STRATOS Asphalt Distributors TRAILER MOUNTED MAINTENANCE UNIT

Transcription

1 STRATOS Asphalt Distributors TRAILER MOUNTED MAINTENANCE UNIT Models: DMT-400, DMT-600 and DMT-1000 PART S MANUAL

2 TABLE OF CONTENTS TABLE OF CONTENTS... 2 YOUR DISTRIBUTOR... 3 TANK SYSTEM... 4 ASPHALT PUMP SYSTEM... 5 FLOAT ASSEMBLY... 6 ASPHALT PIPING SYSTEM... 7 SPRAY WAND ASSEMBLY... 8 SPRAY BAR ASSEMBLY.. 9 BURNER SYSTEM STRAINER 11 ELECTRICAL SYSTEM.. 11 SYSTEM ELECTRO VALVE NEUMATIC.. 12 THE FOLLOWING ARE ATTACHED HL 32 VIKING PUMP MANUAL ADC BECKETT BURNER MANUAL THERMOSTAT CONTROL 3 WAYS VALVE HONDA ENGINE MANUAL 2

3 YOUR MAINTENANCE UNIT MODEL: DMT-400 SERIAL NUMBER: 3133 CAPACITY: 400 Gallons PURCHASE DATE: OCTOBER 2017 INSTRUCTIONS FOR IDENTIFYING AND ORDERING OF REPLACEMENT PARTS For everything related to your Stratos Asphalt Distributor contact: PAVEMENTGROUP.com Toll free: Western Ave, Albany, NY Manufacturer Info: EMPRESAS Y EQUIPOS INDUSTRIALES S.A. DE C.V. Av. Libertad 150, Zona Industrial. San Luis Potosí, S.L.P. México Phone: +52 (444) , Fax +52(444) egz@seaman-gunnison.com Please mention the following information when calling with your service questions: 1) Model Number, Serial Number, Gallons, Pump Brand, Motor Brand 2) Description of the problem 3) Steps you ve already taken to try and correct the problem 4) Need a Part? Part Code number, Description and Quantity CUSTOMER SUPPORT: Our goal is to help make sure that your equipment performs at its best at all times. Call our customer support department with any questions. We appreciate your feedback and equipment improvement suggestions. Toll free: or Western Ave, Albany, NY M-F 9am-5pm 3

4 REF. QTY. DESCRIPTION CODE 1 1 LEVEL GAUGE E-00-B* DIAL THERMOMETER C-14-PB-C MANHOLE LID E-00-PA LID GASKET Q-70-PA BUTTERFLY NUT S-00-PA LOCK ARM S-00-PA STRAINER MESH S-00-BE LEVEL STICK M-00-B* TRAFFIC LIGHT RED COVER C-12-EC-C MARKER LIGHT RED COVER C-12-EC-C MARKER LIGHT AMBER COVER C-12-EC-C DECAL Q-53-PA BURNER DECAL Q-53-HA MAINTENANCE DECAL Q-53-HA VALVES DECAL Q-53-HA MFG PLATE Q-53-PA MANHOLE This drawing is property of SEAMAN-GUNNISON. It can't be reproduced in any way without our written consent. MACHINE QTY DMT-400, 600, MATERIAL INDICATED DRAWN BY J MARTIN R H DESIGNED BY ENGINEERING DRAWING TITLE DESTINATION DATE IF YOUR MODEL ES: 400, REMPLACING * BY E 600, REMPLACING * BY F 1000, REMPLACING * BY G 31/10/2014 DMT TANK SYSTEM DIM UNITS PULG. DRAWING NUMBER E-00-B* TOL. SCALE WEIGHT(Kg) SHEET +/- 1/16" N/A 1/1 N/A

5 REF. QTY. DESCRIPTION CODE 1 1 HONDA ENGINE C-02-NA-C MOTOR SHEAVE M-00-BA V-BELT C-24-GZ-C PUMP SHEAVE M-00-BA MOUNT BEARING C-18-GB-C ASPHALT PUMP HL-32 C-48-KA-C GUARD S-00-BE This drawing is property of SEAMAN-GUNNISON. It can't be reproduced in any way without our written consent. MACHINE DMT-400,600,1000 MATERIAL QTY 1 DRAWING TITLE ASPHALT PUMP SYSTEM 30 GPM DESTINATION DRAWING NUMBER INDICATED DMT E-00-BE DRAWN BY DESIGNED BY DATE DIM UNITS SCALE ISMAEL HDZ. ENGINEERING 31/10/2014 PULG. 1:6 TOL. WEIGHT(Kg) SHEET +/- 1/16" XXX 1/1

6 REF. QTY. DESCRIPTION CODE 1 1 FLOAT GUIDE TUBE M-00-PA NEEDLE ARM M-00-BA TAPERED NUT C-10-QW-D GRAPHITE CORD C-44-ZJ-A HEX NUT C-20-VA-A ADJUST BLOCK M-00-BA FLOAT ARM M-00-B* FLOAT BODY S-00-PA NEEDLE M-00-BA LEVEL GAUGE PLATE DMT-400 DMT-600 DMT-1000 Q-53-BA Q-53-BF Q-53-BA IF YOUR MODEL ES: 400, REMPLACING * BY E 600, REMPLACING * BY F 1000, REMPLACING * BY G This drawing is property of SEAMAN-GUNNISON. It can't be reproduced in any way without our written consent. MACHINE DMT-400, 600, MATERIAL INDICATED DRAWING TITLE DESTINATION FLOAT ASSEMBLY DRAWN BY DESIGNED BY DATE DIM UNITS TOL. SCALE ISMAEL HDZ. ENGINEERING 15/10/2014 PULG. 1:4 DMT DRAWING NUMBER E-00-B* WEIGHT(Kg) SHEET +/- 1/16" XXX 1/1

7 WAND TO SPRAY BAR TANK RETURN 24 5 DIESEL RETURN ECO-FLUSH TO SPRAY BAR DIESEL RECIRCULATION WAND PRESSURE GAUGE TANK SUCTION TANK RETURN TANK SUCTION PRESSURE GAUGE DIESEL SUCTION TANK UNLOADING ASPHALT PUMP DIESEL SUCTION This drawing is property of SEAMAN-GUNNISON. It can't be reproduced in any way without our written consent. MACHINE QTY DMT-400, 600, MATERIAL INDICATED DRAWN BY J MARTIN R H TANK UNLOADING DESIGNED BY ENGINEERING # CODE DESCRIPTION QTY. 1 C-10-SX-B1300 BELL REDUCTION 2 2 C-10-RZ-A0120 NIPPLE 12 3 C-06-ON-A0120 BALL VALVE 2 4 C-10-TS-A0120 BLACK TEE 4 5 C-10-RH-A0120 BLACK ELBOW NIPPLE 4 6 C-10-RZ-A0140 NIPPLE 1 7 C-10-TD-C1671 DP FAST COUPLING 1 8 C-10-TD-C1672 D FAST COUPLING 1 9 E-00-BE PARKER HOSE 1 10 C-10-QV-E2155 ADAPTER 3 11 C-10-SY-B1300 REDUCTION BUSHING 5 12 E-00-BE PARKER HOSE 1 13 C-10-RB-A0140 BLACK ELBOW 3 14 C-10-SY-B1000 REDUCTION BUSHING 1 15 C-10-QW-D0305 ELBOW 2 16 C-10-QW-D2735 PARKER HOSE 1 17 C-14-PA-C0422 DIAL MANOMETER 1 18 C-10-RO-A0120 BLACK CROSS COUPLING 1 19 E-00-BE PARKER HOSE 1 20 C-10-QV-E2713 ADAPTER 2 21 E-00-BE PARKER HOSE 1 22 C-10-SY-B1003 REDUCTION BUSHING 2 23 C-10-RZ-A0080 NIPPLE 2 24 C-06-ON-A0080 BALL VALVE 3 25 C-10-QV-E º ELBOW 2 26 E-00-BE PARKER HOSE 1 27 C-10-RH-A0080 BLACK ELBOW NIPPLE 1 28 E-00-BE PARKER HOSE 1 29 C-10-RB-A0080 BLACK ELBOW 1 30 C-06-ON-A0120 BALL VALVE 1 31 S-00-BE CLEANING PIPING ASSY C-48-KA-C3445 VIKING PUMP 1 33 C-06-ON-A0100 BALL VALVE 3 DRAWING TITLE ASPHALT PIPING SYSTEM DESTINATION DRAWING NUMBER DMT DATE DIM UNITS TOL. SCALE WEIGHT(Kg) SHEET +/- 1/16" N/A 1/1 31/10/2014 PULG. E-00-BE N/A

8 REF. QTY DESCRIPTION CODE 1 1 1/2"Ø X 50' HOSE REEL I-04-MT-C SPRAY WAND E-00-BE NOZZLE C-04-MS-C This drawing is property of SEAMAN-GUNNISON. It can't be reproduced in any way without our written consent. MACHINE QTY DMT MATERIAL DRAWN BY ISMAEL HDZ. INDICATED DESIGNED BY ENGINEERING DRAWING TITLE WAND AND REEL ASSEMBLY DESTINATION DMD DATE DIM UNITS 31/10/2014 INCHES DRAWING NUMBER E-00-BE TOL. SCALE WEIGHT(Kg) SHEET +/- 1/16" XXX 1/1 N/A

9 2 1 2 BOTTOM VIEW FRONT VIEW 4 REF QTY DESCRIPTION CODE 1 1 CENTRAL STD SPRAYBAR S-00-BS FT EXTENSION S-00-BS BALL VALVE C-06-ON-A NOZZLE C-04-MS-C0500 This drawing is property of SEAMAN-GUNNISON. It can't be reproduced in any way without our written consent. MACHINE QTY DMT-400, 600, MATERIAL INDICATED DRAWN BY J MARTIN R H DESIGNED BY ENGINEERING DRAWING TITLE 12' SPRAYBAR FOLDING DESTINATION DRAWING NUMBER DMT DATE DIM UNITS TOL. SCALE WEIGHT(Kg) SHEET +/- 1/16" N/A 1/1 05/05/2015 PULG. S-00-BS N/A

10 # CODE DESCRIPTION QTY. 1 S-00-BE BUERNER TANK ASSY 1 2 C-26-HO-C1492 3/4" BREATHER FILTER 1 3 C-10-QW-D F º ELBOW 1 4 C-10-TD-C1650 2" 'D' FAST COUPLING 1 5 C-10-TD-C1598 "DP" 200 FAST COUPLING (CAP) 1 6 E-00-BE PARKER HOSE 1 7 C-10-QW-D º ELBOW 2 8 C-62-EI-C3576 BASE FOR DIESEL FILTER 1 9 C-26-HM-C1425 DIESEL FILTER 1 10 E-00-BG PARKER HOSE 1 11 C-10-QW-D0308 CONNECTOR 1 12 C-10-QW-D0233 CONNECTOR 1 13 E-00-BF PARKER HOSE 1 14 I-75-NR-C4075 BURNER 1 15 S-00-PA BURNER COVER 2 16 M-00-PA BURNER BASE RING 1 17 E-00-HA REFRACTORY ELEMENT FOR BURNER FIRE TUBE 1 This drawing is property of SEAMAN-GUNNISON. It can't be reproduced in any way without our written consent. MACHINE QTY DMT-400, 600, MATERIAL INDICATED DRAWN BY J MARTIN R H 1 DESIGNED BY ENGINEERING DRAWING TITLE ELECTRONIC BURNER SYSTEM DESTINATION DRAWING NUMBER DMT DATE DIM UNITS TOL. SCALE WEIGHT(Kg) SHEET +/- 1/16" N/A 1/1 31/10/2014 PULG. E-00-BE N/A

11 5 REF. QTY. NAME DESCRIPTION CODE 1 1 STRAINER BASKET SUB ASSEMBLY S-00-BS BASKET SUB ASSEMBLY S-00-BS O'RING O' RING C-24-HA-F CAP BASKET SUB ASSEMBLY S-00-BS SCREW 3/8" x 3/4" HEXAGONAL SCREW 3/8" x 3/4" C-20-UA-B This drawing is property of SEAMAN-GUNNISON. It can't be reproduced in any way without our written consent. MACHINE DMT-400,600,1000 MATERIAL INDICATED J MARTIN R H QTY 1 STRAINER 1 1/2" E-00-BS DRAWN BY DESIGNED BY DATE DIM UNITS TOL. SCALE WEIGHT(Kg) SHEET +/- 1/16" XXX 1/1 ENGINEERING DRAWING TITLE DESTINATION DMT 25/03/2017 PULG. DRAWING NUMBER 1:6

12 REF. QTY. NAME CODE 1 1 VALVE BODY M-00-PA SEAT M-00-PA GUIDE M-00-PA SPRING M-00-PA SEAT SPRING M-00-PA O-RING C-24-HA-R CAP M-00-PA LOCKNUT M-00-PA ADJUSTING SCREW S-00-PA This drawing is property of SEAMAN-GUNNISON. It can't be reproduced in any way without our written consent. MACHINE DMT-400,600,1000 MATERIAL INDICATED J MARTIN R H QTY 1 RELIEF VALVE E-00-PA DRAWN BY DESIGNED BY DATE DIM UNITS TOL. SCALE WEIGHT(Kg) SHEET +/- 1/16" XXX 1/1 ENGINEERING DRAWING TITLE DESTINATION DMT 25/03/2017 PULG. DRAWING NUMBER 1:5

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18 Electronic copies of the most current TSM issue can be found on the Viking Pump website at TECHNICAL SERVICE MANUAL GENERAL PURPOSE PUMPS SERIES 32 AND 432 SIZES G - N SECTION TSM 312 PAGE 1 OF 11 ISSUE G CONTENTS Introduction Special Information Maintenance Disassembly Assembly Installation of Carbon Graphite Bushings Pressure Relief Valve Instructions INTRODUCTION The illustrations used in this manual are for identification purposes only and cannot be used for ordering parts. Obtain a parts list from the factory or a Viking representative. Always give complete name of part, part number and material with model number and serial number of the pump when ordering repair parts. The unmounted pump or pump unit model number and serial number are on the nameplate. In the Viking model number system, basic size letters are combined with series number (32 and 432), indicating either an unmounted pump or mounted pump unit. FIGURE 1 - G Size Unmounted Pump UNMOUNTED PUMP PACKED MECH. SEAL G32 H32 HL32 J32 K32 KK32 L32 LQ32 LL32 Q32 M32 N32 Model Number Chart G432 H432 HL432 K432 L432 UNITS Units are designated by the unmounted pump model numbers followed by a letter indicating drive style. V = V-Belt D = Direct Drive B = Bracket Mounted FIGURE 2 - H and HL Size Unmounted Pump FIGURE 3 - J, K, KK and L Size Unmounted Pump (Shown without pressure relief valve) This manual deals only with Series 32 and 432 General Purpose Pumps. Refer to Figures 1 thru 12 for general configuration and nomenclature used in this bulletin. Pump specifications and recommendations are listed in Catalog Section 310, Series 32 and 432 General Purpose Pumps. FIGURE 4 - LQ, LL, M and N Size Unmounted Pump VIKING PUMP, INC. A Unit of IDEX Corporation Cedar Falls, IA USA

19 SAFETY INFORMATION AND INSTRUCTIONS IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY OR DEATH AND/OR RESULT IN DAMAGE TO PUMP AND/OR OTHER EQUIPMENT. VIKING S WARRANTY DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION, OPERATION OR MAINTENANCE. THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION, OPERATION OR MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP. PUMP MUST BE INSTALLED, OPERATED AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS. THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES. Symbol Legend :! Danger - Failure to follow the indicated instruction may result in serious injury or death. WARNING Warning - In addition to possible serious injury or death, failure to follow the indicated instruction may cause damage to pump and/or other equipment.! BEFORE opening any liquid chamber (pumping chamber, reservoir, relief valve adjusting cap fitting, etc.) be sure that : Any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections. The pump drive system means (motor, turbine, engine, etc.) has been locked out or otherwise been made non-operational so that it cannot be started while work is being done on the pump. You know what material the pump has been handling, have obtained a material safety data sheet (MSDS) for the material, and understand and follow all precautions appropriate for the safe handling of the material. WARNING INSTALL pressure gauges/sensors next to the pump suction and discharge connections to monitor pressures.! BEFORE operating the pump, be sure all drive guards are in place.! WARNING! USE extreme caution when lifting the pump. Suitable lifting devices should be used when appropriate. Lifting eyes installed on the pump must be used only to lift the pump, not the pump with drive and/or base plate. If the pump is mounted on a base plate, the base plate must be used for all lifting purposes. If slings are used for lifting, they must be safely and securely attached. For weight of the pump alone (which does not include the drive and/or base plate) refer to the Viking Pump product catalog. DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is mounted on a pump that is operating.!!! WARNING! WARNING DO NOT operate pump if the suction or discharge piping is not connected. DO NOT place fingers into the pumping chamber or its connection ports or into any part of the drive train if there is any possibility of the pump shafts being rotated. DO NOT exceed the pumps rated pressure, speed, and temperature, or change the system/duty parameters from those the pump was originally supplied, without confirming its suitability for the new service. BEFORE operating the pump, be sure that: It is clean and free from debris all valves in the suction and discharge pipelines are fully opened. All piping connected to the pump is fully supported and correctly aligned with the pump. ump rotation is correct for the desired direction of flow.!! WARNING AVOID contact with hot areas of the pump and/or drive. Certain operating conditions, temperature control devices (jackets, heat-tracing, etc.), improper installation, improper operation, and improper maintenance can all cause high temperatures on the pump and/or drive. THE PUMP must be provided with pressure protection. This may be provided through a relief valve mounted directly on the pump, an in-line pressure relief valve, a torque limiting device, or a rupture disk. If pump rotation may be reversed during operation, pressure protection must be provided on both sides of pump. Relief valve adjusting screw caps must always point towards suction side of the pump. If pump rotation is reversed, position of the relief valve must be changed. Pressure relief valves cannot be used to control pump flow or regulate discharge pressure. For additional information, refer to Viking Pump s Technical Service Manual TSM 000 and Engineering Service Bulletin ESB-31.! WARNING THE PUMP must be installed in a matter that allows safe access for routine maintenance and for inspection during operation to check for leakage and monitor pump operation. SECTION TSM 312 ISSUE G PAGE 2 OF 11

20 SPECIAL INFORMATION DANGER! Before opening any Viking pump liquid chamber (pumping chamber, reservoir, relief valve adjusting cap fitting, etc.) Be sure: 1. That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections. 2. That the driving means (motor, turbine, engine, etc.) has been locked out or made non-operational so that it cannot be started while work is being done on pump. 3. That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid. Obtain a material safety data sheet (MSDS) for the liquid to be sure these precautions are understood. Failure to follow above listed precautionary measures may result in serious injury or death. ROTATION: Viking pumps operate equally well in a clockwise or counterclockwise rotation. Shaft rotation determines which port is suction and which is discharge. Port in area where pumping elements (gear teeth) come out of mesh is suction port. PRESSURE RELIEF VALVES: 1. Viking pumps are positive displacement pumps and must be provided with some sort of pressure protection. This may be a relief valve mounted directly on the pump, an inline pressure relief valve, a torque limiting device, a rupture disk or other device. 2. There are relief valve options available on those pump models designed to accept a relief valve. Options may include a return to tank relief valve or a jacketed relief valve. Pumps equipped with a jacketed head plate are generally not available with a relief valve. 3. If pump rotation is reversed during operation, pressure protection must be provided on both sides of pump. 4. Relief valve adjusting screw cap must always point towards suction side of pump. If pump rotation is reversed, remove pressure relief valve and turn end for end. Refer to Figures 1, 2, and 4, page Pressure relief valves should not be used to control pump flow or regulate discharge pressure. For additional information on pressure relief valves, Refer to Technical Service Manual TSM000 and Engineering Service Bulletin ESB-31. MAINTENANCE Series 32 and 432 pumps are designed for long, trouble-free service life under a wide variety of application conditions with a minimum of maintenance. The points listed below will help provide long service life. LUBRICATION - Periodic external lubrication should be applied slowly with a hand gun at all lubrication fittings provided. A good quality of general purpose grease is satisfactory in the majority of cases, however, applications involving very high or low temperatures may require other types of lubricants. Suggested frequency of lubrication is once every 500 hours of operation. Do not over-grease. Refer to Enginnering Service Bulletin ESB-515. Consult the factory with specific lubrication questions. PACKING ADJUSTMENT - New packed pumps require some initial packing adjustment to control leakage as packing runs-in. Make initial packing adjustments carefully and do not over-tighten the packing gland. After initial adjustment, occasional inspection will reveal the need for packing gland adjustment or replacement of the packing. Refer to instructions under DISASSEMBLY, page 6 and ASSEMBLY, page 7 regarding repacking the pump. CLEANING THE PUMP - Keep the pump as clean as possible. This will facilitate inspection, adjustment and repair work and help prevent overlooking a dirt covered grease fitting. STORAGE - If the pump is to be stored or not used for six months or more, pump must be drained and a light coat of non-detergent SAE 30 weight oil must be applied to all internal pump parts. Lubricate fittings and apply grease to pump shaft extension. Viking suggests rotating pump shaft by hand one complete revolution every 30 days to circulate the oil. SUGGESTED REPAIR TOOLS: The following tools must be available to properly repair Series 32 and 432 pumps. These tools are in addition to standard mechanics tools such as open end wrenches, pliers, screw drivers, etc. Most of the items can be obtained from an industrial supply house. 1. Soft Headed hammer 2. Allen wrenches (some mechanical seals and set collars) 3. Packing hooks, flexible (packed pumps) Small for up to 5/16, G-KK ( ). Large for 3/8 and larger, L size and up ( ). 4. Brass bar 5. Arbor press SECTION TSM 312 ISSUE G PAGE 3 OF 11

21 FIGURE 5 - EXPLODED VIEW MODEL G32 PUMP ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Packing Nut 7 Casing and Bushing Assembly 13 Idler Pin 2 Outer Packing Gland 8 Casing Bushing 14 Head and Idler Pin Assembly 3 Packing Rings 9 Rotor and Shaft Assembly 15 Capscrews for Head 4 Inner Packing Gland 10 Idler and Bushing Assembly 16 Relief Valve Gasket 5 Packing Spring 11 Idler Bushing 17 Relief Valve 6 Packing Spring Washer 12 Head Gasket Set 18 Capscrews for Valve FIGURE 6 - EXPLODED VIEW MODEL G432 PUMP ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Capscrews for End Cap 7 Casing Bushing 13 Head and Idler Pin Assembly 2 End Cap 8 Rotor and Shaft Assembly 14 Capscrews for Head 3 Gasket for End Cap 9 Idler and Bushing Assembly 15 Relief Valve Gasket 4 Mechanical Seal (Complete) 10 Idler Bushing 16 Relief Valve 5 Set Collar with Setscrew 11 Head Gasket Set 17 Capscrews for Valve 6 Casing and Bushing Assembly 12 Idler Pin FIGURE 7 - EXPLODED VIEW MODEL H32 AND HL32 ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Two Piece Packing Gland 7 Casing and Bushing Assembly 13 Head and Idler Pin Assembly 2 Packing Rings 8 Rotor and Shaft Assembly 14 Capscrews for Head 3 Packing Retainer Washer 9 Idler and Bushing Assembly 15 Relief Valve Gasket 4 Casing Bushing 10 Idler Bushing 16 Relief Valve 5 Packing Gland Nuts 11 Head Gasket Set 17 Capscrews for Valve 6 Packing Gland Studs 12 Idler Pin SECTION TSM 312 ISSUE G PAGE 4 OF 11

22 FIGURE 8 - EXPLODED VIEW MODEL H432 AND HL432 PUMP ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Capscrews for End Cap 7 Casing and Bushing Assembly 13 Head and Idler Pin Assembly 2 End Cap 8 Rotor and Shaft Assembly 14 Capscrews for Head 3 Gasket for End Cap 9 Idler and Bushing Assembly 15 Relief Valve Gasket 4 Mechanical Seal 10 Idler Bushing 16 Relief Valve 5 Set Collar with Setscrew 11 Head Gasket Set 17 Capscrews for Valve 6 Casing Bushing 12 Idler Pin FIGURE 9 - EXPLODED VIEW MODEL J32, K32, KK32 AND L32 PUMP ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Two Piece Packing Gland 8 Grease Fitting 15 Capscrews for Head 2 Packing Rings 9 Rotor and Shaft Assembly 16 Pipe Plug 3 Packing Retainer Washer 10 Idler and Bushing Assembly 17 Relief Valve Gasket 4 Casing Bushing 11 Idler Bushing 18 Relief Valve 5 Packing Gland Nuts 12 Head Gasket Set 19 Capscrews for Valve 6 Packing Gland Studs 13 Idler Pin 7 Casing and Bushing Assembly 14 Head and Idler Pin Assembly FIGURE 10 - EXPLODED VIEW MODEL LQ32 PUMP ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Two Piece Packing Gland 9 Pipe Flange Gasket 17 Head and Idler Pin Assembly 2 Packing Rings 10 Capscrews for Flanges 18 Capscrews for Head 3 Packing Retainer Washer 11 Hex Nuts for Flanges 19 Relief Valve Gasket 4 Casing Bushing 12 Rotor and Shaft Assembly 20 Pipe Plug 5 Packing Gland Nuts 13 Idler and Bushing Assembly 21 Capscrews for Valve 6 Packing Gland Studs 14 Idler Bushing 22 Relief Valve 7 Grease Fitting 15 Head Gasket Set 8 Casing and Bushing Assembly 16 Idler Pin SECTION TSM 312 ISSUE G PAGE 5 OF 11

23 FIGURE 11 - EXPLODED VIEW MODEL LL32 PUMP ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Two Piece Packing Gland 10 Capscrews for Rotor Bearing Sleeve 19 Head Gasket Set 2 Packing Rings 11 Gasket for Rotor Bearing Sleeve 20 Idler Pin 3 Lantern Ring 12 Pipe Flange Gasket 21 Head and Idler Pin Assembly 4 Packing Retainer Washer 13 Capscrews for Flanges 22 Capscrews for Head 5 Bushing for Rotor Bearing Sleeve 14 Nuts for Flanges 23 Pipe Plug 6 Rotor Bearing Sleeve and Bushing Assembly 15 Casing 24 Relief Valve Gaskets 7 Packing Gland Nuts 16 Rotor and Shaft Assembly 25 Relief Valve Assembly 8 Packing Gland Studs 17 Idler and Bushing Assembly 26 Capscrews for Valve 9 Grease Fitting 18 Idler Bushing FIGURE 12 - EXPLODED VIEW MODEL Q32, M32 AND N32 PUMP ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART 1 Packing Gland Nut 12 Gasket for Rotor Bearing Sleeve 23 Head Gasket 2 Packing Gland Stud 13 Casing 24 Idler Pin 3 Grease Fitting 14 Pipe Plug 25 Head and Idler Pin Assembly 4 Packing Gland 15 Studs for Flanges 26 Studs for Head 5 Packing Rings 16 Nuts for Flanges 27 Nuts for Head 6 Lantern Ring 17 Pipe Flange Gasket 28 Pipe Plug 7 Packing Retainer Washer 18 Rotor Bearing Sleeve Washer 29 Relief Valve Gasket 8 Bushing for Rotor Bearing Sleeve 19 Rotor Thrust Washer 30 Relief Valve 9 Rotor Bearing Sleeve and Bushing Assembly 20 Rotor and Shaft Assembly 31 Capscrews for Valve 10 Nuts for Rotor Bearing Sleeve 21 Idler and Bushing Assembly 11 Studsfor Rotor Bearing Sleeve 22 Idler Bushing SECTION TSM 312 ISSUE G PAGE 6 OF 11

24 DISASSEMBLY DANGER! Before opening any Viking pump liquid chamber (pumping chamber, reservoir, relief valve adjusting cap fitting, etc.) Be sure: 1. That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections. 2. That the driving means (motor, turbine, engine, etc.) has been locked out or made non-operational so that it cannot be started while work is being done on pump. 3. That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid. Obtain a material safety data sheet (MSDS) for the liquid to be sure these precautions are understood. Failure to follow above listed precautionary measures may result in serious injury or death. 1. Refer to figures 5 through 12 for name of parts. 2. Mark head and casing before disassembly to insure proper reassembly. The idler pin, which is offset in pump head, must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump. 3. Remove the head capscrews. NOTE: The four valve capscrews, valve and gasket must be removed from the G models before the six head capscrews are removed. 4. Do not allow idler to fall from idler pin. Tilt top of head back when removing to prevent this. Remove head from pump. Avoid damaging head gasket set, all gaskets are required to maintain end clearance. 5. Remove idler and bushing assembly. If idler bushing needs replacing, refer to INSTALLATION OF CARBON GRAPHITE BUSHINGS, page 8. Remove the packing gland, packing and packing retainer washer. If you have a mechanical seal pump, remove the end cap and the mechanical seal is exposed. For K and L 432, consult factory. Remove the mechanical seal by sliding off the end of the shaft. Loosen the setscrew in the set collar and remove it. CAUTION: Older pumps may have snap ring on shaftremove the snap ring before removing rotor and shaft. Carefully remove the rotor and shaft from the pump to avoid damaging the casing or rotor bearing sleeve bushing. THRUST WASHERS: Rotor thrust washer and rotor bearing sleeve thrust washer used in Q, M and N size pumps should be removed, examined for excessive wear and replaced if necessary. These thrust washers are located on the hub of the rotor and the casing end of rotor bearing sleeve. If it is necessary to replace the bushing in the casing, rotor bearing sleeve or idler and/or repack the pump, remove the old packing and lantern ring and packing retainer washer. G- LQ pumps don t have a lantern ring. Clean all parts thoroughly and examine for wear and/or damage. Check bushings, and idler pin and replace if necessary. Check all other parts for nicks, burrs, excessive wear and replace if necessary. ASSEMBLY 1. Install bushing into casing or rotor bearing sleeve. If bushing has a lubrication groove, install bushing with groove at 12:00 o clock position in bracket. If carbon graphite, refer to INSTALLATION OF CARBON GRAPHITE BUSHINGS, page Thrust washers used in Q, M and N size pumps should be assembled on the rotor hub and rotor bearing sleeve. Put the plain washer on the two locating pins on the rotor hub. Put the grooved face washer on the pins on the rotor bearing sleeve with the grooved face toward the rotor. 3. Coat shaft of rotor shaft assembly with non-detergent SAE 30 weight oil. Start end of shaft in bracket bushing turning from right to left, slowly pushing rotor into casing. 4. Place the head gaskets on the head. The proper amount of gaskets should be used to provide the necessary end clearance within the pump so it turns freely with no appreciable end play. The Gasket Table (Figure 13) gives the normal amount of gaskets used on each pump. 5. Coat idler pin with non-detergent SAE 30 weight oil and place idler and bushing on idler pin in head. If replacing carbon graphite bushing, refer to INSTALLATION OF CARBON GRAPHITE BUSHINGS, page The head can now be assembled on the pump. Tilt the top of the head away from the pump slightly until the crescent enters the inside diameter of the rotor and rotate the idler until its teeth mesh with the rotor teeth. Do not damage the head gaskets. Tighten the head capscrews or nuts and then check the end clearance. If the pump shaft cannot be rotated, more gaskets must be added. If, however, the pump has any noticeable end play, remove enough gaskets so the pump has no appreciable end play but still turns freely. SECTION TSM 312 ISSUE G PAGE 7 OF 11

25 PUMP MODEL NORMAL AMOUNT USED ONE SET OF GASKETS CONSISTS OF THE FOLLOWING STANDARD END CLEARANCE SPRING WIRE RETAINER CLIP (2 REQUIRED) G32 G H, HL32 H, HL J, K, KK L, LQ, LL Q M, N SPLIT PACKING GLAND (2 REQUIRED) CAPSCREW (2 REQUIRED) FIGURE 13 - GASKET TABLE FIGURE Place packing retainer washer in bottom of packing chamber and pack pump with new packing. Use packing suitable for liquid being pumped. Install packing, staggering the joints from one side of shaft to other. Lubricate packing rings with oil, grease or graphite to aid assembly. A length of pipe will help to seat each packing ring. NOTE: If the pump has a lantern ring it must be located below the grease fitting. The grease fitting may be removed to facilitate positioning of the lantern ring. 8. Install packing gland, capscrews and nuts. DANGER! Before starting pump, be sure all drive equipment guards are in place. Failure to properly mount guards may result in serious injury or death. NOTE: Pump may be equipped with a 2-piece split packing gland. See Figure 14. MECHANICAL SEAL OPTION Install the mechanical seal: Place the set-collar on the shaft and tighten setscrew. See Figure 15, page 8 for set-collar location. The seal used in this pump is simple to install and good performance will result if care is taken during installation. The principle of the mechanical seal is contact between the rotary and stationary members. These parts are lapped to a high finish and their seating effectiveness depends on complete contact. Once rotating position of mechanical seal is installed on rotor shaft, it is necessary to assemble parts as quickly as possible to ensure seal does not stick to shaft in the wrong axial position. The seal should be expected to stick to shaft after several minutes setting time. 1. Never touch sealing faces with anything except clean hands or clean cloth. Minute particles can scratch the seal faces and cause leakage. 2. The spring washer and spring must be put on the shaft first and in that order. (See Figure 15, page 8). 3. Spread a film of lubricating oil on the inside diameter of the synthetic rubber bellows. Check the end of the pump shaft for sharp burrs or edges which might cut the bellows. Slide the seal rotary member over the shaft and up against the spring. 4. Coat the synthetic rubber seal seat with lubricating oil and push the seal seat into the end cap. Put the end cap gasket on the end of the casing. Slide end cap over the shaft and flush both the seal seat and carbon wear ring in the seal rotary member with oil. Push the end cap up until the mating surfaces of the seal meet. Install the capscrews and tighten evenly. SECTION TSM 312 ISSUE G PAGE 8 OF 11

26 SET COLLAR WITH SETSCREW SEAL ROTARY MEMBER END CAP PRESSURE RELIEF VALVE INSTRUCTIONS SEAL SEAT SPRING SPRING WASHER.12 FOR MODEL G FOR MODEL H432 & HL432 FIGURE 15 - SECTIONAL VIEW, SEAL AREA FIGURE 16 - SIZE G, H AND HL INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing carbon graphite bushings, extreme care must be taken to prevent breaking. Carbon graphite is a brittle material and easily cracked. If cracked, the bushing will quickly disintegrate. Using a lubricant and adding a chamfer on the bushing and the mating part will help in installation. The additional precautions listed below must be followed for proper installation: 1. A press must be used for installation. 2. Be certain bushing is started straight. 3. Do not stop pressing operation until bushing is in proper position. starting and stopping will result in a cracked bushing. 4. Check bushing for cracks after installation. FIGURE 17 - SIZE AK AND AL FIGURE 18 - SIZE K, KK, L, LQ AND LL VALVE - LIST OF PARTS 1. Valve Cap 6. Valve Body 2. Adjusting Screw 7. Valve Spring 3. Lock Nut 8. Poppet 4. Spring Guide 9. Cap Gasket 5. Bonnet 10. Bonnet O-ring SECTION TSM 312 ISSUE G PAGE 9 OF 11

27 DISASSEMBLY DANGER! Before opening any Viking pump liquid chamber (pumping chamber, reservoir, relief valve adjusting cap fitting, etc.) Be sure: 1. That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections. 2. That the driving means (motor, turbine, engine, etc.) has been locked out or made non-operational so that it cannot be started while work is being done on pump. 3. That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid. Obtain a material safety data sheet (MSDS) for the liquid to be sure these precautions are understood. Failure to follow above listed precautionary measures may result in serious injury or death. Mark valve and head before disassembly to insure proper reassembly. 1. Remove valve cap. 2. Measure and record length of extension of adjusting screw. Refer to A on Figures 16, 17 and 18, page Loosen locknut and back out adjusting screw until spring pressure is released. 4. Remove bonnet, spring guide, spring and poppet from valve body. Clean and inspect all parts for wear or damage and replace as necessary. ASSEMBLY DANGER! Before starting pump, be sure all drive equipment guards are in place. Failure to properly mount guards may result in serious injury or death. Reverse procedures outlined under Disassembly. If valve is removed for repairs, be sure to replace in same position. Relief valve adjusting screw cap must always point towards suction side of pump. If pump rotation is reversed, remove relief valve and turn end for end. Refer to Figures 1, 2, and 4, page 1. PRESSURE ADJUSTMENT If a new spring is installed or if pressure setting of pressure relief valve is to be changed from that which the factory has set, the following instructions must be carefully followed. 1. Install a pressure gauge in discharge line for actual adjustment operation. Do not deadhead pump for more than 30 seconds at a time. 2. Carefully remove valve cap which covers adjusting screw. Loosen locknut which locks adjusting screw so pressure setting will not change during operation of pump. 3. Turn adjusting screw in to increase pressure and out to decrease pressure. 4. With discharge line closed at a point beyond pressure gauge, gauge will show maximum pressure valve will allow while pump is in operation. IMPORTANT In ordering parts for pressure relief valve, always give model number and serial number of pump as it appears on nameplate and name of part wanted. When ordering springs, be sure to give pressure setting desired. SECTION TSM 312 ISSUE G PAGE 10 OF 11

28 TECHNICAL SERVICE MANUAL GENERAL PURPOSE PUMPS SERIES 32 AND 432 SIZES G - N SECTION TSM 312 PAGE 11 OF 11 ISSUE G WARRANTY Viking warrants all products manufactured by it to be free from defects in workmanship or material for a period of one (1) year from date of startup, provided that in no event shall this warranty extend more than eighteen (18) months from the date of shipment from Viking. The warranty period for Universal Seal series pumps ONLY (Universal Seal models listed below) is three (3) years from date of startup, provided that in no event shall this warranty extend more than forty-two (42) months from the date of shipment from Viking. UNDER NO CIRCUMSTANCES SHALL VIKING BE LIABLE UNDER THIS WARRANTY OR OTHERWISE FOR SPECIAL, INCIDENTAL, INDIRECT, CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY KIND, INCLUDING, BUT NOT LIMITED TO, LOST OR UNREALIZED SALES, REVENUES, PROFITS, INCOME, COST SAVINGS OR BUSINESS, LOST OR UNREALIZED CONTRACTS, LOSS OF GOODWILL, DAMAGE TO REPUTATION, LOSS OF PROPERTY, LOSS OF INFORMATION OR DATA, LOSS OF PRODUCTION, DOWNTIME, OR INCREASED COSTS, IN CONNECTION WITH ANY PRODUCT, EVEN IF VIKING HAS BEEN ADVISED OR PLACED ON NOTICE OF THE POSSIBILITY OF SUCH DAMAGES AND NOTWITHSTANDING THE FAILURE OF ANY ESSENTIAL PURPOSE OF ANY PRODUCT. THIS WARRANTY IS AND SHALL BE VIKING S SOLE AND EXCLUSIVE WARRANTY AND SHALL BE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ALL WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE AND NON-INFRINGEMENT ALL OF WHICH OTHER WARRANTIES ARE EXPRESSLY EXCLUDED. See complete warranty at VIKING PUMP, INC. A Unit of IDEX Corporation Cedar Falls, IA USA 3/2013 Viking Pump Inc. All rights reserved

29 CORPORATION 12Vdc Oil Burner Manual Potential for Fire, Smoke and Asphyxiation Hazards Incorrect installation, adjustment, or misuse of this burner could result in death, severe personal injury, or substantial property damage. 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, quali ed service agency for installation, start-up or service work. READ THESE INSTRUCTIONS AND SAVE FOR REFERENCE. To the Professional, Quali ed Installer or Service Agency: Please read and carefully follow all manual instructions and any supplements provided, 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.

30 Contents Burner Application Scope and Intended Use...2 Prepare Before Installing...3 Speci cations...3 Notice Special Requirements...3 General Information...4 A. Equipment Located in Con ned Space...4 B. Exhaust Fans and Other Air-Using Devices C. Clearances to Burner and Equipment...4 D. Exhausting Hazardous Fumes...4 E. Low Firing Rate Baf e....5 Nozzle Assembly Maintenance...5 A. Replace the Burner Nozzle...5 B. Check/Adjust Electrodes...6 C. Igniter Maintenance...6 D. Servicing Nozzle Line Assembly...6 E. Check/Adjust Z Dimension...6 Fuel Supply...7 A. Connect Fuel Lines...7 B. Fuel Supply Level with or Above Burner...7 C. Fuel Supply Below Level of Burner...7 D. Fuel Line Replacement (Remote Tank Only)...7 E. Fuel Line Valve and Filter...7 Burner Wiring...7 A. Burner installed on equipment...7 B. Burner Replacement...7 Drive Component Maintenance...9 A. Motor, Blower Wheel, and Coupling Replacement... 9 B. Pump Maintenance...10 C. Valve Coil and Stem Replacement...10 Start Up Burner & Set Combustion...10 A. Basic Burner Operation...10 B. Combustion Set-up C. Set Combustion with Instruments Maintain & Service Burner...12 A. Owner s Information...12 B. Owner Service and Maintenance...12 Extended Down Time...12 Regular Service/Maintenance...12 Troubleshooting...13 Replacement Parts...15 Limited Warranty Information...16 Hazard De nitions 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. 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. Intended to bring special attention to information, but not related to personal injury or property damage. Burner Application Scope and Intended Use The ADC burner is designed for use in road maintenance equipment applications that have DC voltage charging systems capable of sustaining the speci ed voltage requirements. For other equipment applications, please contact Beckett Technical Services at

31 Prepare Before Installing Speci cations Section: Prepare Before Installing Owner s Responsibility Incorrect installation, adjustment, and use of this burner could result in severe personal injury, death, or substantial property damage from re, carbon monoxide poisoning, soot or explosion. Capacity Fuels F Head Firing Rate: GPH Input: 105, ,000 Btu/h USA: No. 1 or No. 2 diesel fuel or kerosene; No.1 or No. 2 heating oil (ASTM D396) Contact a professional, quali ed service agency for the installation, adjustment and service of your oil heating system. This work requires technical training, trade experience, licensing or certi 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 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 speci 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. Impaired Burner Performance and Fire Hazard. Do NOT operate the burner beyond speci cations outlined in the table to the right. For applications beyond these limits, consult Beckett Technical Service at NOTE: Some packaged appliances with burners may be agency listed as a unit to operate beyond these limits. Consult the appliance manufacturer s speci cations and agency approvals for veri cation. Electrical DO NOT USE GAS- OLINE, CRANKCASE OIL, OR ANY OIL CONTAINING GASOLINE. Power Supply: 13.5 Vdc Operating Load w/ igniter on: 15 Amps w/ igniter off: 8-10 Amps Motor: 13.5Vdc, 1/6 hp, 3450 RPM, 10 Amps (max.) NEMA M Flange, rotation CCW when facing shaft end. Ignition Secondary: 20KVpk 25mA Interrupted duty OR optional continuous duty. Pump Outlet pressure: Note 1 Dimensions Ambient Operating Temperature Height (maximum): 11 ½ inches Width (maximum): 14 3/8 inches Depth (chassis only): 6 9/16 inches Air tube diameter: 4 inches +32 F. (0 C.) Minimum +115 F. (+46 C.) Maximum (See Warning on Impaired Burner Performance and Fire Hazard.) Note 1. See equipment manufacturer s burner speci cations for recommended outlet pressure. Pressure is 100 psig unless otherwise noted. Notice Special Requirements If you discover damage to the burner or controls during unpacking, notify the carrier at once and 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 nd the serial number on the silver label located on the left rear of the burner. See Figure Vdc ADC Burner Manual 3

32 Model " AFG " Series Oil Burner SERIAL NUMBER R.W.Beckett Corp. Elyria, Ohio Made in the U.S.A. ELYRIA OHIO U.S.A. MFR'S SETTINGS ATC: AF65XN FIRING RNG: GPH HEAD: F3 STC PLT: 2-3/4U NOZZLE: 1.0 X 80B DLVN PUMP PRS: 100 PSI BJB3001 R00 Section: General Information Table 2. Air Tube Combination (ATC) Codes Firing Rate GPH Head Adequate Voltage Required A low or erratic power supply could result in impaired burner operation, severe delayed ignition or an explosion inside the heat exchanger resulting in a burn and/or asphyxiation hazard. The Model ADC requires a continuous supply of 11 to 16 volts DC at 15 amps measured at the burner during operation. An automotive or small engine charging system that is capable of supplying the required continuous voltage/ amperage is recommended with certain road equipment, such as asphalt hot patchers and similar applications. This is especially true while maintaining nominal load temperatures during idle periods. Adequate Combustion and Ventilation Air Supply Required Failure to provide adequate air supply could seriously affect the burner performance and result in damage to the equipment, asphyxiation, explosion or re hazards. 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. Static Plate Size ATC Codes for Usable Air Tube Lengths: ( A in inches see Fig. 2) min-max inches 4-1/2 5-3/8 6-5/ F0 3-3/8U AF44XR AF53XR AF65XR General Information Refer to the Troubleshooting section of this manual when experiencing a possible fault condition. A. Equipment Located in Con ned Space The con ned space should have two 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 then one square inch per 1,000 BTU s per hour of the total input rating of all equipment within the enclosure. The openings shall have free access to the building interior, which should have adequate in ltration from the outside. B. 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, for example), either pipe combustion directly to the burner or provide a sealed enclosure for the burner and provide it with its own combustion air supply. C. Clearances to Burner and Equipment Provide space around burner and equipment for easy service and maintenance. Check minimum clearances against those shown by the equipment manufacturer and by applicable codes. D. Exhausting Hazardous Fumes See warning on this page. Also be conscious of any fumes produced by the materials that are being heated. Always ensure adequate ventilation to exhaust all fumes. Table 1. Low Firing Rate Baf e F3 2-3/4 AF44XN AF53XN AF65XN F4 2-3/4 AF44WH AF53WH AF65WH F6 2-3/4 AF44YB AF53YB AF65YB F12 2-3/4 AF44XO AF53XO AF56XO F22 2-3/4 AF44XP AF53XP AF56XP *See page 3 for capacity and voltage speci cations. Figure 1. Typical Burner Nameplate Head Type F0 F3 F4 or F6 Low Firing Rate Baf e (if speci ed) up to 0.65 gph up to 0.85 gph up to 0.90 gph General Model Information Serial Number Including Date Code Rating Information R.W. Beckett Manufacturer s Settings R.W. Beckett Specification Number and Revision RWB Can Be Customized by Individual Specification Primary Group and Fuel Oil State & Local Approvals SK

33 Section: Nozzle Assembly Maintenance E. Low Firing Rate Baf e. The low ring rate baf e (See LFRB in Replacement Parts) reduces the air ow and pressure. The LFRB is sometimes used for ring rates under 1.00 gph as listed in Table 1. Refer to the equipment manufacturer s instructions. Do not omit the LFRB when speci ed. Omitting the baf e when speci ed or installing the baf e when not speci ed could result in poor burner performance. Nozzle Assembly Maintenance Correct Nozzle and Flow Rate Required Incorrect nozzles and ow rates could result in impaired combustion, under- ring, over- ring, sooting, puff-back of hot gases, smoke and potential re or asphyxiation hazards. Use only nozzles having the brand, ow rate (gph), spray angle and pattern speci ed by the appliance manufacturer. Follow the appliance manufacturer s speci cations for the required pump outlet pressure for the nozzle, since this affects the ow rate. Nozzle manufacturers calibrate nozzle ow rates at 100 psig. When pump pressures are higher than 100 psig, the actual nozzle 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 ow rates at various pressures refer to Table Place a 3/4 open-end wrench on the nozzle adapter. Insert the nozzle into the adapter and nger tighten. Finish tightening with a 5/8 open-end wrench. 3. 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 equipment manufacturer s information). Verify that the electrode tip settings comply with Figure 2. Use care when removing or installing an oil nozzle A damaged nozzle could cause impaired combustion, sooting, puffback of hot gases, oil leakage and potential re or asphyxiation hazards. Inspect the nozzle adapter to insure that the sealing surface is not grooved or scratched. To insure that the nozzle functions properly, check the ori ce and strainer for dirt, scratches or other damage before installation. Do NOT attempt to install or remove a nozzle without securing the adapter to prevent seriously damaging the alignment. Use care when handling the nozzle line assembly to prevent changing the electrode tip settings or damaging the ceramic electrode insulators. Ensure that the electrode settings match the values shown in Figure 2. Figure 2. Electrode Tip Setting 5/32 GAP 1/4 ABOVE CENTER A. Replace the Burner Nozzle. 1. If applicable, remove the plastic plug protecting the nozzle adapter threads. 1/8 NOZZLE-TO-TIP SPACING Figure 5. Nozzle, Line & Electrode Assembly Electrode gap to be centered with nozzle center. Contacts to be parallel with horizontal center line within Item # Description 1 Electrode Contact (3 ATC or extension over 3 ) 2 Nozzle Line 3 Spider spacer assembly 4 Static Plate 5 Electrode clamp 6 Electrode clamp retaining screws 12 Vdc ADC Burner Manual Item # Description 7 Nozzle line setscrew 8 Electrode Insulator 9 Nozzle adapter 10 Nozzle tip 11 Electrode tip 5

34 Section: Nozzle Assembly Maintenance B. Check/Adjust Electrodes Check the electrode tip settings. Adjust if necessary to comply with the dimensions shown in Figure 2. To adjust, loosen the electrode clamp screw and slide/rotate electrodes as necessary. Securely tighten the clamp screw when nished. C. Igniter Maintenance The igniter assembly does not require any adjustments beyond making sure the springs and the burner electrode rods make solid contact when the igniter is in the closed position. The sealing surfaces of the gaskets should be checked and replaced at the rst signs of any damage or deterioration. Clean any dirt or residue from the porcelain bushings, springs, and baseplate. The simplest way to check igniter operation is by supplying voltage to the input and checking to see whether an arc is produced. Check by either looking or listening to see if there is an arc across the electrodes while the burner is running and the igniter is energized. The igniter must be grounded to the burner before checking the following. To check the igniter, ensure all power to the burner is off and use an ohmmeter to check the resistance between the two springs. The meter should read between ohm. The igniter should be replaced if the meter indicates an open circuit, or the spring-to-spring resistance exceeds the ohm range by more than 10%. D. Servicing Nozzle Line Assembly Before proceeding, turn off power to the burner. 1. Disconnect the oil connector tube from the nozzle line. 2. Referring to Figure 3, loosen the two screws securing the igniter retaining clips (a) and rotate both clips to Figure 3. Igniter Hinge & Retainer Clips release the igniter baseplate. Then tilt the igniter back on its hinge. 3. Remove the splined nut (b). 4. Remove the nozzle line assembly from the burner, being careful not to damage the electrodes or insulators while handling. To ease removal of short assemblies, it may be necessary to loosen the escutcheon plate (c). Reset to the edge of the label. 5. To replace the nozzle line assembly, reverse the above steps. E. Check/Adjust Z Dimension Refer to Figure 4. The critical Z dimension is the distance from the face of the nozzle to the at face of the head. This distance for F heads is 1-1/8. The Z dimension is factory set for burners shipped with the air tube installed but should always be veri ed during service and installation. If the Z dimension is out of adjustment, perform the following steps. Before proceeding, turn off power to the burner. 1. Disconnect the oil connector tube from the nozzle line. 2. Referring to Figure 5, loosen the splined nut from the nozzle line. Loosen the hex head screw securing the escutcheon plate to the burner housing. 3. A Beckett T650 gauge should be used to set the Z dimension. 4. 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. 5. Slide the nozzle line forward or back until this dimension for F heads is 1-1/8. 6. 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. 7. Recheck the Z dimension periodically when servicing to ensure the escutcheon plate has not shifted. You will need to reset the Z dimension if you replace the air tube or nozzle line assembly. a Figure 4. Z Dimensions Using Gauge c b SK9787 6

35 Section: Fuel Supply The Beckett Z gauge (part number Z- 2000) is available to permit checking the F head Z dimension without removing the burner. Fuel Supply A. Connect Fuel Lines Do Not Install Bypass Plug with 1-Pipe System Failure to comply could cause Immediate pump seal failure, pressurized oil leakage and the potential for a re and injury hazard. The burner is shipped without the bypass plug installed. Install the bypass plug in two-pipe oil supply systems ONLY. For oil supply system speci cations for tanks not mounted on machines, carefully follow the pump manufacturer s literature and the latest edition of the National Fire Protection Association (NFPA) 31 standard. Pumps with automatic bypass do not require a bypass plug. Verify by referring to the pump manufacturer s instructions. B. Fuel Supply Level with or Above Burner The burner may be equipped with a single stage pump. If a one-pipe system is installed, verify a bypass plug is not installed in the pump, then connect the fuel supply to the burner with a single supply line Note that manual bleeding of the pump is required on initial start-up or when the equipment runs out of fuel. When connecting a twopipe fuel system, install the pump bypass plug. Oil Supply Pressure Control Required Damage to the lter or pump seals could cause oil leakage and a re hazard. The oil supply inlet pressure to the burner cannot exceed 3 psig. Ensure 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 # 22246U) in the pump/nozzle discharge tubing to provide backup oil ow cut-off protection. 12 Vdc ADC Burner Manual C. Fuel Supply Below Level of 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 the horizontal and vertical length, the installation may also require a two-stage pump. Consult the fuel unit manufacturer s literature for lift and vacuum capability. D. Fuel Line Replacement (Remote Tank Only) When replacing fuel lines, continuous lengths of heavy wall copper tubing is recommended. To ensure a tight seal, always use are ttings. Never use compression ttings. Always install ttings in an accessible location. To avoid vibration noise, fuel lines should not run against the appliance or the ceiling joists. E. Fuel Line Valve and Filter Do Not Use Te on Tape Damage to the pump could cause impaired burner operation, oil leakage and appliance soot-up. Never use Te on tape on fuel oil 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. Shutoff valves should be located in the oil supply line. Do not install valves in the return line. Burner Wiring A. Burner installed on equipment Refer to appliance manufacturer s wiring diagram for electrical connections. Electrical Shock Hazard Electrical shock can cause severe personal injury or death. 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.) B. Burner Replacement Burner wiring may vary, depending on the actual primary control and furnished options. Refer to Figure 6 for typical burner wiring, showing cad cell primary controls. Note that the relay and control, shown in the wiring diagram are optional features. 7

36 Section: Burner Wiring Figure 6A. Typical Wiring For Constant Duty Ignition - With No Primary Control SAFETY AND LIMIT CONTROLS OPERATING CONTROLS 50A FUSE 30A FUSE 10A FUSE ORANGE BLUE WITH WHITE STRIPE SOLID WHITE VIOLET(+) MOTOR YELLOW CAPPED (NOT USED) IGNITER VALVE BLACK BLACK WHITE(-) GND FROM Vdc POWER SUPPLY Notes: 1. Wires are to be sized to prevent a voltage drop between battery and burner with burner running at full load. 2. Motor runs continuously in normal con guration. 3. Hard-wire burner ground to battery. DO NOT USE CHASSIS GROUND SYSTEM. SK10087 Figure 6B. Typical Wiring For Interrupted Ignition - With No Primary Control SAFETY AND LIMIT CONTROLS OPERATING CONTROLS 50A FUSE 30A FUSE 10A FUSE ORANGE VIOLET(+) SOLID WHITE BLUE W/ WHITE STRIPE MOTOR VALVE IGNITER YELLOW YELLOW CAD CELL BLACK WHITE(-) BLACK GND FROM Vdc POWER SUPPLY Notes: 1. Wires aret to be sized to prevent a voltage drop between battery and burner with burner running at full load. 2. Hard-wire burner ground to battery. DO NOT USE CHASSIS GROUND SYSTEM. SK

37 Section: Drive Component Maintenance Figure 6C. Typical Wiring with 7556 Primary Safety Control Notes: 1. Wires are to be sized to prevent a voltage drop between the battery and the burner with the burner running at full load. 2. Fuse Sizes (inside control): Motor = 30 Amp Igniter, Control, Valve, & Alarm = 10 Amp 3. Hard-wire burner ground to battery. Do NOT use chassis ground system. 4. Input power to the control s +12 Volt wire shall be provided from a fused service switch, rated at 50 amps or less. 5. Motor-off delay on a 7556P will be disabled if the safety and operating limits as shown in Figure 6C interrupt power to the control s red +12 Volt wire. 6. Do not wire power directly to the burner motor. Only wire the motor as shown in Figure 6C. If instant burner heat is required by the application, purchase or program a control with a long motoroff delay time, which will ensure instant heat if a new call for heat is received within the motor-off delay time. 7. Igniter Yellow leads are capped and not used. Bundle with the other leads in the wiring box with a cable tie. 8. The igniter Blue-White striped and solid White leads are combined with the Y connector and attached to the primary control igniter spade terminal. MAIN POWER 24V IGNITER Note 7 MOTOR ON/OFF/RESET OIL VALVE HIGH LIMIT Note 8 RED WIRE BLACK WIRE ALARM VALVE GND (VLV) IGNITER GND (IGN) MOTOR GND (MTR) CAD CELL ENABLE THERMOSTAT SK10089 CAD CELL Drive Component Maintenance A. Motor, Blower Wheel, and Coupling Replacement The motor will require replacement if the proper voltage is measured at the motor input, and the motor will either not run, or the current draw with a free running pump exceeds 10% of the rated current. To replace the burner motor, coupling and/or blower wheel perform the following steps. 1. Before servicing, turn off and/or disconnect all power to the burner. 2. Disconnect the burner motor wires. 3. Remove the bolts securing the motor to the burner housing. 4. Remove the motor, coupling, and blower wheel. 5. Loosen the set screw on the blower wheel to slide the existing wheel off the shaft. 6. Slide the new blower wheel onto the old shaft (after thoroughly cleaning housing) and/or slide the old blower wheel onto the new motor shaft. 7. Place a.030 (1/32 ± 1/64 ) feeler gauge between the blower wheel and the motor housing. 12 Vdc ADC Burner Manual 8. Slide the blower wheel toward the motor until it contacts the feeler gauge. 9. Rotate the blower wheel until the setscrew is centered on the at of the motor shaft. Tighten the setscrew to secure the wheel. 10. Slide the motor coupling on the motor shaft, then install the motor on the burner housing. Ensure that the motor coupling ts between the motor shaft and the pump shaft inside the housing. Tighten the motor retaining screws. Reconnect the wires. 11. Restore power, start the burner and perform the combustion test described previously in this manual. Figure 7. Blower Wheel Insert feeler gauge between blower and motor Flat face on motor shaft Access hole to set screw 9

38 Section: Drive Component Maintenance B. Pump Maintenance General Pump Information Important information - Long or oversized inlet lines may require the pump to operate dry during initial bleeding period. In such cases, the priming may be assisted by injecting fuel oil in the pump gear set. Under lift conditions, lines and ttings must be air tight. To assure this, Pipe Dope may be applied to both the used and unused inlet and return ttings. Do NOT use Te on tape or compression ttings Mounting Position - Beckett CleanCut pump may be mounted in any position (except upside-down in a single pipe installation). Vacuum Check - A Vacuum Gauge may be installed in either of the 1/4 NPT inlet ports. Pressure Check- When a pressure check is made, use the nozzle port. If the bleed port is used, the reading on the gauge should be approximately 5 psig higher than the pressure reading on the nozzle port. See Figure 8. Cutoff Check - To check cutoff pressure dead head a pressure gauge in the nozzle port. Run the burner for a short period of time. Shut the burner off. The pressure will drop and hold above zero. Pressurized or gravity feed installations must not exceed 3 psig on inlet line or return line at the pump per NFPA 31. A pressure greater than 10 psig may cause damage to the shaft seal. C. Valve Coil and Stem Replacement To determine if the valve coil requires replacement perform the following steps. 1. Remove the cord set from the valve. 2. Place the leads from an ohmmeter across the coil. 3. A 12Vdc volt coil should measure between 15 and 25 ohms. 4. If the meter indicates an open circuit, replace the coil. Figure 8. Pump and Valve Assemblies To check pump operation perform the following. 1. Check the operating pressure by removing the copper tubing from the nozzle line and installing a pressure gauge in the line. With the motor running and the coil energized, check the gauge. The pressure should read 100 psig unless otherwise stated. 2. To check the cutoff function, deadhead the pressure gauge onto the copper connector tube attached to the nozzle port. Run the burner for a short period of time. Shut the burner off; the pressure should drop and hold. To replace the coil and/or pump assembly perform the following steps. 1. Before servicing, turn off and/or disconnect all power to the burner. 2. Remove the copper tube assembly when replacing the pump or when removing the coil and the tube blocks the coil. 3. Using a at tip screwdriver, press the at tip into the spring washer to prevent it from rotating. 4. Using a 10mm wrench or adjustable wrench, remove the nut and spring washer. 5. Remove the coil by lifting it straight up. 6. Remove the two base plate screws, then the base plate by lifting straight up. 7. Remove valve stem assembly by pulling straight up. 8. To install the new stem and coil assemblies, follow the above steps in reverse order, tightening each part as you go. 9. Restore power, start the burner and perform the combustion test described previously in this manual. Start Up Burner & Set Combustion 10 10mm Nut Coil Base Plate Stem Assembly Nozzle Port Fitting Spring Washer Cordset Pump Assembly Bleed Valve SK9810 A. Basic Burner Operation Typical Constant Duty Ignition Con guration - With this Beckett ADC oil burner con guration, the motor and igniter operate continuously while the valve that controls oil ow is cycled by the switches on the power washer. The motor is used to drive the blower and pump. The rotational speed of the motor is determined by the voltage supplied and the load placed on the motor. Pump pressure and air settings are the main factors affecting the motor load. The igniter converts battery DC voltage into a high voltage spark to ignite the oil. The igniter is capable of running continuously as long as the blower wheel is circulating air across the igniter base. The pump and solenoid valve are used to control the ow of oil from the reservoir to the nozzle.

39 Section: Start Up Burner & Set Combustion Igniter with Interrupted Duty Ignition - This optional control circuit is available to reduce current draw on the charging system by turning the igniter off after a ame has been established. This option controls igniter operation based on a signal from a light sensing cad cell. When light hits the cell the control will sense a decrease in resistance across the sensor. A few seconds delay will occur prior to the igniter switching off. As long as suf cient light is reaching the cell eye, the igniter will remain off. If light is removed from the sensor, the igniter will turn on until light is again sensed by the cad cell. With 7556 Primary Safety Control - The 7556 control provides the same bene ts as the ignition control board as described above as well as added safety, convenience, and performance features. It adds a valve on delay and motor-off delay to the burner s operation sequence that promote clean burner operation. It has a lock-out function that shuts the burner down if it is not operating properly. The control adds fusing at the burner to protect against component failures. The control also has redundant motor relays that are checked for proper operation every heat cycle. Variations to the burner circuits may occur due to optional temperature, pressure, and vacuum switches that control burner operation. Note that when external switches are used to control motor operation they must be sized correctly for the rated current or a relay should be installed to isolate the switches from the motor s full load current. B. Combustion Set-up As soon as burner motor starts rotating bleed all the air from the pump. (Required with single-pipe systems.) 12 Vdc ADC Burner Manual Explosion and Fire Hazard Failure to follow these instructions could lead to equipment malfunction and result in heavy smoke emission, soot-up, hot gas puff-back, re and asphyxiation hazards. 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 ame with the burner running if the 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 re extinguisher nearby and ready for use. To bleed the pump, attach a clear plastic hose over the vent tting. Loosen the tting and catch the oil in an empty container. Tighten the tting when all air has been purged from the supply system. Note: If the burner stops after a ame is established, the unit probably requires additional bleeding. Continue to bleed the system until the pump is primed and a ame is established when the bleed valve is closed. C. Set Combustion with Instruments 1. Allow the burner to run for approximately 5 to 10 minutes. 2. Follow these four steps to properly adjust the burner: Step 1: Adjust the air until a trace smoke level is achieved. Step 2: At the trace of smoke level, measure the CO 2 (or O 2 ). This is the vital reference point for further adjustments. Step 3: Increase the air to reduce CO 2 by 1 percentage point (O 2 will be increased by approximately 1.4 percentage points). Step 4: Recheck the smoke level. It should be zero. 3. This procedure provides a margin of reserve air to accommodate variable conditions. 4. Once the combustion level is set, tighten the fasteners on the air band and air shutter. 5. Start and stop the burner several times to ensure satisfactory operation. 6. Test the equipment safety controls to verify they function according to the manufacturer s speci cations. Figure 9. Air supply components Air band position indicator Shutter position indicator 11

40 Section: Maintain & Service Burner Maintain & Service Burner A. Owner s Information Professional Service Required Incorrect installation, adjustment, and use of this burner could result in severe personal injury, death, or substantial property damage from re, carbon monoxide poisoning, soot or explosion. Please read and understand the manual supplied with this equipment. This equipment must be installed, adjusted and put into operation only by a quali ed individual or service agency that is: Licensed or certi 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. Have your equipment inspected at regular intervals by a quali ed service agency to assure continued proper operation. The burner should be adjusted using dedicated combustion test equipment. Failure to properly set the burner could result in inef cient operation, and/or conditions that could potentially cause severe personal injury, death or substantial property damage. B. Owner Service and Maintenance Properly installed and maintained, your ADC burner will provide years of ef cient, trouble-free operation. Please take care of your equipment by following the warnings provided and by immediately contacting your quali ed service agency if your burner is not operating properly. This equipment should be serviced only by a quali ed service agency. The appropriate test instruments must be used. Daily Check the area around your burner/equipment to make sure: Nothing is blocking the burner inlet air openings. Air ventilation openings are clean and unobstructed and the exhaust is not crusted. No combustible materials are stored near the equipment. There are no signs of oil or water leakage around the burner or equipment. Extended Down Time If the equipment will be stored for an extended period of time, insure that the fuel tank is full and add a fuel stabilizer to the tank. Regular Service/Maintenance Have your burner, serviced annually by your quali ed service agency. The following components/assemblies should be checked/adjusted/replaced on a regular basis. Refer to the Replacement Parts exploded view for part locations. Replace the oil supply line lter, if applicable. The line lter cartridge must be replaced to avoid contamination of the pump and nozzle. Inspect the oil supply system. All ttings should be leak-tight. The supply lines should be free of water, sludge and other restrictions. Remove and clean the pump strainer. Verify the nozzle is the one originally speci ed by the appliance manufacturer and replace the nozzle with one having the exact speci cations from the same manufacturer. Clean and inspect the electrodes for damage, 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. 12

41 Section: Troubleshooting Clean the cad cell, if applicable. Make sure Low Firing Rate Baf e is in place, if required, for the burner application. Omitting the baf e can result in unacceptable burner combustion. Inspect all gasket including the igniter base plate gasket. Replace any that are damaged or missing. Clean the blower wheel, air inlet, air guide, retention head and static plate of any dirt, asphalt or other material. Check motor current. The amp draw should not exceed the nameplate rating. Check all wiring for loose connections or damaged insulation. Check the pump pressure and cutoff function. Check primary control safety lockout timing, if applicable. Refer to the information supplied by the control manufacturer for procedures. Check ignition system for proper operation. Inspect the exhaust system for soot accumulation or other restriction. Clean the equipment thoroughly according to the manufacturer s recommendations. Check the burner performance using test instruments. It is good practice to make a record of the service performed and the combustion test results. Troubleshooting Table 2. Nozzle Flow Rate by Size Nozzle 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 Oil burners that are designed for use on road maintenance equipment are built to take temperature extremes, vibration, and rough handling. When performing the following troubleshooting steps, we assume that the oil burner motor and ignition transformer operate continuously and the oil solenoid valve, which controls oil ow, is cycled by the equipment controls. We also assume that there is power to the burner and fuel in the tank. In addition to typical mechanics tools, it is recommended to have the following equipment on hand. Meter capable of measuring volts, ohms and amps, ignition transformer tester, smoke pump tester, combustion analyzer, and 0 to 200 psi pressure gauge. See Table 4 on following page for troubleshooting steps. 12 Vdc ADC Burner Manual 13

42 Section: Troubleshooting Table 4. Troubleshooting Chart Symptom Possible Cause Oil Not Igniting If the burner is not igniting, the burner motor, drive coupling, and oil pump are operating and oil is owing to the nozzle through the solenoid valve, check the following possibilities. 1. Check the air shutter adjustment. If the air shutter is opened too far, the ow of air may prevent the arc from reaching the oil spray. This may appear as a white vapor exhaust from the heater. [Refer to section Start up burner and set combustion ] 2. The ignition system may have failed to supply an adequate arc to ignite the oil. Check the battery and charging system to insure a continuous supply of 11 to 16 volts DC (15 amps). [Refer to section Nozzle Assembly Maintenance ] 3. Check the electrodes for wear and damage. Insure that the electrodes are adjusted properly. [Refer to section Nozzle Assembly Maintenance ] No Flame Motor Not Operating No Oil Spray Fluctuating or No Pump Pressure Slow Motor Rotation If there is no ame, the burner motor and igniter operate continuously and the oil solenoid valve is functional, check the following possibilities. 1. Check for a plugged oil nozzle. [Refer to section 3] 2. If the coil on the solenoid valve is actuating, insure that the valve is opening or closing properly. [Refer to section Fuel Supply ] 3. Check for suf cient fuel pressure. Pressure is 100 psig with valve energized, unless otherwise noted. [Refer to section Drive Component Maintenance ] 4. Check the pump pressure. Check for air in fuel lines. 5. Check burner for broken motor coupling. If the coupling is broken check pump rotation prior to replacing the coupling. [Refer to section Drive Component Maintenance ] 6. Check for contaminated fuel and/or partially plugged fuel lter. [Refer to section Fuel Supply ] If the blower motor is not operating, check the following possibilities. 1. Check voltage at the motor to insure that switches and relays, in line with the motor, are operating properly. [Refer to section Burner Wiring ] 2. Check pump and motor shaft operation. They should work freely without binding. [Refer to section Drive Component Maintenance ] If the blower motor is operating, there is fuel in the tank, but oil does not spray out the end of the nozzle, check the following possibilities. 1. Check for a broken or stripped coupling between the pump and the motor. [Refer to section Drive Component Maintenance ] 2. Check the pump output for oil. [Refer to section Drive Component Maintenance ] 3. Check operation of the oil valve. [Refer to section Drive Component Maintenance ] 4. Check for a plugged nozzle. [Refer to section Nozzle Assembly Maintenance ] 5. Check for air in the oil line. [Refer to section Nozzle Assembly Maintenance ] 6. Check for fuel contamination or plugged lter. [Refer to section Nozzle Assembly Maintenance ] If the pump pressure, as determined by a pressure gauge, is erratic or does not exist, check the following possibilities. 1. Check motor rotational speed. Low rpm can cause erratic or no pump pressure. [Refer to section Drive Component Maintenance ] 2. Check for a broken or worn motor coupling. [Refer to section Drive Component Maintenance ] 3. Check that the pump turns freely. [Refer to section Drive Component Maintenance ] 4. Check for air leaks in the lines. [Refer to section Fuel Supply ] 5. Check for oil froth at the bleed point. [Refer to section Fuel Supply ] 6. Check voltage at the motor. [Refer to section voltage rating on nameplate] 7. Check for fuel contamination or partially plugged lter. If the blower motor is not operating at the rpm s listed on the nameplate, check the following. 1. Check the supply voltage to the motor. [Refer to section voltage rating on nameplate] 2. Check for free operation of the motor shaft and pump assembly. [Refer to section Drive Component Maintenance ] 14

43 Replacement Parts Section: Replacement Parts Illustration # Description Part# Illustration # Description Part# 1 DC Motor n/a 2 Blower Wheel 2999U 3 Coupling Air Guide 31231U 5 Burner Housing - Black 5874BKU 6 Air Band Air Shutter - 4 Slot Air Shutter - 8 Slot Cord set Pump (CleanCut) U 10 Valve Stem 21877U Volt Coil 21754U 12 8 Copper Tubing Escutcheon Plate Spline Nut Escutcheon Plate Electrode Kit over 3-5/ Cad Cell Detector 7492/7006U 17 Igniter Gasket Kit X4 Wiring Box Kit Control Kit 7556x-xxxxU* 20 Igniter Assy with baseplate U 21 Igniter only Air Tube Ass y Specify 23 Flange Mounting Gasket Specify 24 Not Shown * X s indicate timing options. Contact Beckett for available part numbers. Motor Kit with Blower Wheel and Coupling Tune-up Kit for 30 & 35 Air Tube Lengths 52145U Vdc ADC Burner Manual 15

44 Limited Warranty Information 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 bene ts, products must be installed by a quali ed service agency in full compliance with all codes and authorities having jurisdiction, and used within the tolerances of Beckett s de ned product speci cations. To review the complete warranty policy and duration of coverage for a speci c product, or obtain a written copy of warranty form 61545, please choose one of the following options: 1. Visit our website at: your request to: rwb-customer-service@beckettcorp.com 3. Write to: R. W. Beckett Corporation, P. O. Box 1289, Elyria, OH 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. USA: P.O. Box 1289 Elyria, Ohio Canada: R.W. Beckett Canada, Ltd. Unit #3, 430 Laird Road Guelph, Ontario N1G 3X7 Part Number 6104 B12ADC2 R02, Printed in the U.S.A. 04/12

45 Series TSW Single Stage Digital Temperature Switch Specifications - Installation and Operating Instructions Bulletin T-TSW /32 [65.53] 3-5/8 [92.08] 6-21/32 [168.91] The Series TSW Digital Temperature Switch combines the trusted, reliable TS family of temperature controls and an installation friendly weatherproof enclosure. By using the same programming parameters as our Series TS2 and Series TSS2, set up can be quickly completed using the front keys or by using the TS2-K configuration key. In order to prevent tampering from unauthorized users, a parameter lock physical jumper and software passcode security are standard in the unit. The bright, easy-to-read LED display shows the current output status and the temperature measurement. The multiple conduit knockouts on the Series TSW give flexibility to the installer to determine the best location for the conduit entry. Another installation friendly feature of the Series TSW is the ability to quickly jumper the line voltage to the common of the output relay using fast tabs. INSTALLATION NOTICE: The thermostat must be installed by authorized professionals. It should be located in a place free of vibrators, impacts, and corrosive gases. SPECIFICATIONS Probe Range: PTC: -58 to 302 F (-50 to 150 C). NTC: -58 to 230 F (-50 to 110 C). Input: PTC ( C)/NTC 25 C). Output: R1 SPDT Relay Resistive Load: 240 VAC. Horsepower Rating: R1 VAC. Control Type: On/Off. Power Requirements: 90 to 255 VAC or 12 to 24 VAC/VDC (±10%) depending on model. Power Consumption: 3.6VA. Accuracy: ±1% FS. Display: 3 digits plus sign. Resolution: 0.1 < 100 ; Memory Backup: Non-volatile memory. Ambient Temperature: 32 to 104 F (0 to 40 C). Weight: 1.2 lbs (544 g). Front Protection: NEMA 4X (IP66). Agency Approvals: CE, UL, cul. NOTICE: Protective plastic overlay should be peeled off after final installation. DWYER INSTRUMENTS, INC. Phone: 219/ P.O. BOX 373 MICHIGAN CITY, INDIANA 46360, U.S.A. Fax: 219/ info@dwyermail.com

46 WIRING INSTRUCTIONS Wiring diagram is displayed on the inside cover of the unit and in figure 1. NOTICE: If the length of the probe cables measures more than 100 meters, a recalibration adjustment must be made (parameter P1). NOTICE: Avoid installing the probe cables in proximity with any power cables. TS2-K PROBE INPUTS Sd PROGRAMMING PARAMETERS In order to adjust parameters, jumper must be set in unlocked position. Locked OUT 1 OUTPUTS Figure 1 Figure 2 POWER SUPPLY Unlocked Access only to Set Points SP (without software code protection): Press and release SET. Parameter SP appears on the display. Press SET to see the value of the parameter. Modify the value using the UP and DOWN keys. Press SET Key to save the value. Press SET and DOWN to quit programming, or wait 1 minute for the TIMEOUT. Access to all parameters (software code protected): Press SET for 8 seconds. The access code value 0 is shown on the display. Using the UP and DOWN buttons, set the code (factory-set code is 0). Press SET to confirm the code. If it is correct, the first parameter label will be shown on the display (SP). Move to the desired parameter with the UP and DOWN keys. Press SET to see the value of the parameter. Modify the value with the UP and DOWN keys. Press SET to save and exit parameter list. Press SET and DOWN to quit programming, or wait 1 minute for the TIMEOUT. Resetting the parameter pass code The parameter code can be set to zero by holding the SET key and cycling power to the unit. LED INDICATIONS This indicates that the output is energized or that the compressor is connected. It waits for the programmed minimum stop time of the compressor. This indicates that defrosting is activated. Error Messages In normal operation, the probe temperature will be shown. In case of alarm or error, the following messages will be shown: Er- Memory error. -- Shorted-circuited probe error. oo- Open probe error. Parameter List SP r0 r1 r2 d0 d2 d8 c0 c1 c2 c3 P0 P1 H5 H6 t0 Description Set Point Differential or hysteresis Lower value for set point Higher value for set point Heating or Cooling Control Time for Defrosting Interval time between Defrosts Minimum stop time for compressor Continuous cycle time On time of fault cycle Off time of fault cycle Engineering Units Ambient Probe Adjustment Parameter acess code Probe Input Type Maximum Temperature on Display PARAMETER DESCRIPTIONS SP = Set Point. Temperature desired to regulate the machine. Can vary from r1 to r2. r0 = Differential. Heating: If temperature is SP then output is OFF. If temperature is < SP - r0 then output is ON. Cooling: If temperature is SP + r0 then output is ON. If temperature is < SP then output is OFF. r1 = Lower Set Point Limit. r2 = Upper Set Point Limit. d0 = Heat or Cooling Control. Ht = heating control, Co = cooling control. d2 = Defrosting Time Remaining, in minutes. If d2 = 0, defrosting will not start. d8 = Interval Between Two Defrostings, in hours. c0 = Minimum Time for Compressor to be OFF. Minimum time for compressor to stop until it can start again. c1 = Continuous Cycle Time. The remaining time for a continuous cold cycle. c2 = ON Time of fault cycle, during probe error. c3 = OFF Time of fault cycle, during probe error. P0 = Selection of Engineering units between F and C. P1 = Ambient Probe Calibration. Offsets temperature in degrees to adjust the ambient probe. H5 = Access Code to Parameters. Factory-set to 0. H6 = Selection of Input Probe Type: PTC or NTC. t0 = Temperature Display Limit. Maximum temperature shown on the display, although the real temperature can be greater. OPERATION IN CASE OF ERROR If the probe or thermostat memory should fail, the compressor will be connected in accordance to the parameters set in C2 and C3. MAINTENANCE/REPAIR Upon final installation of the Series TSW, no routine maintenance is required. The Series TSW is not field serviceable and should be returned if repair is needed. Field repair should not be attempted and may void warranty. WARRANTY/RETURN Refer to Terms and Conditions of Sales in our catalog and on our website. Contact customer service to receive a Return Goods Authorization number before shipping the product back for repair. Be sure to include a brief description of the problem plus any additional application notes. Dwyer Instruments,Inc. Attn: Repair Department 102 Highway 212 Michigan City, IN U.S.A. Units Degrees Degrees Degrees Degrees Option Minutes Hours Minutes Hours Minutes Minutes Option Degrees Number Option Degrees Range r1 to r2 1 to to 150 C -50 to 302 F -50 to 150 C -50 to 302 F Ht/Co 0 to 59 0 to 24 0 to 59 0 to 24 0 to to 999 C/ F -10 to 10 0 to 99 Ptc/ntc -50 to 150 C -50 to 302 F Copyright 2014 Dwyer Instruments, Inc. Printed in U.S.A. 7/14 FR# R Rev. 2 DWYER INSTRUMENTS, INC. Phone: 219/ P.O. BOX 373 MICHIGAN CITY, INDIANA 46360, U.S.A. Fax: 219/ info@dwyermail.com

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