Horizon Manual
Installation, Operation and Maintenance Instructions
Document 1104B
Installation,
Operation and
Maintenance
Instructions for
Horizon
Oil Fired Boiler
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualified in boiler installation and maintenance. Improper installation and/or operation could create
carbon monoxide gas in flue gases which could cause serious injury, property damage, or death.
Improper installation and/or operation will void the warranty.
WARNING
If the information in this manual is not followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or
any other appliance.
57-207B
Installation and service must be performed by a qualified installer, service agency, or fuel oil
supplier.
LAARS HEATING SYSTEMS
Page 2
TABLE OF CONTENTS
SECTION 1.
General Information
1A.
1B.
1C.
1D.
1E.
1F.
1G.
1H.
1I.
1J.
1K.
1L.
1M.
1N.
Freight Claims .............................................. 3
General Information ...................................... 3
Boiler Installation .......................................... 3
Boiler Location .............................................. 3
Boiler Clearances (minimum) ....................... 3
Floor ............................................................. 3
Combustion and Ventilation Air ..................... 3
Chimney and Draft Requirements ................. 3
Jacket (normally fitted) .................................. 3
Oil Burner (normally fitted) ............................ 3
Boiler Controls (normally fitted) ..................... 3
Oil ................................................................. 4
Oil Storage and Pipe Layout ......................... 4
Electrical Connections .................................. 4
1O.
1P.
Operation
(using Honeywell L.8124A aquastat relay) .... 4
Domestic Water Piping ................................. 4
SECTION 2.
Maintenance
2A.
2B.
2C.
2D.
2E.
Cleaning the Boiler ....................................... 4
Cleaning the Chimney ................................... 4
Servicing the Burner ..................................... 4
Maintenance of the Tankless Coil ................. 5
Coil Removal ................................................ 5
SECTION 3.
Part Numbers
................................................................... 11
Horizon
Page 3
SECTION 1.
1D. Boiler Location
General Information
The boiler should be positioned as near to the
chimney as possible and have a minimum smoke-pipe
connector length of 18".
1A. Freight Claims
Inspection should be made of boiler and
components for damage upon arrival. Any claims for
damage should immediately be filed against the
carrier by the consignee.
1E. Boiler Clearances (minimum)
1B. General Information
The boiler must be mounted on a noncombustible masonry or cement floor with no
combustibles underneath.
These boilers have been designed and
constructed according to the requirements of the
relevant ASME Codes using heavy gage steel plate
and boiler tubes. They are of the three pass horizontal
tube design using a reverse flame technique in the
boiler to impart a high heat transfer in the primary
heating zone before directing gases into the third pass.
The compact tubular third pass incorporates
special stainless steel flue gas baffles with extension
rods to allow full insertion of the baffles into the back
end of tubes where they are most effective.
A 5 gal/min. domestic hot water coil is located at
the top of the boiler in the hottest zone for ample hot
water supply. A unique feature of its attachment is the
raised coil flange which allows the use of clamping
bolts rather than studs, thereby eliminating water leaks
caused by broken studs.
Two ceraform lined doors provide easy access
for cleaning, the lower door with burner attached
remaining in position while the upper door is removed
for tube cleaning.
A flame observation port is provided for settingup burner and a test hole gives access for CO2 and
draft readings.
The boiler is encased in a fully insulated baked
enamel jacket and comes completely pre-assembled
for easy installation. Alternatively, it can be supplied
in knock-down form.
Caution
This boiler is designed for use in closed systems
where air is eliminated from the system and no more
oxygen is allowed to enter (typical baseboard or
radiator system). Do not directly connect this boiler
to a system utilizing rubber or plastic tubing which
has an oxygen permeation rating greater than 0.1
milligrams / liter / day. Damage to the boiler will
result and the warranty will be void (see warranty
section 4g).
1C. Boiler Installation
For recommended installation practice reference
should be made to the National Fire Protection
Standard for Oil Burning Equipment - NFPA 31 Latest Edition.
Top - 6"; Front - 24"; Rear - 6"; Sides - 6".
1F. Floor
1G. Combustion and Ventilation Air
To insure an adequate supply of fresh air for
combustion and ventilation an inlet and outlet opening
should be provided at floor and ceiling level. Each
opening must have a minimum of one square inch of
free area for every 1000 BTU/h of input or 140 square
inches per gallon of oil burned per hour. The openings
must not be in a position liable to blockage.
1H. Chimney and Draft Requirements
To assure the safe and proper operation of the oil
burner the boiler must be connected to a chimney
having sufficient draft at all times to evacuate the flue
gases to atmosphere. A draft regulator should be
installed in the smoke-pipe as near to the flue as
possible and adjusted to achieve an over fire draft of
0.01 in. W.C.
1I. Jacket (normally fitted)
If not fitted, assemble panels in accordance with
instructions in Figure 2.
1J. Oil Burner (normally fitted)
If not fitted, insert burner tube into boiler so that
it is recessed approximately 1/4" back from the inside
wall of door insulation, then clamp mounting flange
and bolt up to front-plate.
The burner should be wired and connected to the
oil line in accordance with the manufacturer’s
instructions.
1K. Boiler Controls (normally fitted)
If controls are supplied separately, fit them to the
boiler in the positions shown in Figure 2, with jacket
in place.
Circulator - 1 1/4' return tapping at rear of boiler.
Tridicator - temp./press. gauge - 1/2" tapping at
top of boiler.
Relief Valve - 3/4" tapping at top of boiler. Pipe
to safe place of discharge.
Aquastat Relief - L8124A - 3/4" tapping.
Fit a drain valve (not supplied) in the hydronic
return tee. Check that all connections are made water
tight.
LAARS HEATING SYSTEMS
Page 4
1L. Oil
Use only No. 2 Heating Oil. Do not use gasoline,
crankcase draining or any oil containing gasoline.
1M. Oil Storage and Pipe Layout
(See Figures 3 and 4)
Figure 3: One-pipe system - pipe and tank layout.
Figure 4: Two-pipe system - pipe and tank layout.
Connect gate or shutoff valve (13) to tempering
valve (12) “MIX” port, and cold water inlet.
Connect pressure relief valve (11) (if required by
codes), maximum 150 PSI as close to the unit as
possible. No other valves or restrictions may be
installed between the DHW coil and the relief valve.
(DO NOT USE A TEMPERATURE/
PRESSURE RELIEF VALVE AS THIS IS NOT A
STORAGE HOT WATER HEATER).
1N. Electrical Connections
All electrical wiring must conform to local codes
and/or the National Electrical Code ANSI / NFPA No.
70 - Latest Edition. The system must be electrically
grounded in accordance with the requirements of the
authority having jurisdiction or, in the absence of such
requirements, with the National Electrical Code
mentioned above.
1O. Operation
(using Honeywell L.8124A
aquastat relay)
1P. Domestic Water Piping
Connect hot water tempering valve (12) “HOT”
port to hot water outlet from unit. This valve should
be mounted 8" to 12" below the outlet and set for
120°F mixed delivery temperature or as local codes
dictate.
13
11
8 - 12"
12
WARNING
Flue gases are dangerous - do not operate boiler if
there is an escape of flue gas. Call a qualified
serviceman and have the entire flue and venting
system inspected.
2A. Cleaning the Boiler
A call for heat from the room thermostat causes
the relay to “make” the burner circuit and also feed
the circulator, provided the boiler water temperature is
above the low limit setting (usually 190° to 210°F).
The burner and circulator then continue to run until
the room thermostat is satisfied.
A high limit switch shuts off burner in the event
of water temperature exceeding the high limit setting,
usually 20° to 30°F above the low limit setting.
The low limit switch and circulator maintain
boiler water temperature for domestic hot water
service and prevents circulation of heating system
water if domestic water is not hot enough.
B
O
I
L
E
R
SECTION 2.
Maintenance
To maintain the high thermal efficiency and a
long life from your boiler, it should be cleaned at least
once a year, preferably at the end of the heating
season. This is particularly important as rusting can
occur when the boiler is idle.
It is recommended that a service contract be
arranged with a properly equipped serviceman who
will be able to do the job efficiently and without mess.
1. Switch off electrical supply to the boiler.
2. Remove front cleaning cover.
3. Remove flue baffles and thoroughly brush out
flue tubes.
4. Remove flue deposits from flue collector box
using a vacuum nozzle through side cleaning
ports.
5. Vacuum out accumulated deposits from
combustion chamber through cleaning cover
opening.
6. Replace all parts, ensuring flue baffles are
correctly located and cleaning cover is tightly
sealed.
2B. Cleaning the Chimney
Sweep all soot deposits from chimney and
smoke-pipe once a year, preferably at the end of the
heating season. It is also advisable to inspect the
chimney and smoke-pipe at the beginning of heating
season as birds may have built their nest inside or
other material may be causing a blockage.
2C. Servicing the Burner
Figure 1.
This should only be carried out by a trained and
licensed service technician in accordance with the
burner maker’s instructions.
Horizon
Page 5
2D. Maintenance of the Tankless Coil
2E. Coil Removal
After several years of use, the water flow
through the coil may become restricted by mineral
deposits from the water. Mild accumulations may be
removed by an acid treatment, but your servicing
company can advise on the most satisfactory method
of cleaning or whether a replacement coil is
necessary.
1.
2.
3.
4.
5.
6.
7.
Switch off electrical supply and turn off water
to boiler.
Drain the complete system.
Disconnect the pipe connections to the coil.
Unscrew the eight retaining bolts from coil plate.
Pull out coil and clean / fit replacement as
necessary.
Ensure gasket makes a water tight seal.
Refill & purge before returning system to
service.
LAARS HEATING SYSTEMS
Page 6
SIDE PANEL TO FRONT
PANEL FIXING
1. FIT FRONT PANEL (1)
2. ATTACH SIDE PANELS (2) AND (3) TO
BOTTOM OF BOILER AND FRONT
PANEL
3. FIX REAR PANELS (4) AND (5) TO SIDE
PANELS
4. FIT TOP PANEL (6)
Vent Pipe
Hydronic Supply
with dip tube
Heavy gauge Enamelled Jacket
Tankless Coil 4 gal./min. in
hottest zone
Horizontal Fire Tube Design
Stainless Steel Flue Gas
Tubulators for optimum heat
transfer and highest efficiency
Flue Cleaning Ports
Flue Collector external fixing
no bolt corrosion
Extra Heavy Duty Insulation
for low stand-by losses
Relief Valve
Bolted Coil Flange for easy
re-tightening - no Studs to
break
Aquastat Relay
Domestic Water Connections
Removable Flue Cover for
easy tube cleaning
CO2 and Draft Test Plug
Flame Observation Glass
CO2 and Draft Test Plug
Flame Retention Oil Burner
Hydronic Return
Sludge Clean-out Socket
Glass fiber Rope for positive
gas tight seal
Flame Reverse Combustion
Figure 2.
Horizon
Page 7
Supply Pipe
Vent
Draft Regulator
and Smoke Pipe
(not supplied)
Relief Valve
Tridicator ½"
N.P.T.
Aquastat Relay
L8124A ¾" N.P.T.
Wiring Conduit
to Circulator
Tankless Domestic
Hot Water Coil ½" N.P.T.
Wiring Conduit to
Burner
Flame Observation
Glass
Oil Burner
Tapping
Figure 3.
NPT
Tankless Coil
¾"
Tridicator
¼"
Hydronic Return
1¼"
Hydronic Supply
1¼"
Aquastat Well
¾"
Relief Valve Fitting
¾"
Alternate Hydronic Return
1¼"
LAARS HEATING SYSTEMS
Page 8
C
3½"
8¾"
Relief Valve — ¾" N.P.T.
Domestic
Hot Out
B
Tankless Coil
½" N.P.T.
Supply — J N.P.T.
Domestic
Cold In
H
Aquastat
Well
¾" N.P.T.
G
Fire Sight
Glass
A
E
F
7"
8"
D
FRONT
Return — J N.P.T.
Drain Valve
SIDE
REAR
Figure 4.
Dimensions
REF
HC 100
HC 125
HC 145
HC 175
HC 205
HC 240
HC 270
HC 300
A
39"
39"
42"
42"
45¾"
45¾"
45¾"
45¾"
Jacket Width
B
21"
21"
23"
23"
25"
25"
25"
25"
Jacket Length
C
21"
21"
23"
23"
25"
25"
29"
29"
Overall Length
D
32"
32"
34"
34"
36"
36"
40"
40"
Smoke Outlet Height
E
24½"
24½"
27"
27"
29½"
29½"
29½"
29½"
Burner Center Line
F
10¾"
10¾"
11¾"
11¾"
12½"
12½"
12½"
12½"
Smoke Outlet Diameter
G
6"
6"
6"
6"
8"
8"
8"
8"
Smoke Box
H
1¾"
1¾"
1¾"
1¾"
2½"
2½"
2½"
2½"
Supply Size Water
I
1¼"
1¼"
1¼"
1¼"
1½"
1½"
1½"
1½"
HC 100
HC 125
HC 145
HC 175
HC 205
HC 240
HC 270
HC 300
D.O.E. Heating Capacity
100
125
145
175
205
240
270
300
Net Output M.B.H.
87
109
126
152
178
209
235
261
84.2
84
85.8
85.2
85.4
84.2
85.2
84.4
Jacket Height
Specification
A.F.U.E. %
Firing Rate G.P.H.
.85
1
1.25
1.50
1.75
2.00
2.25
2.50
Net Stack Temperature
333
371
319
354
325
350
330
360
Water Capaqcity Gal.
21
21
34
34
42
42
48
48
Coil Capacity G.P.M.
5
5
5
5
5
5
5
5
Approx. Weight lbs.
494
494
608
608
764
764
810
810
Burner
Head Type
Static
Plate Stop
Blower Wheel
Nozzle Type
HC100
AFG
F3
3 5/8"
4 1/4" x 2 7/16"
.75 x 70°A
HC125
AFG
F3
3 5/8"
4 1/4" x 2 7/16"
.90 x 80°B
HC145
AFG
F6
2 3/4"
4 1/4" x 2 7/16"
1.10 x 80°B
HC175
AFG
F6
2 3/4"
4 1/4" x 2 7/16"
1.25 x 80°B
HC205
AFG
F16
2 3/4"
4 1/4" x 2 7/16"
1.50 x 80°A
HC240
AFG
F16
2 3/4"
4 1/4" x 2 7/16"
1.75 x 80°B
HC270
AFG
F22
2 3/4"
4 1/4" x 2 7/16"
2.00 x 80°B
HC300
AFG
F22
2 3/4"
4 1/4" x 2 7/16"
2.25 x 80°B
Horizon
Page 9
Air Vent
1¼" min
Fill Pipe
Valve
Oil Tank
"P"
Burner
Filter
Boiler
"H"
Figure 5. One-Pipe System.
Air Vent 1¼" min.
Burner
Fill Pipe
Filter
Boiler
Valve
"H"
Oil Tank
Figure 6. Two-Pipe System.
PIPE LENGTHS
"H"
ft
PIPE LENGTHS
One Pipe Gravity System
3/8" O.D.
1/2" O.D.
ft
ft
0
"H"
Two Pipe Lift System
3/8" O.D.
1/2" O.D.
ft
ft
ft
0
115
330
1½
33
65
1½
100
330
3
65
130
3
80
330
5
130
260
5
65
295
6½
195
325
6½
50
230
9½
25
100
11
20
65
WARNING
The height should not exceed 13 feet.
WARNING
The vacuum must not excedd 11.44 HG (11.44
inches of Mercury). Burner is shipped from the
factory set up for two pipe system.
Important
An external filter must be placed in the fuel line
between the fuel tank and the burner pump.
LAARS HEATING SYSTEMS
Page 10
Power supply provides disconnect means & overload protection as required.
24V
Room Thermostat
L1 (Hot)
Power Supply
120V
1K
L2
Circulator
Switch
1K1
Low Limit
Circulator
Hi Limit
Oil Burner
Relay
1K2
Heating Circulator
Aquastat Relay L8124A
Wiring Arrangement for HC Boiler
Controlling Operation of Boiler and Circulator
Figure 7.
Horizon
Page 11
SECTION 3.
Part Numbers
Part Number
Description
57-002
57-072
57-090
57-136
57-170
57-164
57-154
57-194
57-176
57-186
57-145-2
57-146
Boiler Body ............................... 100/125
Inspection Cover Assembly ..... 100/125
Burner Door Assembly ............ 100/125
Flue Cover Assembly .............. 100/125
Front Panel Assembly ............. 100/125
Left Panel Assembly ................ 100/125
Right Panel Assembly ............. 100/125
Top Panel Assembly ................ 100/125
Rear Upper Panel Assembly ... 100/125
Rear Bottom Assembly ............ 100/125
Target, Wall ............................. 100/125
Baffle, 110/125 (13), 145/175 (18), ... All
205/240 (26)
Boiler Body ............................... 145/175
Inspection Cover Assembly ..... 145/175
Burner Door Assembly ............ 145/175
Flue Cover Assembly .............. 145/175
59-002
59-072
59-090
59-136
Size
Part Number
Description
59-170
59-164
59-154
59-194
59-176
59-186
59-145-2
61-002
61-072
61-090
61-136
61-170
61-164
61-154
61-194
61-176
61-186
61-145-2
Front Panel Assembly
Left Panel Assembly ................
Right Panel Assembly .............
Top Panel Assembly ................
Rear Upper Panel Assembly ...
Rear Bottom Assembly ............
Target Wall ..............................
Boiler Body ...............................
Inspection Cover Assembly .....
Burner Door Assembly ............
Flue Cover Assembly ..............
Front Panel Assembly .............
Left Panel Assembly ................
Right Panel Assembly .............
Top Panel Assembly ................
Rear Upper Panel Assembly ...
Rear Bottom Assembly ............
Target Wall ..............................
Size
145/175
145/175
145/175
145/175
145/175
145/175
145/175
205/240
205/240
205/240
205/240
205/240
205/240
205/240
205/240
205/240
205/240
205/240
57-207B
Waterpik Technologies, Inc.
6000 Condor Drive, Moorpark, CA 93021 • 805.529.2000 • FAX 805.529.5934
20 Industrial Way, Rochester, NH 03867 • 603.335.6300 • FAX 603.335.3355
480 S. Service Road West, Oakville, Ontario, Canada L6K 2H4 • 905.844.8233 • FAX 905.844.2635
www.laars.com
Litho in U.S.A. © Laars Heating Systems 0103 Document 1104B
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