot water. The control will re-energize the circulator whenthe indirect tank is satisfied or if the boiler temperature reaches 170°F. If the indirect call continues for 45 minutes, the controlwill override the priority function energizing the circulator to provide space heating.

NOTE: The Program Mode – – is accessed by turning the LO TEMP dial to a position just above OFF.

Thermal Pre-PurgeThermal Pre-Purge is designed to maximize boiler efficiency. When activated, the control will supply latent heat that mayremain in the boiler from a previous run cycle to the heating zone that is now calling. The control monitors how quickly the boil-er temperature is declining and activates the burner only when it determines that the latent heat is insufficient to satisfy the call.During the purge cycle, the display will indicate . This feature works with single-zone and multi-zone heating systems uti-lizing circulators or zone valves. No change in wiring is needed.

To activate Thermal Pre-Purge1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as 2. Turn the HI TEMP dial to select feature 3. Push the Test/Settings Button to turn Thermal Pre-Purge or 4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 7)

Degrees Fahrenheit or Celsius The control has the ability to operate in degrees Fahrenheit or Celsius. When operating in Celsius, a will appear in the dis-play next to the temperature whenever the temperature is below 100 degrees.

To change between degrees Fahrenheit and degrees Celsius1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as2. Turn the HI TEMP dial to select feature 3. Push the Test/Settings Button to for Celsius or for Fahrenheit4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 7)

MORE OPTIONAL FEATURES ON NEXT PAGE

9

OPTIONAL FEATURES continued

Manual Reset Low Water Cut-OffThe low water cut-off operation on the HydroStat can be set to operate in automatic (default) or manual reset mode. When inmanual reset mode, the control will shut-down the burner immediately when a low water condition is detected. If the low watercondition is sustained for 30 seconds, the low water light will blink, indicating that the control has locked out the burner. Thecontrol can only be reset by pushing the Test Settings button on the top of the control. The manual reset feature meets CSD-1code requirements.

IMPORTANT: The system must be checked by a qualified heating professional prior to resuming operation. WARNING: DO NOT ADD WATER UNTIL THE BOILER HAS FULLY COOLED.

To activate Manual Reset LWCO mode1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as 2. Turn the HI TEMP dial to select feature3. Push the Test/Settings Button to for Automatic Reset Mode or for Manual Reset Mode4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 7)To Test the Manual Reset Feature: Press and hold the Test/Settings button located on the top ofthe control for 30 seconds to simulate a low water condition. After 30 seconds, the Low Water lightwill blink indicating that the control is locked out. To reset the lock-out condition, press theTest/Settings button momentarily.

Circulator Activation OptionsWhen in the default mode, the HydroStat activates the circulator (C1/C2 contacts) on calls to TT. The control can be pro-grammed to activate the circulator on calls to ZC/ZR in place of, or in addition to, calls to TT.

To change how the Circulator is activated1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as 2. Turn the HI TEMP dial to select feature 3. Push the Test/Settings Button to select between the following options:

- Circulator on TT call only- Circulator on ZC/ZR call only- Circulator on both TT & ZC/ZR calls

4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 7)

Circulator Hold Off (Enhanced Condensing Protection)To reduce the potential for condensing, on a call for heat the control will allow the boiler to heat to 125°F prior to energizing thecirculator. Once energized, the circulator will remain on for the duration of the heating call unless the boiler temperature dropsbelow 115°F. If this occurs, the circulator will re-energize when the boiler returns to 125°F.

To activate Circulator Hold Off1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as 2. Turn the HI TEMP dial to select feature 3. Push the Test/Settings Button to turn Circulator Hold Off or4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 7)

MORE OPTIONAL FEATURES ON NEXT PAGE

10

Low Water Cut-Off Function

To turn off Low Water Cut-Off1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as 2. Turn the HI TEMP dial to select feature 3. Push the Test/Settings Button to turn Low Water Cut-Off or4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 7)

Restore Factory Default Settings

To restore all features to the factory default settings (see following chart for default settings)1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as2. Turn the HI TEMP dial to select feature 3. Push the Test/Settings Button to to reset all features to the default settings.4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 7)

Dial Setting Feature Options Description

Default Setting

1 Thermal Pre-Purge OFFOn

Purge InactivePurge Active OFF

2 Fahrenheit or Celsius Fc

Degrees FahrenheitDegrees Celsius F

3 LWCO Manual orAutomatic Reset

Ab

Automatic ResetManual Reset A

4 Circulator Options AbC

Circulator operation on TT call onlyCirculator operation on ZC/ZR call onlyCirculator operation on call from either

A

Circulator Hold Off Circulator Hold Off – ActiveCirculator Hold Off – Inactive

Not available on this controlNot available on this control

Low Water Cut-OffFunction

Low Water Cut-Off ONLow Water Cut-Off OFF

dEF Restore FactoryDefaults

Yn

Restore DefaultsDo Not Restore Defaults n

SEE PAGE 7 FOR ADDITIONAL SETTINGS

OPTIONAL FEATURES continued

11

� TEMP ACTIVE Indicates that the Fuel SmartHydroStat control is powered and that the temperaturefunction is active.� TEMP HI TEMP Illuminates when the boiler watertemperature reaches the high limit setting. It will remain lituntil the water temperature falls 10°. The Fuel SmartHydroStat prevents burner operation while this LED is on.See Differential explanation on page 7.� LWCO ACTIVE Indicates that the low water cut-off(LWCO) function of the Fuel Smart HydroStat is active. Whenthe control is installed with a Hydrolevel Electro-Well™, thisLED will be on at all times when the control is powered.IMPORTANT: If the control is installed with a well other thanthe Electro-Well™, this LED will not illuminate indicating thatthe control is not providing low water cut-off functionality.� LWCO LOW WATER Indicates that the boiler is in alow water condition. The HydroStat control will preventburner operation during this condition. If the LOW WATERlight is blinking, the control has been programmed to providelock-out protection in the event a low water condition isdetected (see Manual Reset Low Water Cut-Off on page 9).Pressing the TEST/SETTINGS button will reset the control.IMPORTANT: The system must be checked by a qualifiedheating professional prior to resuming operation.

WARNING: ALLOW THE BOILER TO FULLY COOL BEFORE ADDING WATER.

� ECONOMY ACTIVE Indicates that the ThermalTargeting function is active and the Fuel Smart HydroStat willreduce boiler temperature to conserve fuel. The Economyfeature is activated using the ECONOMY dial. (See “HowThermal Targeting Works” on page 8 for more information). � ECONOMY TARGET When the Economy feature isactive, the Fuel Smart HydroStat continually sets target

temperatures below the high limit setting to maximize fuelefficiency. When the boiler water reaches the targettemperature, the LED illuminates and the burner will shutdown. The boiler water will continue to circulate and heat thehouse as long as the thermostat call continues. The LED willstay lit until the boiler temperature drops below thedifferential set point at which point the boiler will be allowedto fire again. See Differential explanation on page 7.NOTE: This LED illuminates regularly during normal boileroperation.

� TEST/SETTINGS ButtonTo Test Low Water Cut-Off: Press and hold the Test/Settings button for 5 seconds. The display will read LCO.

LWCO TEST 00The red Low Water light should illuminate and the burnercircuit (B1 and B2) should de-energize. NOTE: The controlmust be installed with a Hydrolevel Electro-Well™ for lowwater cut-off functionality (see page 2 for more details).To View Current Settings: Press and release theTest/Settings Button in short intervals to sequentially displaythe following settings:

HIGH LIMIT SETTING 00�

LOW LIMIT SETTING 00�

ECONOMY SETTING 000�

CURRENT TARGET TEMPERATUREThe display will return to boiler temperature (default) if

Test/Settings Button in not pressed for 5 seconds.

LED LEGEND and TEST/SETTINGS BUTTON

12

MAINTENANCERemove the Electro-Well™ from the heating system every five years and clean any scale or sediment deposits from all parts thatare exposed to the boiler water. After cleaning, reinstall the well using pipe sealing compound. Teflon tape is not recommended.

TROUBLESHOOTING

Burner Will Not Fire See Flow Chart 1, page 13Burner Will Not Shut Down See Flow Chart 2, page 14

Temperature Display ExceedsHigh Limit Setting

Under normal operation, boiler temperature will continue to rise after the control shuts offthe burner. This condition, known as “thermal stacking”, results from hot boiler surfacescontinuing to release heat into the boiler water.

No or Insufficient Domestic Hot Water

For boilers equipped with a tankless coil, make sure the low limit setting on the HydroStatis set properly. NOTE: If the low limit setting is dialed fully counter clockwise, it will shutoff the low temperature maintenance feature and will function as a cold start control. Ifinstalled with an indirect water heater, check that the Zone/Indirect Switch is set in theIndirect (I) position. Verify that the end switch in the relay box controlling the indirect waterheater is connected to the ZC-ZR terminals. This will ensure that the domestic water callsare prioritized. (see “Heating and Indirect Water Heater” on page 4-6).

Low Water Light(Red LED) is On

or Blinking

WARNING: A low water condition is a serious and potentially dangerous condition. Do not attempt to add water to a hot boiler. Allow the boiler to fully cool before adding water.

When Installed on an Electro-Well™When the LOW WATER light is on, this indicates that the control is not detecting water inthe boiler. When the LOW WATER light is blinking, this indicates that the control hasbeen programmed to provide low water lock-out protection and is currently locked out(see Manual Reset Low Water Cut-Off on page 9). Pressing the TEST/SETTINGS buttonafter the low water condition is resolved will reset the lock-out condition.1. If the light is on and the heating system is filled with water, pull the sensor out of the

well and inspect it. Make sure that the metal clip is protruding enough to come incontact with the inside of the well tube. Check that the well does not have excessivebuild-up of heat transfer grease that may interfere with the clip contacting the well.

2. Remove well and examine for excessive residue build-up. Clean and re-install.When Installed on a Standard Immersion WellIf either LWCO LED lights are illuminated and the control is installed on a standardimmersion well, this is a false reading caused by a loss of continuity between the sensorand the inside of the well tube. It is recommended when the control is installed on astandard immersion well, the LWCO Function be turned off (see page 10 for details).

Boiler Will Not Maintain Low Limit Temperature

Check for overlapping high temperature setting. If the high limit setting is set below thelow limit setting, the control will default to the high limit setting and the correspondinghigh limit differential setting.

House Will Not Getor Stay Warm

1. Check for air-bound radiators. 2. Check thermostat settings including heat anticipator settings (common on non-digital

thermostats). 3. Check the Economy setting. The Economy feature, much like outdoor reset controls,

lowers average boiler temperature and can slow or, in some cases, prevent the housefrom coming up to temperature. Move to a lower setting (see “Setting the EconomyFeature” on page 7).

Circulator Contacts C1 and C2 Not Energized

on Call for Heat

Check to see that boiler water is at or above 125°F. On a call for heat, the control will notpermit the circulator to operate if the boiler water temperature is below 125°F (see“Circulator Hold Off” on page 9).

All LED Lights and TempDisplay are Blinking

If the LED lights and the temp display are blinking alternately, this indicates the control hassensed a boiler temperature of 250°F. When this occurs, the control pulses the burner relayand then shuts down and locks-out the burner. The system should be analyzed to determinethe cause of the overheating condition. Check the load on the burner contacts: If the loadexceeds the 7.4 Amp rating, the contacts may have welded. Correct the overloading conditionand replace the control before reenergizing the system. If the load on the contacts is belowthe rating, check system wiring and operation as well as the controlʼs high limit setting. If thecause of the overheating is found and the system is deemed safe, the control can be reset byremoving power from the control and then repowering while simultaneously pressing theTest/Settings button on the top of the control. If the cause of the overheating condition is notdetermined, the control should be replaced.

13

NO

YES NO

Is theThermostat (T-T) Calling for Heat?

Is There120 VAC

Between B1and B2?

NO

Is the External Zone(ZC-ZR) Calling

for Heat?

NOIs the

Low Limit Dial Set to OFF?

YES

NO

YES

Is theRed LED

(LOW WATER)On?

The Control isSensing

Low Water.

CAUTION – ALWAYS ALLOW A BOILER TO COOL BEFORE ADDING WATER

The burner will not fire until the low water condition is satisfied.

� Check that the system is filled with water.

� Check that the sensor is inserted fully into the well and contactbetween its spring clip and the copper well tube is made.

� Check that the control is tightly clamped to the well.

Also see page 12 for additional troubleshooting information.

Is theYellow LED(HI TEMP)

On?

The Control isSensing High Temperature.

If both the red and yellow LEDs are off andthere is a call to fire the burner, there will be120 VAC on terminals B1 and B2.� If 120 VAC is not present, the control should

be replaced.

HydroStat is supplying 120 VAC to the burner circuit.� Recheck wiring and operation of burner and other limit controls.

The Control is OperatingProperly.

ReplaceControl

The burner will not fire until the boiler water has dropped to thehigh limit differential set-point (10° below high limit setting).

� Check that the high temperature setting is correct.

Troubleshooting Flow Chart 1 – Burner Will Not Fire

YES

YES

NO

Is theYellow LED(TARGET)

On?

The Boiler hasReached the

Target Temperature.

When the ECONOMY function is active, the control monitors heatingdemand and establishes Target boiler temperatures below the highlimit setting to conserve fuel (see “How Thermal Targeting Works”on page 8). The burner will not fire until the boiler temperaturedrops to the automatically calculated Target Temp Differential.

YES

NO

Is theGreen LED

(TEMP ACTIVE)On?

The Control isNot Powered.

The Temp Active LED will be on at all times when the control ispowered.

� Check for 120 VAC on terminals L1 and L2.

YES

NO

When the low temperaturesetting is set to OFF, theHydroStat will act as a coldstart control. The burnerwill not fire unless there isa call from the thermostat(T-T) or an external zone(ZC-ZR).� Set thermostat to call

for heat. Burner shouldfire.

� If the boiler has a tank-less coil, set the LowTemperature Limit tomaintain temperature.

YES

Does theDisplay Read

?

The Control isPurging LatentHeat from the

Boiler.

The Thermal Pre-Purge feature holds off the burner until thecontrol determines if the latent heat in the boiler can satisfythe heat call.

NO

YES

14

YES

RecheckWiring.

ReplaceControl.

When there is no call to fire the burner, the voltageshould be 0 volts between B1 and B2.

� Make sure the burner is wired to B1.

YES

NOIs the

Low Limit DialSet to OFF?

Is there 120 VAC between

B1 and B2?

NO

Is theThermostat (T-T) Calling for Heat?

YES

YES

Is the External Zone(ZC-ZR) Calling

for Heat?

NO

NO

Is theRed LED

(LOW WATER)On?

The Control isSensing

Low Water. WARNING!TURN OFF POWER TO BURNER IMMEDIATELY!CAUTION – ALWAYS ALLOW A BOILER TO FULLY COOLBEFORE ADDING WATER.

� Recheck wiring. Make sure that burner is wired toB1. Burner should never fire when red or yellowLED is lit.Is either

Yellow LEDOn?

The Control hasReached Targetor High LimitTemperature.

The Control isOperating Normally.

The Control isOperating Normally.

The burner will continue to fire when there is a callfrom the thermostat or external zone.

� Check temperature display. When the Low Limit isset, the HydroStat will fire the burner until thetemperature reaches the Low Limit Setting.

If there is no call for heat (from T-T, ZC-ZR or LowLimit), there should be 0 VAC between B1-B2.

� If there is voltage between B1-B2, the controlshould be replaced.

Troubleshooting Flow Chart 2 – Burner Will Not Shut Down

YES

YES

NO

NO

15

ELECTRO-WELLS™

Fuel Smart HydroStatinstalled with Electro-Well™When installed with the Hydrolevel Electro-Well™,Fuel Smart HydroStat will provide both temperatureand low water cut-off functionality. If the control wassupplied by the boiler manufacturer, it was installedwith an Electro-Well™. The Electro-Well™ is availableseparately for field installations.

Electro-Well™ Models

IIMMPPOORRTTAANNTT:: For proper opera-tion of the lowwater cut-off func-tion, there mustbe a minimum of½" clearancebetween the cop-per well tube andany surface withinthe boiler.

1683 Water Street • New Haven, CT 06511 • Phone (203) 776-0473 • FAX (203) 773-1019 • www.hydrolevel.com

REMOTE MOUNTING KITS

OUTDOOR SENSOR KIT

Hydrolevel's optional Outdoor Sensor Kit automatically activates outdoor reset functionality and warm weather shutdown capa-bility when plugged in to the Fuel Smart HydroStat control. This low cost, easy to install kit is available separately at Hydroleveldistributors.

Part No. Description48-140 Model OS-100 Outdoor Sensor Kit

Part No. Description48-101 HydroStat Remote Mount Kit with 24" sensor48-102 HydroStat Remote Mount Kit with 48" sensor

Part No. Description48-103 HydroStat Remote Mount Kit with 10' sensor48-104 HydroStat Remote Mount Kit with 20' sensor48-121 HydroStat Pipe Mounting Kit with 48" sensor

SPECIFICATIONS FUEL SMART HYDROSTAT MODEL 3250-Plus

DIMENSIONS

LIMITED MANUFACTURERʼS WARRANTYWe warrant products manufactured by Hydrolevel Company to be free from defects inmaterial and workmanship for a period of two years from the date of manufacture orone year from the date of installation, whichever occurs first. In the event of any claimunder this warranty or otherwise with respect to our products which is made withinsuch period, we will, at our option, repair or replace such products or refund the pur-chase price paid to us by you for such products. In no event shall Hydrolevel Company

be liable for any other loss or damage, whether direct, indirect, incidental or conse-quential. This warranty is your EXCLUSIVE remedy and shall be IN PLACE OF any otherwarranty or guarantee, express or implied, including, without limitation, any warrantyof MERCHANTABILITY or fitness for a particular purpose. This warranty may not beassigned or transferred and any unauthorized transfer or assignment thereof shall bevoid and of no force or effect.

Input voltage 120 VAC, 60 HZBurner contacts 7.4 FLA, 44.4 LRA@120 VACCirculator contacts 5.8 FLA, 34.8 LRA@120 VACOperating range – low limit Off or 110°F (43°C) - 200°F (93°C)Operating range – high limit 100°F (38°C) - 220°F (104°C)Operating range – differentials AutomaticThermostat heat anticipator setting 0.2A

3250-0313

2 06

5 40

9-Ed

. 01/

2006

-10-

GRD

Wilo-MVI 10, 15, 30, 50, 80

GB Installation and operating instructions

F Notice de montage et de mise en service

E Instrucciones de instalación y funcionamiento

Fig. 1: Fig. 2:

Fig. 3a: MVI 10, 15, 30

3 15/16"

6 3/4"

9 13/16"

(100)

(171.6)

(250)

2 15

/ 16"

(75)

7 1/16"

8 5/16"

(180)

(212)

Ø 3 15/16"(100)

Ø 3/4"

(Ø 19)(DN 32)

13/ 1

6"(2

0)

DN 1 1/4"

4 X Ø 1/2"(4 X Ø 12)

Fig. 3b: MVI 10, 15 NPT 1“; MVI 30 NPT 1 1/4“

(4 X Ø 12)

4 X Ø 1/2"

MVI 10-15 NPT 1"MVI 30 NPT 1 1/4"

3 7/8"

(98.4)

6 3/16

(157)

8 1/16"(204)

1 1

5/ 1

6"

(50

)

13

/ 16"

(20

)2 15/16"(75)

7 1/16"

(180)

8 3/8"

(212)

"

Fig. 3c: MVI 50, 80

11 13/16"

(130)

(187)

(300)

(90)

5 1/8" 8 7/16"

13/ 1

6"

9 13/16"7 3/8"

3 9 /

16"

4 X Ø 1/2"

(215)

(250)

(4 X Ø 12)

DN 2"(DN50)

(20)

8 X Ø 3/4"(8 X Ø 19)

Ø 5"(127)

Fig. 3d: MVI 50 NPT 1 1/2“; MVI 80 NPT 2“

(80)

(130)

(187)

(250)

(4 X Ø 12)

(20)

(100)

(215)

(252)

(4 X Ø 12)

(20)

(100)

(215)

(252)

MVI 80 NPT 2"

3 15/16"

8 7/16"

9 15/16"

13/ 1

6"

NPT 2"

4 X Ø 1/2"

MVI 50 NPT 1 1/2"

3 1 /

8"

5 1/8"

7 3/8"

9 13/16"

3 15/16"

8 7/16"

9 15/16"

13/ 1

6"

NPT 1 1/2"

4 X Ø 1/2"

(90)

(130)

(187)

(250)

3 9 /

16"

5 1/8"

7 3/8"

9 13/16"

Fig. 4: Fig. 5:

Table of contents page1 General.......................................................................................................................32 Safety .........................................................................................................................33 Transport and interim storage................................................................................44 Intended use (Application)......................................................................................45 Technical data...........................................................................................................46 Description and function.........................................................................................57 Installation and electrical connection ...................................................................58 Start up ......................................................................................................................79 Maintenance / Service .............................................................................................8

10 Faults, causes and remedies ...............................................................................911 Spare parts ............................................................................................................. 10

Table des matières page1 Généralités ............................................................................................................. 112 Sécurité................................................................................................................... 113 Transport et stockage ......................................................................................... 124 Utilisation prévue (Application) .......................................................................... 125 Données techniques ............................................................................................. 126 Description et fonctionnement........................................................................... 137 Installation et raccordement électrique............................................................. 138 Démarrage.............................................................................................................. 159 Entretien et réparation ......................................................................................... 17

10 Défauts, causes et mesures de dépannage ....................................................... 1711 Pièces de rechange ............................................................................................... 18

Contenido página1 Generalidades ........................................................................................................ 192 Seguridad................................................................................................................ 193 Transporte y almacenaje ...................................................................................... 204 Uso previsto (aplicación)...................................................................................... 205 Datos técnicos ....................................................................................................... 206 Descripción y funcionamiento............................................................................. 217 Instalación y conexión eléctrica .......................................................................... 218 Puesta en marcha .................................................................................................. 239 Mantenimiento / Reparación ............................................................................... 25

10 Averías, causas y soluciones ................................................................................ 2511 Repuestos............................................................................................................... 26

English

Installation and operating instructions Wilo-MVI 10, 15, 30, 50, 80 3

1 General

1.1 About this documentThese Installation and Operating Instructions form an integral part of the unit. They must be kept close to the unit and in readiness whenever required. Pre-cise observance of these instructions is a pre-condi-tion for use of the unit for the intended purpose and for its correct operation.These Installation and Operating Instructions con-form to the relevant version of the equipment and the underlying safety standards valid at the time of going to press.

2 SafetyThese instructions contain important information which must be followed when installing and operat-ing the pump. It is therefore imperative that they be read by both the installer and the operator before the pump is installed or started up.Both the general safety instructions in the ‘Safety precautions’ section and those in subsequent sec-tions indicated by danger symbols should be care-fully observed.

2.1 Symbols and signal words used in these operating instructions

Symbols:

NOTE:...

Signal words:

NOTE:A NOTICE WITH USEFUL INFORMATION FOR THE USER IN RELATION TO THE PRODUCT. IT INFORMS THE USER TO POSSIBLE PROBLEMS.

2.2 Qualified PersonnelThe personnel installing the pump must have the appropriate qualifications for this work.

2.3 Risks incurred by failure to comply with the safety precautionsFailure to comply with the safety precautions could result in personal injury or damage to the pump or installation. Failure to comply with the safety pre-cautions could invalidate warranty and/or damage claims.In particular, failure to comply with these safety pre-cautions could increase the possibility of the follow-ing risks:

• the failure of important parts of the pump or instal-lation,

• personal injury due to electrical and mechanical causes,

• material damage.

2.4 Safety precautions for the operatorExisting regulations for the prevention of accidents must be observed.National Electrical Codes, local codes and regula-tions must be followed.

2.5 Safety precautions for inspection and installationThe operator must ensure that all inspection and installation work is carried out by authorized and qualified specialists who have carefully reviewed these instructions. Work on the pump/unit must be carried out only with the pump switched off and at complete standstill.

2.6 Unauthorized alterations and manufacture of spare partsAlterations to the pump or installation may only be carried out with the manufacturer's consent. The use of original spare parts and accessories authorized by the manufacturer will ensure safety. The use of any other parts may invalidate claims invoking the liabil-ity of the manufacturer for any consequences.

2.7 Improper useThe operational safety of the pump or installation supplied can only be guaranteed if it is used in accor-dance with paragraph 4 of the operating instruc-tions. The limits given in the catalogue or data sheet must under no circumstances be exceeded.

General Safety symbol

Hazards from electrical causes

DANGER!Imminently hazardous situation.Will result in death or serious injury if not avoided.

WARNING!The user can be exposed to (severe) injury. 'Warn-ing' refers that harm to the user when the user is neglecting the procedure.

CAUTION!The product is at risk of damage. 'Caution' refers to the product when the user is neglecting the procedures.

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4 WILO AG 10/2006

3 Transport and interim storageWhen receiving the material, check that there has been no damage during the transport. If shipping damage has occurred, take all necessary steps with the carrier within the allowed time.

Handle the pump carefully so as not to damage the unit prior to installation.

4 Intended use (Application)

Typical applications for the MVI pumps are clean flu-ids relatively free of abrasive particles in commercial, agricultural, industrial and municipal areas. Water supply, water towers, irrigation, high pressure wash down, fire protection, boiler feed, condensate return and pressure boosting systems.

Application areas:• water distribution and boosting installations• industrial circulation systems• process fluids.• cooling water circuits.• fire-fighting and washing stations.• watering installations, etc.

5 Technical data

5.1 Type key

CAUTION! Outside influences may cause damagesIf the delivered material is to be installed later on, store it in a dry place and protect it from impacts and any outside influences (humidity, frost etc.).

WARNING! Bodily injuryDue to the high centre of gravity and small pump footprint, beware of instability during handling to avoid the pump falling over.

CAUTION! Possible damage of the pumpThese pumps are intended for use with water only

Example: MVI220-02/1-1/A3/E80/3-575-14-T

MVI pump family220 nominal flow in GPM at 60Hz / 2 poles- 02 number of stages/ 1 Number of reduced impellers- 1 1 = stainless steel 304

2 = stainless steel 316L3 = pump casing cast iron cataphoresis coated volute, 304 stainless steel hydraulic

/ A3 P = Victaulic couplingA3 = ANSI Flange 300 lbO = 2 bolt oval flanges, NPT threaded

/ E Pump SealsE = O rings: EPDM (KTW/WRC)V = O rings: VITON

80 Only 1 digit Means:K = Standard seals with cardridgeS = Standard seals without cardridge

(EPDM or VITON materials depending on pump seals)

2 digits means special executions:00 = mechanical seal Silicon carbide / Sili-

con carbide EPDM80 = mechanical seal Silicon carbide / Sili-

con carbide EPDM cardrige system10 = mechanical seal Silicon carbide / Sili-

con carbide VITONA0 = mechanical seal Silicon carbide / Sili-

con carbide VITON cardrige system11 = mechanical seal Silicon carbide / Car-

bon VITON01 = mechanical seal Silicon carbide / Car-

bon EPDM/ 3 1 = Single phase

3 = Three phasenothing = Without motor

- 575 1-230 = Single phase 115/230 V 60 Hz3-460 = Three phase 208-230/460 V 60 Hz3-575 = Three phase 575 V 60 Hz

- 14 56 = 56C NEMA Motor Frame14 = 143TC & 145TC18 = 182TC & 184 TC21 = 213TC & 215 TC28 = 284TC & 286 TC32 = 324TSC36 = 364 TSC

-T O = ODP Motor EnclosureT = TEFC

5.2 Data table

Maximum operating pressurePump casing Oval flange: 230 PSI (16 bar)

ANSI flanges 300 lb: 360 PSI (25 bar)"Victaulic" flanges: 230 PSI (16 bar)

Maximum suction pressure

140 PSI (10 bar)

Temperature rangeLiquid temperatures EPDM Version: 5 °F to 250 °F

(- 15° to + 120 °C)VITON Version: 5 °F to 194 °F (- 15° to + 90 °C)

Ambient temperature +104 °F Max (+ 40 °C)

Example: MVI220-02/1-1/A3/E80/3-575-14-T

English


Outline and pipe dimensions:See fig. 3a - d

5.3 Scope of Supply • Installation and operating instructions• Flanges:

- Oval two bolt style: companion flanges, bolts and gaskets are included with the pump.

- ANSI 300lb: pump delivered with gaskets and bolts without counter-flanges (accessories as option),

- Victaulic type with rapid hose coupling for Vic-taulic bracket: pump delivered without brackets (accessories as option).

5.4 Accessories • By-pass kit• Counter Flanges (300 # round type, various connec-

tions and Oval 2 bolt threaded)

6 Description and function

6.1 Product description (see fig. 1 & 2)1-Strainer-foot valve2-Pump suction valve3-Pump discharge valve4-Non-return valve5-Venting and filling plug6-Drain-priming plug7-Pipe supports8-Strainer9-Storage tank

10-Town water supply11-Motor starter12-Lifting hook13-Foundation blockHA: Maximum suction headHC: Minimum inlet pressure

6.2 Design of pump and motorVertical multistage in-line, glanded (with mechani-cal seal) centrifugal pump. Motor standard NEMA frame type, coupled to the pump with a shaft cou-pling and coupling guards.

7 Installation and electrical connection

Installation and electrical work in compliance with any local codes and by qualified personnel only!

7.1 Installation• The pump must be installed in a dry, well-ventilated

and frost-free place.

• Install the pump in a dry place protected from frost and as close as possible to the water in a suction lift application.

• Locate the pump in an accessible location to facili-tate inspection and maintenance. The pump must be installed in a vertical configuration on a concrete base.

• For especially heavy pumps, place a hook or a ring of sufficient capacity (total weight of pump) to allow the use of a hoist or similar device for the servicing and repair of the pump.

• Install the pump on a concrete block (at least 4” / 10 cm high). Consider an vibration insulation pad between the concrete base and pump in locations where noise might cause problems.

• The installation surface must be level and flat: any tilting of the pump could cause premature bearing wear.

5.2 Data table

Electrical dataMotor Enclosure: ODP: Enclosure Type 1, for indoor use

onlyTEFC: Enclosure Type 2

Insulation class: FFrequency 60 HzVoltages 1~: 115/230 V (± 10 %)

3~: 208-230 V/460 V, 575 V (± 10 %)OthersMinimum suction head:

according to NPSH of the pump

Ambient humidity: <90 %Noise level Depends on pump size, rotation speed,

working point, motor type: it can reach 77 dB(A) for ODP and 86 dB(A) for TEFC motors.

WARNING! Bodily injuryExisting regulations for the prevention of acci-dents must be observed.

WARNING! Electrical shock hazardDangers caused by electrical energy must be excluded. National Electrical Codes, local codes and regula-tions must be followed.

CAUTION! Possible damage of the pumpDirt and solder drops into the pump body can effect the pump operation.

• It is recommended that any welding and soldering work be done before installing the pump.

• Thoroughly flush the system out before installing the pump.

WARNING! Risk of accident by hot surfacesThe pump must be positioned so that someone cannot come into contact with the hot pump sur-faces while operation.

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6 WILO AG 10/2006

7.2 Hydraulic connection• The installation and connection dimensions are

given in fig. 3.- Pump with two bolt oval flanges: Pipe is

threaded (NPT) directly into the companion flanges supplied with the pump.

- Pump with round 300 lb flange have accessory companion flagnes (counter flanges) that attach to system piping in a manner dependant on the flange type (threaded NPT, weld neck etc.).

• When fitting the oval flange, only the bolts supplied should be used. The use of longer bolts might dam-age the base of the pump.

• The fluid flow direction is indicated on the pump body.

• Pump must be installed in such a way that it is not stressed by the pipework. The pipes must be attached so that the pump does not bear their weight.

• It is recommended that isolation valves be installed on the suction and discharge side of the pump. This will save having to drain and refill the system if the pump needs replacing.

• It is recommended that the pipe leading into the suction side of the pump has a minimum length which is three times as long as the pipe diameter.

• A check valve should be placed on the discharge pipe to protect it from water hammer.

• Note: To pump water with a large content of air or hot water, we recommend installing the by-pass kit.

Fig. 2: Flooded or pressurized suction applications• For direct connection to a public drinking water sys-

tem please refer to local plumbing codes for the requirement of a back flow protection device.

• For indirect connection via a tank, the suction pipe must have a strainer, to keep any impurities out of the pump.

Fig. 1: Suction lift applications• To avoid any loss of head, use the shortest possible

suction pipe and keep it free of bends that would increase the piping friction losses.

• Connections have to be correctly sealed: No air entrance is allowed on the suction pipe (2 %). See figure 1

7.3 Electrical connection • The electrical characteristics (frequency, voltage, nominal current) of the motor are mentioned on the name plate: check if it complies with the mains sup-ply used.

• The pump must be connected to the power supply by a solid cable equipped with a grounded plug-con-nection or a main power switch.

• Three-Phase motors must be connected to an approved motor starter. The set nominal current of which must correspond to the electrical data on the pump name plate

• The supply cable must be laid so that it never touches the pipe work and/or the pump and motor casing.

CAUTION! Possible damage of the pump caused by cavitation (boiling water at the eye of the first impellerDo not install in a suction lift position with fluids above 175 deg F (80 Deg C). Please refer to the chart below for NPSH required corrections for suction lift applications above sea level.

Altitude Loss of head

0 ft 0.0 ft1000 ft 1.2 ft

2000 ft 2.4 ft3000 ft 3.5 ft5000 ft 5.7 ft7000 ft 7.6 ft10000 ft 10.7 ft

Temperature Loss of suction head (HA) Temperature Loss of suction head (HA)

20 °C 0.20 mCL 70 °F 0.70 ft30 °C 0.40 mCL 90 °F 1.50 ft40 °C 0.70 mCL 100 °F 2.00 ft50 °C 1.20 mCL 120 °F 3.70 ft60 °C 1.90 mCL 140 °F 5.70 ft70 °C 3.10 mCL 160 °F 10.10 ft80 °C 4.70 mCL 180 °F 16.20 ft90 °C 7.10 mCL 200 °F 26.20 ft

100 °C 10.30 mCL 210 °F 32.60 ft

WARNING! Electrical shock hazardDangers caused by electrical energy must be excluded.

• Electrical work by a qualified electrician only!• National Electrical Codes, local codes and regula-

tions must be strictly followed.• All electrical connections must be performed

after the electrical supply has been switched off and secured against unauthorized switching.

• For safe installation and operation a proper grounding of the pump to the power supply’s grounding terminals is required.

English


• The pump/installation should be grounded in com-pliance with local regulations. A ground fault inter-rupter can be used as extra protection.

• The connection to the network must be in accor-dance with the connection plan (see Fig. 4).

• The position of the terminal box can be changed a quarter turn by removing the motor attachment screws (if necessary, remove the coupling guards) and turning the motor to the desired position.

• The electric motors used on the pumps can be con-nected to a frequency converter. Strictly follow the instructions given by the data sheet of the con-verter's manufacturer.The converter must not generate voltage peaks at the motor terminals higher than 850 V and dU/dt (Voltage/Time variation) higher than 2500 V/µs. If the value of the voltage signal are higher than those, risk of damage the motor are to forecast.In the con-trary provide a LC filter (inductance – capacitor) between the converter and the motor. It must be connected to the motor with a minimum length cable, armoured if necessary.

8 Start up

8.1 Preliminary rinsing

8.2 System filling - Venting

Two standard cases: - Fig. 1: Suction lift applications- Fig. 2: Flooded or pressurized suction

applications on storage tank (9) or town water supply (10) with dry-running protection system.

Air evacuation process with pump under pressure (see fig. 2):

• Close the discharge valve (3)• Open the venting plug (5), and the suction valve (2)

and completely fill the pump.

• Close the venting plug only after water flows out with no visible air at the venting plug.

Air evacuation process with pump in suction (see fig. 5):Two possible cases:1st case (see fig. 5.1)- Close the discharge valve (3), open the suction

valve (2)- Remove the venting plug (5)- Unscrew the bottom drain-priming plug (6)

located on the pump casing 4 to 5 turns.- Put a funnel into the venting plug port and com-

pletely fill the pump and the suction pipe.- After water flows out with no visible air at the

vent plug , filling is complete.- Screw the venting plug and the bottom drain-

priming plug back in.

2nd case (see fig. 5.2)Filling can be made easier by fitting on the suction pipe of the pump, a vertical pipe fitted with a Ø ½" ball valve and a funnel.

WARNING! Bodily injury!Refit the attachment screws of the motor and the coupling guards.

WARNING! Electrical shock hazardDO NOT FORGET TO CONNECT TO GROUND.

WARNING! Health hazardPumps are tested regarding hydraulic features in factory, some water may remain in them. It is rec-ommended for hygiene purposes, to carry out a rinsing of the pump before any using with potable water supply.

CAUTION! Possible damage of the pumpNever operate the pump dry.

WARNING! Bodily injuryPump under pressure! In hot water, a stream of water may escape from the venting port.Take all required precautions as regards persons and motor.

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8 WILO AG 10/2006

NOTE:The length of the pipe must be at least 2 inches (50 mm) taller than the venting plug level.- Close the discharge valve (3), open the suction

valve (2).- Open the ball valve and the venting plug.- Unscrew 4 to 5 turns the drain-priming plug (6).- Fill the pump and the suction pipe completely

until water flows out of the venting plug (5).- Close the ball valve (which can be left in place),

remove the pipe and close the bleed device (5) and reseat the drain-priming plug (6).

Dry-running protectionTo ensure that the pump is always primed, we rec-ommend to protect it with a pressure switch or a float switch.

8.3 Confirm correct rotationPrior to turning the pump on ensure the rotating assembly is free of any binding.

• Remove either one or both coupling guards.• Turn the coupling by hand to make sure the pump

turns freely without sticking.• Once the correct rotation has been confirmed (refer

to three-phase or single-phase procedure noted below) re-install the coupling guard(s) before the power is activated full time.

Three-phase motor• Switch on the motor by briefly pressing the circuit-

breaker and check that it turns in the direction indi-cated by the arrow located on the lantern or on the identification label of the pump.

• If the rotation is backwards insure power is off and switch two of the three motor leads and recheck the rotation. Once proper rotation is confirmed a amper-age balance is recommended across each of the three phases – maximum allowable difference is +/-5 %.

Single phase motor• Typically the rotation should be correct on single

phase applications however if the pump seems to lack performance please check the rotation. If run-ning backwards refer the motor nameplate for instructions to reverse rotation.

8.4 Starting up

• Keep the discharge valve closed.• Start the pump• Open venting plug to drain air. If no water leaks

within 20 seconds, close the plug and stop the pump, then wait 20 seconds to allow air to settle.

• Start again the pump.• If necessary (particularly if the suction height

exceeds 16 ft - 5 m) repeat these operations.• If water leaks at draining plug (it means the pump

delivers its pressure), slowly open the discharge valve. The pump has to be primed.

• Check discharge pressure for pressure fluctuations with a pressure gauge. If fluctuations are present please check the inlet conditions and/or re-prime the pump.

• To insure all air has been removed, close the dis-charge valve and the draining plug, then stop the pump 20 seconds, start the pump again and open the draining plug. Do it as long as air comes out

• Open the discharge valve fully or at a desired posi-tion determined by the installation.

• Check that the current input does not exceed the value indicated on the motor data plate.

9 Maintenance / ServiceAll servicing should be performed by an authorized service representative!

WARNING! Electrical shock hazardDangers caused by electrical energy must be excluded. Do not attempt the following unless 100% sure power is off.

CAUTION! Possible damage of the pumpPrior to starting the pump there must be fluid at the seal area.

WARNING! Risk of scaldingUnder some pump or installation operating condi-tions (temperature of pumped liquid, volume flow), the whole pump, including the motor, may become very hot. There is a real risk of burns just from touching the pump.

CAUTION! Possible damage of the pumpThe pump must not operate at zero flow (closed discharge valve) for more than 10 minutes with cold water (T < 104 °F (40 °C)) and more than 5 minutes above 140 °F (60 °C).We recommend to ensure a minimum flow of about 10 % of the nominal flow of the pump to avoid the formation of a vapour lock at the top of the pump.

WARNING! Electrical shock hazardDangers caused by electrical energy must be excluded. All electrical work must be performed after the electrical supply has been switched off and secured against unauthorized switching.

WARNING! Risk of scaldingAt high water temperatures and system pressure close isolating valves before and after the pump. First, allow pump to cool down.

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• No special maintenance in operation.• Keep the pump and the motor perfectly clean.• In case of prolonged stopping, if there is no risk of

frost, it is best not to drain the pump.• The bearing holding the coupling is lubricated for its

total lifetime and does not require any lubrication. It is recommended to grease the motor shaft end as well as the coupling boring with a high adhering grease (type type D321R Molikote or 8191 Loctite for example) to facilitate any further diassembling.

Motors without lubricating devices• Bearings are lubricated for their lifetime and do not

require any lubrication.

Motors with lubricating devices• See instructions put on motor. If missing, lubricate

every 5 000 hours with a grease resistant to high temperature.

Mechanical seals• The mechanical seal does not require any mainte-

nance in operation. It must never operate dry.

10 Faults, causes and remedies

If the fault cannot be remedied, please contact your local sanitary and heating specialist or WILO customer services.

WARNING! Electrical shock hazardDangers caused by electrical energy must be excluded. All electrical work must be performed after the electrical supply has been switched off and secured against unauthorized switching.

WARNING! Risk of scaldingAt high water temperatures and system pressure close isolating valves before and after the pump. First, allow pump to cool down.

DEFAULTS/CAUSES REMEDIES

1) Pump turns but no deliverya) The internal parts are obstructed by particlesb) Suction pipe obstructedc) Air in suction pipes d) Pump has lost it’s primee) Suction pressure is too low, it causes cavitation noise

f) The supply voltage of the motor is too low

a) Dismantle the pump and clean itb) Clean all the pipesc) Check tightness of the whole pipe up to the pump and make

it tightd) Fill the pump to prime again. Check foot valve is tighte) Too high loss of head on suction or suction head (check the

NPSH of the pump installed and of the installation)f) Check the voltage on the terminals of the motor and the

cross-section of the conductors2) The pump vibratesa) Loose on its foundationb) Particles obstructing the pumpc) Rotation variancesd) Bad electrical connection

a) Check and tighten completely the nuts of the stud boltsb) Dismantle the pump and clean itc) Check the pump turns freely without abnormal stickingd) Check the connections to the pump motor

3) The motor overheatsa) Voltage too low

b) Pump obstructed by particlesc) Ambient temperature above +40 °C

d) Election connection problem in terminal boxe) Phase imbalance on three phase

a) Check voltage on terminals of the motor, it should be within ± 10 % in 50 Hz or ± 6 % in 60 Hz of the rated voltage

b) Dismantle the pump and clean itc) The motor is aimed at operating at a maximum ambient tem-

perature of + 40°Cd) Be in conformity with the motor plate and see figure 4e) Check amperage at each leg, if more than 5 % variance total

call electrician to balance (rotate all three legs)4) The flow is irregulara) The suction head (HA) is not adequate

b) The suction pipe has a lower diameter than the one of the pump

c) The strainer and the suction pipe are partially obstructed

a) Study again the installation conditions and the recommen-dations described in this instruction

b) The suction pipe must have the same diameter as the suction pump port

c) Remove and clean

WARNING! Health hazardIf the liquid is toxic, corrosive or dangerous for human being, WILO must be informed or the qual-ified person in charge of the repairing. In this case, clean the pump to ensure a complete safety to the repairing man.

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10 WILO AG 10/2006

11 Spare partsAll spare parts must be ordered through your local specialist and/or Wilo Customer Services.In order to avoid returns and incorrect orders, please specify the name plate data for all orders.

Français

Notice de montage et de mise en service Wilo-MVI 10, 15, 30, 50, 80 11

Informations de base du manuel d’utilisation1 Généralités

1.1 À propos de ce documentCette notice de montage et de mise en service fait partie intégrante du produit. Elle doit être conservée à proximité du produit et être prête à l’emploi en cas de besoin. Le respect scrupuleux de ces instructions est une condition préalable à l’utilisation du produit aux fins prévues, ainsi qu’à son fonctionnement cor-rect.Cette notice de montage et de mise en service est conforme à la version respective de l’équipement et aux normes de sécurité sous-jacentes en vigueur au moment de la mise sous presse.

2 SécuritéLa présente notice contient des instructions primor-diales, qui doivent être respectées lors du montage et de la mise en service. Il est donc impératif qu’elle soit lue à la fois par l’installateur et l’opérateur avant l’installation ou la mise en service de la pompe.Il y a lieu d’observer non seulement les instructions générales de cette section, mais aussi les prescrip-tions spécifiques abordées dans les points suivants.

2.1 Symboles et signaux utilisés dans cette notice de mise en service

Symboles :

REMARQUE : ...

Signaux :

REMARQUE :Note contenant des informations sur le produit uti-les à l’utilisateur. Elle attire l’attention de l’utilisateur sur les problèmes éventuels.

2.2 Personnel qualifiéIl convient de veiller à la qualification du personnel amené à réaliser le montage.

2.3 Dangers encourus en cas de non-observation des consignesLa non-observation des consignes de sécurité peut avoir des conséquences graves sur la sécurité des personnes et sur l’installation. Elle peut également entraîner la suspension de tout recours en garantie.En particulier, le non-respect de ces consignes de sécurité peut accroître la probabilité des risques suivants :

• défaillance de fonctions importantes de la pompe ou de l’installation ;

• dangers pour les personnes par influences électri-ques ou mécaniques ;

• dommages matériels.

2.4 Consignes de sécurité pour l’utilisateurIl convient d’observer les consignes existantes en vue d’exclure tout risque d’accident.Les codes électriques nationaux, de même que les codes et règlements nationaux, doivent être respec-tés.

2.5 Consignes de sécurité pour l’inspection et l’installationL’opérateur doit veiller à ce que tous les travaux d’inspection et d’installation soient réalisés par des spécialistes autorisés et qualifiés ayant pris connais-sance du contenu de la notice. Les travaux réalisés sur la pompe/l’unité ne doivent avoir lieu que si la pompe est hors tension et à l’arrêt complet.

2.6 Modification du matériel et utilisation de pièces détachées non agrééesToute modification de la pompe ne peut être effec-tuée que moyennant l’autorisation préalable du fabricant. L’utilisation de pièces de rechange d’ori-gine et d’accessoires autorisés par le fabricant garantit la sécurité. L’utilisation d’autres pièces peut dégager notre société de toute responsabilité.

2.7 Modes d’utilisation non autorisésLa sécurité de fonctionnement de la pompe ou de l’installation livrée n’est garantie que si les prescrip-tions précisées au chapitre 4 de la notice d’utilisation sont respectées. Les valeurs indiquées dans le cata-logue ou la fiche technique ne doivent en aucun cas être dépassées.

Symbole général de sécurité

Dangers par influences électriques

DANGER !Situation dangereuse imminente.Cause de décès ou de blessure grave si elle n’est pas évitée.

AVERTISSEMENT !L’utilisateur peut être exposé à des blessures (graves). « Avertissement » indique qu’une blessure de l’utilisateur est possible lorsque l’utilisateur néglige la procédure.

ATTENTION !Le produit risque d’être endommagé. « Attention » se réfère au produit lorsque l’utilisateur néglige les procédures.

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12 WILO AG 10/2006

3 Transport et stockage avant utilisationÀ la livraison du matériel, vérifiez qu’il ne présente aucune avarie de transport. En cas d’avarie, entre-prenez toutes les démarches nécessaires auprès du transporteur dans les délais impartis.

Manipulez la pompe avec précaution de façon à ne pas endommager le produit avant l’installation.

4 Utilisation prévue (application)

Les pompes MVI sont généralement utilisées pour le pompage de liquides propres et pratiquement exempts de particules abrasives, dans les secteurs du commerce, de l’agriculture et de l’industrie ainsi que dans les services communaux. Adduction d’eau, châteaux d’eau, irrigation, lavage haute pression, protection incendie, alimentation de chaudières, retour de condensats et systèmes de surpression.

Domaines d’applications : • Installations de distribution d’eau et de surpression• Systèmes de circulation industriels• Technique des procédés• Circuits d’eau de refroidissement• Stations d’incendie, de lavage • Installations d’arrosage...

5 Données techniques

5.1 Dénomination

ATTENTION ! Les influences extérieures peuvent être à l’origine de dommages.Si le matériel livré doit être installé ultérieurement, stockez-le dans un endroit sec à l’abri des impacts et de toutes influences extérieures (humidité, gel, etc.).

AVERTISSEMENT ! Blessure corporelleSon centre de gravité se trouvant à une hauteur élevée et sa surface au sol étant réduite, veillez à ce que la pompe soit bien stable lorsque vous la manipulez afin d’éviter qu’elle ne bascule et ne tombe.

ATTENTION ! Risque d’endommager la pompeCes pompes conviennent uniquement au refoulement de l’eau

Exemple : MVI220-02/1-1/A3/E80/3-575-14-T

MVI Famille de pompe220 Débit nominal (GPM à 60 Hz / 2 pôles)-02 Nombre d’étages/1 Nombre de roues rognées

-1 1 = INOX 3042 = INOX 316L3 = Corps de pompe : volute en fonte, revêtement traité par cataphorèse, hydrau-lique inox 304

/A3 P = Raccord de type Victaulic A3 = Bride ANSI 300lbO = Bride ovale 2 boulons filetage NPT

/E Joints de pompeE = Joints toriques : EPDM (KTW/WRC)V = Joints toriques : VITON

80 Valeur hexadécimale1 lettre signifie :K = Garniture standard avec système

cartoucheS = Garniture standard sans système

cartouche(matériaux EPDM ou VITON suivant le type de joint de la pompe)

2 lettres indique une version spéciale :00 = Garniture mécanique carbure de sili-

cium / carbure de silicium avec jointsEPDM

80 = Garniture mécanique carbure de sili-cium / carbure de silicium avec jointsEPDM et système cartouche

10 = Garniture mécanique carbure de sili-cium / carbure de silicium avec jointsVITON

A0 = Garniture mécanique carbure de sili-cium / carbure de silicium avec jointsVITON et système cartouche

11 = Garniture mécanique carbure de sili-cium / carbone et joints VITON

01 = Garniture mécanique carbure de sili-cium / carbone et joints EPDM

/3 1 = Monophasé3 = Triphasérien = sans moteur

-575 1-230 = Monophasé 115/230V 60Hz3-460 = Triphasé 208-230/460V 60Hz3-575 = Triphasé 575V 60Hz

-14 56 = 56C Bâti de moteur NEMA14 = 143TC & 145TC18 = 182TC & 184 TC21 = 213TC & 215 TC28 = 284TC & 286 TC32 = 324TSC36 = 364 TSC

-T O = ODP Boîtier du moteurT = TEFC

Exemple : MVI220-02/1-1/A3/E80/3-575-14-T

Français


Encombrement et raccordements :Voir fig. 3 a - d

5.3 Étendue de livraison• Notice de montage et de mise en service• Brides :

- ovales 2 boulons : la pompe est fournie avec contre-brides, joints et boulons.

- ANSI 300 lb : pompe fournie avec joints et bou-lons sans contre-brides (accessoires en option).

- de type "Victaulic" : pompe fournie sans colliers (accessoires en option).

5.4 Accessoires• Kit by-pass• Contre-brides (300 # type rond, raccordements

divers et type oval 2 taraudée)

6 Description et fonctionnement

6.1 Description du produit (voir fig. 1 et 2)1-Clapet de pied de crépine2-Vanne à l’aspiration pompe3-Vanne au refoulement pompe4-Clapet anti-retour5-Bouchon remplissage et purge d’air6-Bouchon vidange – amorçage7-Supports de tuyauterie8-Crépine9-Bâche de stockage

10-Réseau d’eau de ville11-Démarreur12-Crochet de levage13-MassifHA : Hauteur d’aspiration maxiHC : Hauteur de charge mini

6.2 Conception de la pompe et du moteurPompe centrifuge verticale multi-étages en ligne, à presse-étoupe (avec garniture mécaniqueType de bâti de moteur normalisé NEMA, relié à la pompe par un accouplement avec protecteurs de sécurité.

7 Installation et raccordement électrique

Les travaux d’installation et les travaux électri-ques ne peuvent être effectués que par un person-nel qualifié et conformément aux codes locaux !

7.1 Installation• La pompe doit être montée dans un endroit sec, bien

aéré et à l’abri du gel.

5.2 Tableau de données

Pressions de serviceCorps de pompe Bride Ovale : 230 PSI

(16 bars)Brides ANSI 300lb : 360 PSI

(25 bars)Brides « Victaulic » : 230 PSI

(16 bars)Pression d’aspiration maximum

140 PSI (10 bars)

Temperature Températures des liquides

Version EPDM : 5°F à 250°F (- 15° à + 120° C)Version VITON : 5°F à 194°F (- 15° à + 90° C)

Température ambiante +104°F max (+ 40° C)Données électriquesBoîtier du moteur ODP : Boîtier de Type 1, à employer

uniquement à l’intérieur.TEFC : Boîtier de Type 2

Classe d’isolation FFréquence 60 HzTension 1~ : 115/230V (± 10 %)

3~ : 208-230V/460V, 575V (± 10 %)

AutresPression min. à l’entrée côté aspiration

Conformément au NPSH de la pompe

Humidité ambiante <90 %Niveau sonore Il dépend de la taille de la pompe,

de la vitesse de rotation, du point de fonctionnement et du type de moteur : dans certains cas, il peut atteindre 77 dB(A) en moteur ODP et 86 dB(A) en moteur TEFC.

AVERTISSEMENT ! Blessure corporelleIl convient d’observer les consignes existantes en vue d’exclure tout risque d’accident.

AVERTISSEMENT ! Risque de choc électriqueIl y a également lieu d’exclure tous dangers liés à l’énergie électrique. Les codes électriques nationaux, de même que les codes et règlements nationaux, doivent être respectés.

ATTENTION ! Risque d’endommager la pompeLes salissures et gouttes de brasure tendre dans le corps de pompe peuvent affecter le fonctionnement de la pompe.

• Il est recommandé d’effectuer toutes les opéra-tions de soudage et de brasage avant d’installer la pompe.

• Nettoyez le système en profondeur avant d’ins-taller le pompe.

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14 WILO AG 10/2006

• Installer la pompe dans un endroit sec et à l’abri du gel et aussi près que possible du lieu de puisage dans le cas d’une aspiration vers le haut.

• Placez la pompe dans un endroit aisément accessible afin de simplifier les travaux d’inspection et d’entre-tien. La pompe doit toujours être montée à la verti-cale sur un socle en béton.

• Dans le cas de pompes particulièrement lourdes, placez un crochet ou un anneau pourvu d’une force portante appropriée (poids total de la pompe), de façon à permettre l’utilisation d’un treuil ou d’engins similaires lors de l’entretien ou de la réparation de la pompe.

• Installer la pompe sur un massif (mini 10cm / 4" de haut). Prévoir une plaque d’isolation aux vibrations entre le socle en béton et la pompe aux endroits où le bruit peut entraîner des problèmes.

• La surface d’installation doit être horizontale et plane. Toute inclinaison de la pompe provoque l’usure prématurée du palier.

7.2 Connexion hydraulique • Les dimensions de montage et les cotes de raccor-

dement sont reprises en fig.3.- Pompe à bride ovale 2 boulons : la tubulure est

filetée (NPT) pour un raccordement direct aux contre-brides fournies avec la pompe.

- Les pompes à bride ronde 300 lb ont en acces-soires des contre-brides qui s’attachent à la tuyauterie du système de manière dépendante du type de bride (filetage NPT, collerette à sou-der).

• Lors du montage de la bride ovale, seuls les boulons fournis doivent être utilisés. L’emploi de boulons plus longs risquerait d’endommager la base de la pompe.

• Le sens de circulation du fluide est indiqué sur le corps de la pompe.

• Veillez à monter les tubulures d’aspiration et de refoulement de manière à n’exercer aucune con-trainte sur la pompe. Les conduites doivent être fixées de façon à ce que la pompe ne supporte pas leur poids.

• Il est recommandé d’installer les vannes d’isolement côtés aspiration et écoulement de la pompe, ce qui évitera de devoir vider et remplir de nouveau le sys-tème si la pompe doit être remplacée.

• Il est recommendé que le tuyau menant au côté aspiration de la pompe ait un longueur qui est le tri-ple du diamètre du tuyau.

• Il convient de prévoir un clapet anti-retour sur la tubulure de refoulement pour protéger la pompe contre les risques de coups de bélier.

• Nota : pour le pompage d’eau fortement aérée ou d’eau chaude, nous recommandons la mise en place d’un kit by-pass.

Fig.2 : Cas d’aspiration immergée ou sous pression• En cas de raccordement direct au réseau public d’eau

potable, veuillez vous conformer aux règles de plomberie locales concernant les dispositifs de pro-tection anti-retour nécessaires.

• En cas de raccordement indirect via un réservoir, la tubulure d’aspiration doit être équipée d’une crépine d’aspiration, afin d’éviter que des impuretés n’abou-tissent dans la pompe.

Fig.1 : Cas d’aspiration vers le haut• Afin d’éviter toute perte de pression, il convient

d’opter pour une tubulure d’aspiration la plus courte possible et d’empêcher tout coudage susceptible d’accroître les pertes par frottement.

• Bien étancher les raccordements avec des produits adaptés : aucune prise d’air ne doit être tolérée sur la tuyauterie d’aspiration (2 %). Voir fig. 1.

AVERTISSEMENT ! Risque d’accident en raison des surfaces chaudesLa pompe doit être positionnée de façon à empêcher toute personne d’entrer en contact avec les surfaces chaudes de la pompe pendant son fonctionnement.

ATTENTION ! Risque d’endommagement de la pompe par cavitation (eau en ébullition au niveau de l’entrée de la première roue)A ne pas installer en position d’aspiration vers le haut avec des fluides dépassant 175°F (80°C). Le tableau ci-dessous indique les rectifications de NPSH requises pour les cas d’aspiration vers le haut au-dessus du niveau de la mer.

AltitudeAltitude

Perte de hauteurLoss of head

AltitudeAltitude

Perte de hauteurLoss of head

0 m 0.00mCL 0 ft 0.0 ft500 m 0.60 mCL 1000 ft 1.2 ft

1000 m 1.15 mCL 2000 ft 2.4 ft1500 m 1.70 mCL 3000 ft 3.5 ft2000 m 2.20 mCL 5000 ft 5.7 ft2500 m 2.65 mCL 7000 ft 7.6 ft3000 m 3.20 mCL 10000 ft 10.7 ft

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7.3 Raccordement électrique

• Les caractéristiques électriques (fréquence, tension, intensité nominale) du moteur sont indiquées sur sa plaque signalétique : vérifier qu’il est adapté au réseau sur lequel il va être utilisé.

• La pompe doit être raccordée au réseau au moyen d’un câble solide équipé d’un connecteur mâle ou d’un interrupteur d’alimentation principal.

• Les moteurs triphasés doivent être connectés à un système de protection agréé. Le courant nominal de réglage doit correspondre à la valeur indiquée sur l’étiquette de la pompe.

• Le câble de raccordement doit être placé de façon à ne jamais entrer en contact avec la canalisation prin-cipale et/ou le corps de pompe et la carcasse moteur.

• La pompe/installation doit être mise à la terre con-formément aux réglementations locales. Un disjonc-teur de fuite à la terre peut servir de protection supplémentaire.

• Le raccordement au réseau doit être conforme au plan de raccordement (voir fig. 4).

• Il est possible de modifier par l’orientation du moteur la position de la boîte à bornes par quart de tour : retirer les vis de fixation moteur (si besoin retirer les protecteurs d’accouplements) et réorienter le moteur à la position souhaitée.

• Les moteurs électriques équipant les pompes peu-vent être raccordés à un convertisseur de fréquence. Se conformer scrupuleusement à la notice du fabri-cant du convertisseur.Celui-ci ne devra pas générer aux bornes du moteur des pics de tension supérieurs à 850V et des dU/dt (variation Tension/Temps) supérieures à 2500 V/ms. Si le signal de tension présente des valeurs supérieu-res à celles précitées, des risques de dégradation du bobinage moteur sont à craindre. Dans le cas con-traire, prévoir un filtre LC (inductance - condensa-teur) entre le convertisseur et le moteur. Il devra être connecté au moteur avec un câble de longueur mini-male, blindé si nécessaire.

8 Démarrage

8.1 Rinçage préliminaire

8.2 Remplissage et dégazage du système

Deux cas types :Fig.1 : Cas d’aspiration vers le hautFig.2 : Cas d’aspiration immergée ou sous pression sur bâche de stockage (9) ou réseau d’eau de ville (10) avec système de protection contre le manque d’eau

TempératureTemperature

Perte de hauteur d’aspiration (HA)Loss of suction head (HA)

TempératureTemperature

Perte de hauteur d’aspiration (HA)Loss of suction head (HA)

20°C 0.20 mCL 70 °F 0.70 ft30°C 0.40 mCL 90 °F 1.50 ft40°C 0.70 mCL 100 °F 2.00 ft50°C 1.20 mCL 120 °F 3.70 ft60°C 1.90 mCL 140 °F 5.70 ft70°C 3.10 mCL 160 °F 10.10 ft80°C 4.70 mCL 180 °F 16.20 ft90°C 7.10 mCL 200 °F 26.20 ft

100°C 10.30 mCL 210 °F 32.60 ft

AVERTISSEMENT ! Risque de choc électriqueIl y a également lieu d’exclure tous dangers liés à l’énergie électrique.

• Travaux électriques à faire réaliser uniquement par un électricien qualifié !

• Les codes électriques nationaux, de même que les codes et règlements nationaux, doivent être scrupuleusement respectés.

• Avant d’effectuer les raccordements électriques, la pompe doit être mise hors tension et protégée contre les redémarrages non autorisés.

• Pour garantir la sécurité d’installation et de fonc-tionnement, il est nécessaire de réaliser une mise à la terre correcte avec les bornes de terre de l’ali-mentation électrique.

AVERTISSEMENT ! Blessure corporelleRemettre les vis de fixation moteur et les protecteurs d’accouplement.

AVERTISSEMENT ! Risque de choc électriqueNE PAS OUBLIER DE RACCORDER LA MISE A LA TERRE.

AVERTISSEMENT ! Mise en danger de la santéLa performance hydraulique de chaque pompe est testée en usine, de l’eau en faible quantité peut donc se trouver dans la pompe. Il est recommandé pour des questions d’hygiène d’effectuer un rinçage de la pompe avant son utilisation sur un réseau d’eau potable.

ATTENTION ! Risque d’endommager la pompeNe faites jamais fonctionner la pompe à sec.

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16 WILO AG 10/2006

Processus d’évacuation d’air avec une pompe en charge (voir fig. 2) :

• Fermer la vanne au refoulement (3)• Ouvrir le purgeur (5), ouvrir la vanne à l’aspiration (2)

et procéder au remplissage complet de la pompe.• Ne refermer le purgeur qu’après l’eau est sortie et

qu’il n’y a plus d’air visible.

Processus d’évacuation d’air avec une pompe en aspiration (voir fig. 5) :Deux cas possibles :1er cas (voir fig. 5.1)- Fermer la vanne au refoulement (3), ouvrir la

vanne à l’aspiration (2)- Retirer le bouchon-purgeur (5)- Dévisser de 4 à 5 tours le bouchon inférieur de

vidange-amorçage (6) situé sur le corps de pompe.

- A l’aide d’un entonnoir engagé dans l’orifice du purgeur, remplir complètement la pompe et la tuyauterie d’aspiration.

- Après l’eau est sortie et il n’y a plus d’air visible, le remplissage est terminé.

- Revisser le bouchon-purgeur et le bouchon infé-rieur de vidange amorçage.

2ème cas (voir fig. 5.2)Le remplissage peut être facilité par l’installation sur la tubulure d’aspiration de la pompe d’un tuyau ver-tical muni d’un robinet à tournant sphérique Ø ½" et d’un entonnoir.

REMARQUE :La longueur du tuyau doit dépasser le niveau du pur-geur d’au moins 2 pouces (50 mm).- Fermer la vanne au refoulement (3), ouvrir la

vanne à l’aspiration (2).- Ouvrir le robinet à tournant sphérique et le pur-

geur.- Dévisser de 4 à 5 tours le bouchon d’amorçage-

vidange (6).- Procéder au remplissage complet de la pompe et

de la conduite d’aspiration, jusqu’à écoulement d’eau par le purgeur (5).

- Fermer le robinet (celui-ci peut rester en place), retirer le tuyau et fermer le purgeur (5) et revisser le bouchon d’amorçage/vidange (6).

Protection manque d’eauPour éviter les désamorçages accidentels de la pompe, nous recommandons sa protection par un pressostat ou un interrupteur à flotteur.

8.3 Contrôle du sens de rotationAvant de démarrer la pompe, assurer que les élé-ments rotatifs ne sont pas coincés..

• Retirer soit un soit les deux protecteurs d’accouple-ment.

• Faire tourner l’accouplement à la main pour s’assurer que la pompe tourne librement sans point dur.

• Dès que le sens de rotation a été confirmé (cf. les procédures pour les moteurs triphase et monophase en-dessous), replacer les protecteurs d’accouple-ment avant de rebrancher la pompe. .

MOTEUR TRIPHASE• Mettre le moteur sous tension par une brève

impulsion sur le discontacteur et vérifier que celui-ci tourne bien dans le sens indiqué par la flèche située sur la lanterne ou sur l’étiquette d’identifi-cation de la pompe.

• Si le moteur tourne dans le sens contraire, veiller à mettre le moteur hors tension, connecter deux des trois conducteurs du moteur et contrôler la rota-tion. Une fois que vous vous êtes assuré que le sens de rotation est correct, un équilibre d’ampé-rage est recommandé à travers chacune des trois phases (différence maximum autorisée : +/- 5%).

MOTEUR MONOPHASE• Généralement, la rotation peut être correcte dans

les cas de moteurs monophasés, mais si la pompe semble manquer de puissance, veuillez contrôler la rotation. Si le moteur tourne en arrière, consulter la plaque signalétique du moteur pour savoir com-ment inverser le sens de rotation.

AVERTISSEMENT ! Blessure corporellePompe sous pression ! En eau chaude, un jet d’eau peut s’échapper de l’orifice de purge. Prendre toutes les précautions nécessaires vis à vis des personnes et du moteur.

AVERTISSEMENT! Risque de choc électriqueIl y a lieu d’exclure tous dangers liés à l’énergie électrique. Essayer le suivant uniquement s’il est de 100% assuré que la pompe est débranchée.

ATTENTION! Risque d’endommager la pompeIl doit être du fluide aux joints avant de démarrer la pompe.

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8.4 Démarrage

• Maintenir fermée la vanne au refoulement.• Démarrer la pompe.• Ouvrir le purgeur pour évacuer l’air. En l’absence d’un

jet d’eau franc dans les 20s, refermer le purgeur et arrêter la pompe puis attendre 20s environ pour lais-ser l’air décanter.

• Redémarrer la pompe.• Si nécessaire (surtout si la hauteur d’aspiration

dépasse 16ft - 5m), renouveler ces opérations.• Si un jet d’eau franc apparaît au purgeur (signe que la

pompe délivre sa pression), ouvrir lentement la vanne au refoulement. La pompe doit être amorcée.

• Contrôler la pression au refoulement à l’aide d’un manomètre pour vérifier les variations de pression. En cas de variations. contrôler les conditions d’entrée et/ou réamorcer la pompe.

• Pour parfaire la purge d’air, fermer la vanne au refou-lement et le purgeur, puis arrêter la pompe 20 s, remettre en route la pompe et ouvrir le purgeur. A renouveler tant qu’il sort de l’air.

• Ouvrir la vanne au refoulement entièrement ou sur une position souhaitée déterminée par l’installation.

• Vérifier que l’intensité absorbée est inférieure ou égale à celle indiquée sur la plaque moteur.

9 Entretien / ServiceTous les travaux d’entretien doivent être effec-tués par un représentant autorisé !

• Aucun entretien particulier en cours de fonctionne-ment.

• Maintenir la pompe et le moteur en parfait état de propreté.

• En cas d’arrêt prolongé, s’il n’y a pas risque de gel, il est déconseillé de vidanger la pompe.

• Le roulement maintenant l’accouplement est graissé pour sa durée de vie et ne nécessite donc pas de graissage. Il est fortement recommandé de graisser l’extrémité de l’arbre moteur ainsi que l’alésage de l’accouplement avec une graisse à forte adhérence (type D321R Molikote ou 8191 Loctite par exemple) à chaque montage ou remontage du moteur afin de faciliter des démontages ultérieurs.

Moteurs sans graisseurs• Les roulements sont graissés pour leur durée de vie

et ne nécessitent donc pas de graissage.

Moteurs avec graisseurs• Se reporter aux instructions figurant sur le moteur.

En leur absence, graisser toutes les 5 000 heures à l’aide d’une graisse haute température.

Garnitures mécaniques• La garniture mécanique ne nécessite aucun entre-

tien en cours de fonctionnement. Elle ne doit jamais fonctionner à sec.

AVERTISSEMENT ! Risque de brûlureEn fonction des conditions de fonctionnement de la pompe ou de l’installation (température du liquide refoulé, débit volume), l’ensemble de la pompe, y compris le moteur, peut devenir extrêmement chaud. Il existe de réels risques de brûlures au simple contact de la pompe.

ATTENTION ! Risque d’endommager la pompeLa pompe ne doit pas fonctionner à débit nul (vanne au refoulement fermée) plus de 10 minutes en eau froide (T < 104°F (40°C)) et plus de 5 min au-delà de 140°F (60°C).Nous recommandons d’assurer un débit minimum égal à 10 % environ du débit nominal de la pompe afin d’éviter la formation d’une poche gazeuse en partie haute de la pompe.

AVERTISSEMENT ! Risque de choc électriqueIl y a également lieu d’exclure tous dangers liés à l’énergie électrique. Avant d’effectuer les travaux électriques, la pompe doit être mise hors tension et protégée contre les redémarrages non autorisés.

AVERTISSEMENT ! Risque de brûlureSi la température de l’eau et la pression du système sont élevées, fermez les vannes d’isolement en amont et en aval de la pompe. Dans un premier temps, laissez la pompe se refroidir.

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18 WILO AG 10/2006

10 Pannes, causes et remèdes

S’il n’est pas possible de remédier au défaut, veuillez faire appel à votre spécialiste local en ins-

tallations sanitaires ou de chauffage, ou au SAV WILO.

11 Pièces détachéesToutes les pièces détachées doivent être comman-dées auprès de votre spécialiste local et/ou du ser-vice clientèle de Wilo.Afin d’éviter les retours et les commandes incorrec-tes, veuillez indiquer les données de la plaque signa-létique pour toutes les commandes.

AVERTISSEMENT ! Risque de choc électriqueIl y a également lieu d’exclure tous dangers liés à l’énergie électrique. Avant d’effectuer les travaux électriques, la pompe doit être mise hors tension et protégée contre les redémarrages non autorisés.

AVERTISSEMENT ! Risque de brûlureSi la température de l’eau et la pression du système sont élevées, fermez les vannes d’isolement en amont et en aval de la pompe. Dans un premier temps, laissez la pompe se refroidir.

INCIDENTS/CAUSES REPARATION

1) La pompe tourne mais ne débite pasa) Les organes internes sont obstrués par des corps étrangers a) Faire démonter la pompe et la nettoyerb) Tuyauterie d’aspiration obstruéec) Entrées d’air par la tuyauterie d’aspiration

d) La pompe est désamorcée

b) Nettoyer toute la tuyauteriec) Contrôler l’étanchéité de toute la tubulure jusqu’à la pompe

et étancherd) Réamorcer par remplissage pompe. Vérifier l’étanchéité du

clapet de piede) La pression à l’aspiration est trop faible, elle est générale-

ment accompagnée de bruits de cavitation

f) Le moteur est alimenté à une tension insuffisante

e) Trop de pertes de charge à l’aspiration ou la hauteur d’aspi-ration est trop élevée (contrôler le NPSH de la pompe instal-lée et de l’installation).

f) Contrôler la tension aux bornes du moteur et la bonne sec-tion des conducteurs

2) La pompe vibrea) Mal serrée sur son socle

b) Corps étrangers obstruant la pompec) Variations de rotation

d) Mauvais branchement électrique

a) Vérifier et visser complètement les écrous des boulons de scellement

b) Faire démonter la pompe et la nettoyerc) Vérifier que la pompe tourne librement sans opposer de

résistance anormaled) Vérifier les connexions au moteur de la pompe

3) Le moteur chauffe anormalementa) Tension insuffisante

b) Pompe obstruée par des corps étrangers

a) Vérifier la tension aux bornes du moteur, cette tension doit se situer à ± 10 % en 50 Hz ou ± 6 % en 60 Hz de la tension nominale

b) Faire démonter la pompe et la nettoyerc) Température ambiante supérieure à + 40°C

d) Problème de connexion sélectionnée dans la boîte à bornese) Déséquilibre de phase sur triphasé

c) Le moteur est prévu pour fonctionner à une température ambiante maxi de + 40°C

d) Se conformer à la plaque moteur et à la figure 4e) Contrôler l’ampérage sur chaque section ; si la différence totale dépasse 5%, faire appel à un électricien pour qu’il procède à un équilibrage (tourner les trois sections)

4) Le débit n’est pas réguliera) La hauteur d’aspiration (Ha) n’est pas respectée

b) La tuyauterie d’aspiration est d’un diamètre inférieur à celui de la pompe

a) Revoir les conditions d’installation et les recommandations décrites dans ce manuel

b) La tuyauterie d’aspiration doit être de même diamètre que l’orifice d’aspiration pompe

c) La crépine et la tuyauterie d’aspiration sont partiellement obstruées

c) Démonter et nettoyer

AVERTISSEMENT ! Mise en danger de la santéSi le liquide est toxique, corrosif ou dangereux pour l’homme, en informer impérativement WILO ou le réparateur agréé. Dans ce cas, nettoyer la pompe de manière à assurer une totale sécurité au réparateur.

Español

Instrucciones de instalación y funcionamiento Wilo-MVI 10, 15, 30, 50, 80 19

Información básica del manual de utilización1 Generalidades

1.1 Acerca de este documentoLas instrucciones de instalación y funcionamiento forman parte del producto y, por lo tanto, deben estar disponibles cerca del mismo en todo momento. Es condición indispensable respetar estas instruc-ciones para poder hacer un correcto uso del pro-ducto de acuerdo con las normativas vigentes.Las instrucciones de instalación y funcionamiento se aplican al modelo actual del producto y a la versión de las normativas técnicas de seguridad aplicables en el momento de su publicación.

2 SeguridadEste manual contiene indicaciones básicas que deberán tenerse en cuenta durante la instalación y uso del aparato. Por este motivo, el instalador y el operador responsables deberán leerlo antes de mon-tar y poner en marcha el aparato.No sólo es preciso respetar las instrucciones generales de seguridad incluidas en este apartado, sino también las instrucciones especiales de los apartados siguien-tes que van precedidas por símbolos de peligro.

2.1 Identificación de los símbolos e indicaciones utilizados en este manualSímbolos:

INDICACIÓN:...

Palabras identificativas:

INDICACIÓN:INFORMACIÓN DE UTILIDAD PARA EL MANEJO DEL PRODUCTO. TAMBIÉN PUEDE INDICAR LA PRESEN-CIA DE POSIBLES PROBLEMAS.

2.2 Personal cualificadoEl personal de montaje deberá estar debidamente cualificado para realizar las tareas asignadas.

2.3 Peligro por no seguir las instrucciones de seguridadSi no se siguen las instrucciones de seguridad, podrían producirse lesiones personales, así como daños en la bomba o el sistema. La no observación de dichas instrucciones puede anular cualquier derecho a reclamaciones por los daños sufridos.Si no se siguen las instrucciones se pueden producir, entre otros, los siguientes daños:

• fallos en funciones importantes de la bomba o el sis-tema,

• lesiones personales debidas a causas eléctricas, mecánicas o bacteriológicas,

• daños materiales.

2.4 Instrucciones de seguridad para el operadorDeberán cumplirse las normativas vigentes de pre-vención de accidentes.Deberán respetarse las normativas nacionales, loca-les y los reglamentos en material de electricidad.

2.5 Instrucciones de seguridad para las tareas de inspección e instalaciónEl operador deberá asegurarse de que todas las tareas de inspección e instalación son efectuadas por personal autorizado y cualificado, y de que dicho personal ha consultado detenidamente el manual para obtener la información necesaria suficiente.Las tareas relacionadas con la bomba o el sistema deberán realizarse únicamente con el sistema des-conectado y completamente parado.

2.6 Modificación y fabricación de repuestos no autorizadasSólo se permite modificar la bomba o el sistema pre-via consulta con el fabricante. El uso de repuestos originales y accesorios autorizados por el fabricante garantiza la seguridad del producto. El fabricante no se responsabiliza de las consecuencias derivadas de usar otras piezas.

2.7 Utilización inadecuadaLa seguridad de la bomba o del sistema suministra-dos sólo se puede garantizar si se respetan las ins-trucciones de uso del apartado 4 de este manual. Asimismo, los valores límite indicados en el catálogo u hoja de características técnicas no deberán sobre-pasarse.

Símbolo de peligro general

Peligro por tensión eléctrica

¡PELIGRO!Situación de peligro inminente.Si no se tienen en cuenta las instrucciones si-guientes, se corre el peligro de sufrir lesiones graves o incluso la muerte.

¡ADVERTENCIA!El usuario puede estar expuesto a lesiones (graves). «Advertencia» significa que es probable que se produzcan daños personales si no se res-petan las indicaciones.

¡ATENCIÓN!Hay riesgo de daños materiales. «Atención» sig-nifica que el producto puede resultar dañado si no se respetan las indicaciones.

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3 Transporte y almacenamiento antes de la utilizaciónEn el momento de la entrega del material, com-pruebe que éste no haya resultado dañado durante el transporte. En caso afirmativo, realice las gestiones pertinentes con el transportista en los plazos esta-blecidos.

Manipule la bomba con precaución para evitar dañar el producto antes de instalarlo.

4 Utilización prevista (aplicación)

Las aplicaciones comunes de las bombas MVI se refieren a líquidos limpios con un contenido poco importante de partículas abrasivas en los sectores comercial, agrícola, industrial y los servicios públicos. Abastecimiento de agua, depósitos de agua, irriga-ción, limpieza a alta presión, sistemas antiincendio, acometidas de agua en calderas, retornos de con-densado y sistema de sobrepresión.

Ámbitos de aplicación: • sistemas de abastecimiento de agua y de sobre-

presión• sistemas industriales de circulación• procesamiento de agua• circuitos de agua de refrigeración• dispositivos antiincendio, de lavado• instalaciones de regadío, etc.

5 Datos técnicos

5.1 Claves del tipo

¡ATENCIÓN! Las condiciones externas pueden provocar daños.Si el material entregado se va a instalar más tarde, guárdelo en un lugar seco y protegido contra impactos y agentes exteriores (humedad, hielo, etc.).

¡ADVERTENCIA! Lesión corporalDebido a la posición elevada del centro de grave-dad y a la base de apoyo pequeña, tome las pre-cauciones necesarias durante las tareas de mantenimiento para evitar que la bomba se caiga y pueda poner en peligro la seguridad de las per-sonas.

¡ATENCIÓN! Peligro de dañar la bombaEstas bombas sólo son útiles para impulsar agua

Ejemplo: MVI220-02/1-1/A3/E80/3-575-14-T

MVI Familia de bomba220 Caudal nominal (GPM a 60 Hz / 2 polos)-02 Número de etapas/ 1 Número de rodetes recortados-1 1 = Acero inoxidable 304

2 = Acero inoxidable 316L3 = Carcasa de la bombaCubierta en voluta de hierro colado tratado por cataforesis, sistema hidráulico de acero inoxidable 304

/ A3 P = Racor rápido para collar de tipo Victaulic

A3 = Brida ANSI 300lbO = 2 bridas ovaladas con pernos, rosca

NPT/E Junta de bomba

E = Juntas tóricas : EPDM (KTW/WRC)V = Juntas tóricas : VITON

80 1 carácter significa :K = Juntas estándar con sistema cartuchoS = Juntas estándar sin sistema cartucho

(materiales EPDM o VITON según el tipo de junta de la bomba)

2 caracteres indican una versión especial:00 = Juntas mecánicas de carburo de silicio

/ carburo de silicio de EPDM80 = Juntas mecánicas de carburo de silicio

/ carburo de silicio de EPDM y sistema de cartucho

10 = Juntas mecánicas de carburo de silicio / carburo de silicio de VITON

A0 = Juntas mecánicas de carburo de silicio / carburo de silicio de VITON y sistema de cartucho

11 = Juntas mecánicas de carburo de silicio / carbono de VITON

01 = Juntas mecánicas de carburo de silicio / carbono de EPDM

/ 3 1 = Monofásico3 = TrifásicoNada= Sin motor

-575 1-230 = Monofásico 115/230V60Hz

3-460 = Trifásico 208-230/460V 60Hz3-575 = Trifásico 575V 60Hz

-14 56 = Bastidor de motor NEMA 56C14 = 143 TC & 145 TC18 = 182 TC & 184 TC21 = 213 TC & 215 TC28 = 284 TC & 286 TC32 = 324 TSC36 = 364 TSC

-T O = Carcasa del motor ODPT = TEFC

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Dimensiones de salida y de los tubos:Ver fig. 3a - d

5.3 Suministro• Instrucciones de instalación y funcionamiento• Bridas:

- ovaladas con dos pernos : bridas auxiliares, per-nos y juntas incluidos en la bomba.

- ANSI 300 lb : bomba suministrada con juntas y pernos sin contrabridas (accesorios opcionales).

- tipo “Victaulic”: bomba suministrada sin collares (accesorios opcionales).

5.4 Accesorios• Kit de tubo by-pass• Contrabridas (300 # tipo redondo, conexiones

diversas y ovalada 2 conexión roscada)

6 Descripción y funcionamiento

6.1 Descripción del producto (ver figura 1 y 2)1-Válvula de base de filtro de aspiración2-Válvula en la aspiración de la bomba3-Válvula en la impulsión de la bomba4-Válvula antirretorno5-Tapón de llenado y purga de aire6-Tapón de drenaje – antibloqueo7-Soportes de tubería o collares8-Filtro de aspiración9-Depósito de almacenamiento

10-Red de agua pública11-Motor de arranque12-Gancho de elevación13-Macizo HA: Altura máx. de aspiraciónHC: Altura de carga mín.

6.2 Concepto de la bomba y del motorBoma centrífuga multietapa en serie con casquillo (con junta mecánica). Tipo de bastidor del motor estándar NEMA, acoplado al motor mediante un eje y protecciones.

7 Instalación y conexión eléctrica

Sólo personal cualificado de acuerdo con la norma-tiva vigente local podrá efectuar los trabajos de instalación y eléctricos.

5.2 Tabla de datos

Presión máx. de funcionamientoCarcasa de la bomba Brida ovalada:

230 PSI (16 bares)Bridas ANSI 300lb:360 PSI (25 bares)Bridas «Victaulic»:230 PSI (16 bares)

Presión máx. de aspira-ción

140 PSI (10 bares)

Rango de temperatura Temperaturas de los líquidos

Versión EPDM: de 5°F a 250°F (de - 15° a + 120° C)Versión VITON: de 5°F a 194°F (de - 15° a + 90° C)

Temperatura ambiente +104°F máx. (+ 40° C)Datos eléctricosProtección del motor ODP: Carcasa del tipo 1, emplear

únicamente en el interiorTEFC: Carcasa del tipo 2

Clase de aislamiento FFrecuencia 60 HzTensión 1~: 115/230V (± 10 %)

3~: 208-230V/460V, 575V (±10 %)OtrosPresión mín. en la entra-da del lado aspiración

Conforme al NPSH de la bomba

Humedad ambiental <90 %Nivel sonoro Depende del tamaño de la bomba,

de la velocidad de rotación, del punto de funcionamiento y del tipo de motor: en determinados casos, puede llegar a los 77 dB(A) en motor ODP y 86 dB(A) en motor TEFC.

¡ADVERTENCIA! Lesión corporalPara evitar el riesgo de que se produzcan acciden-tes, deben respetarse las instrucciones existen-tes.

¡ADVERTENCIA! Peligro de electrocuciónEvite los riesgos vinculados a la electricidad. Respete tanto los códigos nacionales, locales y los reglamentos en materia de electricidad.

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7.1 Instalación• La bomba debe intalarse en un lugar seco, bien ven-

tilado y protegido contra las heladas.

• Instalar la bomba en un lugar seco, protegido contra las heladas y situado a la mayor proximidad posible al agua en aplicaciones de elevación del agua.

• Coloque la bomba en un lugar accesible a fin de faci-litar los trabajos de inspección y mantenimiento. La bomba se debe montar en posición vertical sobre un zócalo de hormigón.

• En el caso concreto de las bombas que sean particu-larmente pesadas, ponga un gancho o anillo que tenga la fuerza de carga adecuada (peso total de la bomba), a fin de poder utilizar una grúa o aparato similar en las tareas de mantenimiento o reparación de la bomba.

• Instale la bomba sobre un macizo de hormigón (mín. 10cm / 4" de altura). Tenga en cuenta una capa de aislamiento contra la vibración entre el zócalo de hormigón y la bomba en lugares donde se debe reducir el ruido.

• La superficie de instalación tiene que ser lisa y plana. Si la bomba está inclinada, se producirá un desgaste prematuro del cojinete.

7.2 Conexión hidráulica • Las dimensiones de montaje y las de conexión se

indican en la fig.3.- Bomba con bridas ovaladas de dos pernos: los

tubos están roscados (NPT) directamente en las bridas auxiliares.

- Las bombas con brida redonda de 300lb tienen bridas auxiliares (contrabridas) para conectar a las bridas dependiendo del tipo de brida (con rosca NPT. soldada, etc.)

• Al montar la brida ovalada, utilice únicamente los pernos suministrados. Si utiliza pernos más largos, corre el riesgo de dañar la base de la bomba.

• El sentido del caudal está indicado en la bomba.• Los tubos de aspiración y de impulsión deben mon-

tarse de tal manera que no ejerzan ninguna restric-ción sobre la bomba. Los tubos deben fijarse de forma que la bomba no tenga que aguantar su peso.

• Se recomienda instalar las válvulas de compuerta en los lados de aspiración e impulsión de la bomba, a fin de evitar tener que vaciar y volver a llenar el sistema si es preciso sustituir la bomba.

• Se recomienda que la tubería que lleva al lado de aspiración de la bomba tiene una longitud mínima que sea tres veces más larga que el diámetro de tuberías.

• Aconsejamos prever una válvula de retención en el tubo de impulsión para proteger la bomba contra los golpes de agua.

• Nota: para bombear agua fuertemente aireada o caliente, recomendamos instalar un kit de tubo by-pass.

Fig. 2: Aplicaciones sumergidas o de aspiración de carga

• En caso de conexión directa a la red pública de agua potable, consulte a las autoridades locales sobre los requisitos de un dispositivo de protección antirre-torno del caudal.

• En caso de conexión indirecta mediante un depósito, el tubo de aspiración tiene que ir provisto de un filtro de aspiración, a fin de evitar que lleguen impurezas a la bomba.

Fig. 1: Aplicaciones de aspiración de elevación• Para evitar pérdidas de presión, es conveniente

utilizar un tubo de aspiración que sea lo más corto posible y evitar que aumenten las pérdidas por fric-ción.

• Aísle correctamente las conexiones con los pro-ductos adecuados: no debe instalarse ninguna toma de aire en esta tubería, 2 %. Ver figura 1.

¡ATENCIÓN! Peligro de dañar la bombaLas impurezas y las gotas de soldadura sin solidi-ficar en el cuerpo de la bomba pueden influir en el funcionamiento de ésta.

• Se recomienda efectuar todas las operaciones de soldado antes de instalar la bomba.

• Limpie a fondo el sistema antes de instalar la bomba.

¡ADVERTENCIA! Peligro de accidente por la pre-sencia de superficies calientesLa bomba debe colocarse de tal manera que nadie pueda entrar en contacto con las superficies calientes de la misma durante su funcionamiento.

¡ATENCIÓN! Peligro de dañar la bomba por cavita-ción (agua hirviendo en el ojo de la primera hélice)No instale una posición de aspiración de elevación con un fluido a más de 175°F (80°C). Consulte en la tabla de más abajo las correcciones requeridas por NPSH para aplicaciones de aspiración de ele-vación por encima del nivel del mar.

Altura Pérdida de altura Altura Pérdida de altura0 m 0,00 mCL 0 pies 0,0 pies

500 m 0,60 mCL 1000 pies 1,2 pies1000 m 1,15 mCL 2000 pies 2,4 pies1500 m 1,70 mCL 3000 pies 3,5 pies2000 m 2,20 mCL 5000 pies 5,7 pies2500 m 2,65 mCL 7000 pies 7,6 pies3000 m 3,20 mCL 10000 pies 10,7 pies

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7.3 Conexión eléctrica

• Las características eléctricas (frecuencia, voltaje, intensidad nominal) del motor están indicadas en las claves de tipo: compruebe que esté adaptado a la red en la que se va a utilizar.

• La bomba debe conectarse a la red mediante un cable sólido dotado de un conector macho o de un interruptor de alimentación principal.

• El motor trifásico tiene que estar conectado a un motor de arranque homologado. La corriente nomi-nal de regulación tiene que corresponder al valor indicado en la placa de la bomba.

• El cable de conexión tiene que colocarse de tal manera que nunca entre en contacto con la canaliza-ción principal y/o el cuerpo de la bomba y la carcasa del motor.

• La bomba/instalación deben ponerse a tierra de acuerdo con la normativa local vigente. Como pro-tección adicional, puede instalarse un interruptor de toma a tierra.

• La conexión a la red debe efectuarse de acuerdo con un plan de conexión del borne (ver fig. 4).

• Se puede modificar en un cuarto de giro la posición de la caja de bornes: retire los tornillos de fijación del motor (si es preciso retirar los protectores de acopla-miento) y volver a orientar el motor a la posición deseada.

• Los motores eléctricos de las bombas pueden conectarse a un convertidor de frecuencia. Siga al pie de la letra las instrucciones del fabricante del con-vertidor.El convertidor no puede generar en los bornes del motor picos de tensión que sean superiores a 850V y dU/dt (variaciones de tensión/tiempo) superiores a 2500 V/µs. Si la señal de tensión presenta valores superiores a los citados anteriormente, el motor puede resultar dañado. De lo contrario, prevea un fil-tro LC (inductancia - condensador) entre el conver-tidor y el motor. Dicho filtro tendrá que conectarse al motor con un cable de longitud mínima y, si es pre-ciso, blindado.

8 Arranque

8.1 Limpieza preliminar

8.2 Llenado y purgado del sistema

Dos tipos de casos:Fig. 1: Aplicaciones de aspiración de elevaciónFig. 2: Aplicaciones sumergidas o de aspiración de carga en un depósito de almacenamiento (9) o en la red municipal (10) con un sistema de protección de marcha en seco.

Temperatura Pérdida de altura de aspiración (HA) Temperatura Pérdida de altura de aspiración (HA)

20 °C 0,20 mCL 70 °F 0,70 pies30 °C 0,40 mCL 90 °F 1,50 pies40 °C 0,70 mCL 100 °F 2,00 pies50 °C 1,20 mCL 120 °F 3,70 pies60 °C 1,90 mCL 140 °F 5,70 pies70 °C 3,10 mCL 160 °F 10,10 pies80 °C 4,70 mCL 180 °F 16,20 pies90 °C 7,10 mCL 200 °F 26,20 pies

100 °C 10,30 mCL 210 °F 32,60 pies

¡ADVERTENCIA! Peligro de electrocución• Evite los riesgos vinculados a la electricidad. • Sólo un electricista cualificado puede realizar tra-

bajos eléctricos en el producto.• Respete estrictamente tanto los códigos eléctri-

cos nacionales, como los códigos y reglamentos nacionales.

• Antes de proceder a realizar las conexiones eléc-tricas, es preciso desconectar la bomba y prote-gerla contra arranques no autorizados.

• Para garantizar la seguridad de la instalación y del funcionamiento, es preciso efectuar una toma de tierra correcta con los bornes de tierra del sumi-nistro eléctrico.

¡ADVERTENCIA! Lesión corporalVuelva a colocar los tornillos de fijación y los protectores de conexión.

¡ADVERTENCIA! Peligro de electrocuciónNO SE OLVIDE DE CONECTAR LA TOMA A TIERRA.

¡ADVERTENCIA! Peligro para la saludEn fábrica se puede probar el rendimiento hidráu-lico de cada bomba, por lo que es posible que que-den pequeñas cantidades de agua dentro de la bomba. Por motivos de higiene, se recomienda limpiar la bomba antes de utilizarla en una red de agua potable.

¡ATENCIÓN! Peligro de dañar la bombaLa bomba no debe funcionar nunca en seco.

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Proceso de purga de la instalación con una bomba en carga (ver fig. 2):

• Cierre la válvula de impulsión (3)• Abra el purgador (5), abra la válvula de aspiración (2)

y llene totalmente la bomba.• Cierre el purgador sólo cuando haya salido el agua

del purgador sin que se note aire.

Proceso de purga de la instalación con una bomba en aspiración (ver fig. 5): Dos casos posibles:1er caso (ver fig. 5.1)- Cierre la válvula de impulsión ( 3) y abra la de

aspiración (2)- Retire el tapón del purgador (5)- Destornille de 4 a 5 giros el tapón inferior de dre-

naje y antibloqueo (6) situado en el cuerpo de la bomba.

- Mediante un embudo introducido en el orificio del purgador, llene completamente la bomba y el tubo de aspiración.

- Cuando haya salido agua sin que se note aire al purgador, habrá finalizado el llenado.

- Atornille el tapón del purgador y el tapón inferior de drenaje antibloqueo.

2o caso (ver fig. 5.2)El llenado se puede facilitar instalando en el con-ducto de aspiración de la bomba un tubo vertical dotado de una válvula de bola de Ø ½" y un embudo.

INDICACIÓN:La longitud del tubo debe sobrepasar el nivel del purgador como mínimo 2 pulgadas (50 mm).- Cierre la válvula de impulsión (3), abra la válvula

de aspiración (2).- Abra la válvula de bola y el purgador.- Desenrosque de 4 a 5 giros el tapón de drenaje y

antibloqueo (6).- Llene completamente la bomba y el conducto de

aspiración hasta que salga agua por el purgador (5).

- Cierre la válvula de bola (puede quedarse insta-lado) retire el tubo, cierre el purgador (5) y ator-nille el tapón de drenaje antibloqueo (6).

Protección de marcha en secoPara garantizar que la bomba recibe siempre agua, le recomendamos que la proteja mediante un presos-tato o un interruptor de flotador.

8.3 Confirme rotación correctaAntes de arrancar la bomba, asegúrese de que los elementos rotatorios están carente de cualquier tipo de obstrucción.

• Retire o uno o ambos protectores de conexión.• Gire la conexión a mano para asegurarse de que la

bomba gire libremente sin obstáculos.• Una vez la rotación correcta ha sido confirmada

(refiérase al procedimiento trifásico o monofásico abajo indicado) reinstala el protector o los protecto-res de conexión antes de que la corriente sea acti-vada completamente.

Motor trifásico• Conecte el motor pulsando brevemente el inte-

rruptor y compruebe que gire correctamente en el sentido indicado por la flecha en la indicación luminosa o en la placa de identificación de la bomba.

• Si gira en el sentido contrario, asegúrese de que la corriente está desconectada, cambie la conexión de dos cables del motor y vuelva a comprobar el sentido de la rotación. Cuando se haya confirmado el sentido correcto de la rotación, se recomienda equilibrar la intensidad de las tres fases; la diferen-cia máxima permitida es de +/-5%.

Motor monofásico• Por lo general, la rotación de aplicaciones monofá-

sicas deben ser correctas, pero si la bomba funcio-nase indebidamente, compruebe el sentido de la rotación. Si gira en sentido contrario, indique el número de la placa de la bomba para recibir más instrucciones para cambiar el sentido.

¡ADVERTENCIA! Lesión corporal¡Bomba bajo presión! Con agua caliente, se puede escapar un chorro de agua por el orificio de purga. Tome todas las medidas necesarias para proteger las personas y el motor.

¡ADVERTENCIA! Peligro de electrocuciónSe tienen que excluir peligros causados por energía eléctrica. No intente lo siguiente hasta que no esté comple-tamento seguro de que la corriente es desconectada.

¡ATENCIÓN! Posible peligro de dañar la bombaAntes de arrancar la bomba, asegúrese que el área del cierre contiene fluido.

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8.4 Arranque

• Mantenga cerrada la válvula de impulsión.• Arranque la bomba.• Abra el purgador para purgar el aire. Si, al cabo de

20 segundos, no sale un chorro de agua, vuelva a cerrar el purgador, pare la bomba y espere alrededor de 20 segundos para que el aire se asiente.

• Vuelva a arrancar la bomba.• Si es preciso (sobre todo si la altura de la aspiración

supera los 16 pies – 5m), vuelva a ejecutar estas operaciones.

• Si sale un chorro de agua del purgador (señal de que la bomba libera presión), abra lentamente la válvula de impulsión. Debe entrar agua en la bomba.

• Controle con un manómetro si fluctúa la presión de impulsión. Si se detectan fluctuaciones, compruebe las condiciones de entrada y/o vuelva a llenar la bomba.

• Para asegurarse de haber purgado todo el aire, cierre la válvula de impulsión y el purgador y, a continua-ción, apague la bomba durante 20 segundos, vuelva a poner la bomba en marcha y abra el purgador. Esta operación debe repetirse mientras siga saliendo aire.

• Abra la válvula de impulsión completamente o en la posición que indica la instalación.

• Compruebe que la corriente de entrada sea inferior o igual a la indicada en la placa del motor.

9 Mantenimiento / servicioSólo personal autorizado realizará los trabajos de mantenimiento.

• Durante el funcionamiento no es preciso ningún mantenimiento determinado.

• La bomba y el motor deben estar perfectamente lim-pios.

• En caso de parada prolongada y si no hay riesgo de congelación, se desaconseja drenar la bomba.

• El rodillo que mantiene el acoplamiento está engra-sado para toda su vida útil, por lo que no es preciso engrasarlo. Recomendamos que lubrique el motor del eje así como el orificio de acoplamiento con una grasa de fuerte adherencia (por ejemplo, de tipo D321R Molikote o 8191 Loctite) a fin de facilitar los desmontajes posteriores.

Motores sin dispositivo de engrase• Los rodillos están lubricados para toda su vida útil y,

por consiguiente, no es preciso lubricarlos.

Motores con dispositivo de engrase• Consulte las instrucciones que figuran en el motor.

A falta de instrucciones, engrase cada 5 000 horas mediante una grasa de alta temperatura.

Juntas mecánicas • Las juntas mecánicas no precisan ningún tipo de

mantenimiento durante su funcionamiento. No debe funcionar nunca en seco.

¡ADVERTENCIA! Peligro de quemadurasSegún las condiciones de funcionamiento de la bomba o de la instalación (temperatura del fluido de impulsión, caudal del volumen), el conjunto de la bomba, incluido el motor, puede llegar a alcan-zar temperaturas muy elevadas. Existe peligro real de quemarse sólo con tocar la bomba.

¡ATENCIÓN! Peligro de dañar la bombaLa bomba no debe funcionar con un caudal nulo (válvula de impulsión cerrada) más de 10 minutos en agua fría (T < 104°F (40°C)) y más de 5 minutos a temperaturas superiores a 140°F (60°C).Le recomendamos que garantice un caudal mínimo de aprox. 10 % del caudal nominal de la bomba, a fin de evitar que se forme una bolsa gaseosa en la parte superior de ésta.

¡ADVERTENCIA! Peligro de electrocuciónEvite los riesgos vinculados a la electricidad. Antes de proceder a efectuar trabajos eléctricos, la bomba deberá apagarase y protegerse contra una puesta en marcha no autorizada.

¡ADVERTENCIA! Peligro de quemadurasSi la temperatura del agua y la presión del sistema son elevadas, cierre las válvulas de aislamiento por encima y por debajo de la bomba. Deje que la bomba se enfríe.

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10 Fallos, causas y soluciones

Si no se puede solucionar el fallo, póngase en contacto con el especialista local en instalaciones sanitarias o de calentamiento, o bien con el servi-cio de atención al cliente de WILO.

11 Piezas de repuestoLas piezas de repuesto deben pedirse al especialista local o al departamento de servicio de atención al cliente de Wilo.A fin de evitar devoluciones o pedidos incorrectos, indique los datos de la placa de características en todos los pedidos.

¡ADVERTENCIA! Peligro de electrocuciónEvite los riesgos vinculados a la electricidad. Antes de proceder a efectuar trabajos eléctricos, la bomba deberá cerrarse y protegerse contra los arranques no autorizados.

¡ADVERTENCIA! Peligro de quemadurasSi la temperatura del agua y la presión del sistema son elevadas, cierre las válvulas de aislamiento situadas por encima y por debajo de la bomba. En un primer tiempo, deje que la bomba se enfríe.

FALLOS/CAUSAS REPARACIÓN

1) La bomba gira pero no sale caudala) Los órganos internos están obstruidos por cuerpos extraños a) Desmonte la bomba y límpielab) La tubería de aspiración está obstruidac) Entradas de aire por la tubería de aspiración

d) La bomba ha perdido el líquido

b) Limpie la tuberíac) Controle la estanqueidad de toda la tubería hasta la bomba y

repare las fugasd) Vuelva a desbloquear llenando la bomba. Compruebe la

estanqueidad de la válvula de basee) La presión en la aspiración es demasiado baja, por lo general

va acompañada de un ruido de cavitación

f) El motor se alimenta con un voltaje insuficiente

e) Se producen demasiadas pérdidas de carga en la aspiración o la altura de aspiración es demasiado elevada (controlar el NPSH de la bomba instalada y de la instalación).

f) Controle el voltaje en los bornes del motor y la sección de los cables

2) La bomba vibraa) Está mal ajustada al zócalo

b) La bomba está obstruida por cuerpos extrañosc) Rotación no constante

d) Conexión eléctrica incorrecta

a) Compruebe y apriete totalmente los tornillos de los pernos de sellado

b) Desmonte la bomba y límpielac) Compruebe que la bomba gire sin problemas ni resistencias

anormalesd) Compruebe las conexiones con el motor de la bomba

3) El motor se calienta de forma anormala) Voltaje insuficiente

b) La bomba esa obstruida por cuerpos extraños

a) Compruebe la tensión en los bornes del motor. Debe estar entre ± 10 % en 50 Hz y ± 6 % en 60 Hz de la tensión nominal

b) Desmonte la bomba y límpiela

c) Temperatura ambiente superior a + 40°C

d) Problema de conexión en la caja de bornese) Desequilibrio de fase o trifase

c) El motor tiene que funcionar a una temperatura ambiente máx. de + 40°C

d) Cumpla lo indicado en la placa del motor y vea la figura 4.e) Compruebe la intensidad de todos los montantes y, si la dife-

rencia es mayor que 5%, solicite a un electricista que la equi-libre.

4) El caudal no es regulara) No se respeta la altura de aspiración (HA)

b) La tubería de aspiración tiene un diámetro inferior al de la bomba

a) Revise las condiciones de instalación y las recomendaciones de estas instrucciones

b) La tubería de aspiración ha de tener el mismo diámetro que el orificio de aspiración de la bomba

c) El filtro y la tubería de aspiración están parcialmente obstruidos

c) Desmóntelos y límpielos.

¡ADVERTENCIA! Peligro para la saludSi el líquido es tóxico, corrosivo o peligroso para la salud, es obligatorio informar a WILO o al operario de reparación aprobado. En dicho caso, limpie la bomba para que el operario de reparación esté totalmente seguro.

thor “frost buster” operating manual€¦ · thor “frost buster” operating manual model...

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