Instruction Manual. Automatic fuel oil de-aerator SMART-FLO 3/K B100 COMPATIBLE

Transcription

1 Sid Harvey s 605 Locust Street Garden City, NY Instruction Manual Automatic fuel oil de-aerator SMART-FLO 3/K Read manual before use! Observe all safety information! Keep manual for future use! B100 COMPATIBLE

2 Contents 1 About this instruction manual Structure of warning Safety Intended use Predictable incorrect application Safe handling Qualification of personnel Modifications to the product Use of spare parts and accessories Liability information Product description Function Application examples Specifications Approvals Transport and storage Installation Right dimension of the suction tube Pressure test Parallel connection Connecting the vent hose Operation Oil foam Oil level in the float housing Pressure mode Troubleshooting Warranty Copyright Customer satisfaction SMART-FLO 3/K

3 About this instruction manual 1 About this instruction manual 1.1 Structure of warning This instruction manual is part of the product. Read this manual before using the product. Keep this manual during the entire service life of the product and always have it readily available for reference. Always hand this manual over to future owners or users of the product. WARNING TERMThe type and source of danger is shown here. Precautions to take in order to avoid the danger are shown here. Warning term CAUTION Meaning Dangerous situation! Failure to observe the information may result in minor or serious injuries as well as damage to property. SMART-FLO 3/K 3

4 Safety 2 Safety 2.1 Intended use The automatic fuel oil de-aerator SMART-FLO 3/K may only be used in single-line systems with return pipe connection to the de-aerator for continuous de-aeration of the following liquids in oil-fired systems: # 2 Home Heating Oil according to ASTM D396 Biodiesel according to ASTM D6751 Bio-fuel % Biodiesel fuel oil blends according to ASTM D6751 and ASTM D396 Any use other than the use explicitly stated in this instruction manual is not permitted. 2.2 Predictable incorrect application The automatic fuel oil de-aerator SMART-FLO 3/K must never be used in the following: Use with undissolved additives, alcohols and acids 2.3 Safe handling This product represents state-of-the-art technology and is manufactured in accordance with the pertinent safety regulations. Each unit is subjected to a function and safety test prior to shipment. Operate this product only when it is in perfect condition. Always follow the instruction manual, all pertinent local, state and federal codes and guidelines as well as health and safety regulations and rules regarding the prevention of accidents. 2.4 Qualification of personnel Installation must be done by a qualified technician familiar with oil heating systems, equipped with the proper tools and equipment, and licensed by the proper authority where applicable. 2.5 Modifications to the product Changes or modifications made to the product by unauthorized persons may lead to malfunctions and are prohibited for safety reasons. 2.6 Use of spare parts and accessories Use of unsuitable spare parts and accessories may cause damage to the product. Use only the manufacturer s genuine spare parts and accessories. 4 SMART-FLO 3/K

5 Safety 2.7 Liability information The manufacturer shall not be liable for any direct or consequential damage resulting from failure to observe the technical instructions, guidelines and recommendations. The manufacturer and the sales company shall not be liable for costs or damages incurred by the user or by third parties in the use or application of this device, particularly in case of improper use of the device, misuse or malfunction of the connection, malfunction of the device or of connected devices. The manufacturer or the sales company shall not be liable for damages resulting from any use other than the use explicitly stated in this instruction manual. The manufacturer shall not be liable for misprints. SMART-FLO 3/K 5

6 Product description 3 Product description Fig. 1: SMART-FLO 3/K SMART-FLO 3/K consists of a diecast zinc housing with female ¼- NPT connection thread at the tank side and for connection of the burner hoses. Flow-Control 3/K features two separate float chambers. The lower float chamber contains the operating float; the upper float chamber contains the safety float. The upper float chamber keeps oil foam from escaping via the vent opening (e.g. during commissioning/filter exchange) and indicates malfunctions of the vent valve. 6 SMART-FLO 3/K

7 Product description 3.1 Function a b c d Q Tank = Q nozzle Q Supply Q Return Q Nozzle Fig. 2: SMART-FLO 3/K with filter and fusible valve The burner pump draws the fuel oil from the tank via the filter and the non-return valve installed in Flow-Control and delivers it to the nozzle. The excess oil (i.e. the oil exceeding the nozzle capacity) is pumped into the float chamber via the return pipe. While the oil level gradually increases in the float chamber, the oil is de-aerated by the de-aeration valve. When the oil reaches a level of approx. 1 3/16 above the bottom, the floats begin to operate and actuate the bypass valve, thus delivering the de-aerated return oil to the suction pipe. This way, the system only withdraws the amount of oil from the tank via the filter which is actually needed for combustion. This considerably prolongs the filter service life. The maximum possible service life can be obtained with the long filter insert made of sintered plastic (Optimum). The oil that now flows to the pump primarily consists of de-aerated fuel oil plus oil from the tank that still contains air. SMART-FLO 3/K 7

8 Product description 3.2 Application examples Fig. 3: Burner should be installed a maximum of 15 feet (a) above the bottom of the oil pickup tube. 1 Diaphragm type antisiphon valve MAV 2 Static pre-pressure for sizing the MAV 3 Filter 4 SMART-FLO 3/K 5 Burner Fig. 4: Installation of SMART-FLO 3/K below the tank level. We recommend to install an anti-siphon valve or an oil safety valve to prevent fuel oil from escaping in the case of a defective suction line with a higher oil level in the tank. In case of fire, the valve will prevent oil from running out and intensifiying the fire. 8 SMART-FLO 3/K

9 Specifications 4 Specifications Table 1: Specifications Parameter General specifications Value Dimensions: (W x H x D) 3.75 x 6.4 x 3.75 Burner connection Tank connection Nozzle capacity Return flow Oil flow Separation capacity air/gas Mounting position Operating overpressure Suction vacuum Test pressure Operating temperature range Ambient Operation ¼-NPT inner thread ¼-NPT inner thread Max. 26 gph Max. 37 gph Max. 58 gph Over 4 quarts Float housing vertical to the top Max. 10 psi (corresponds to static oil column of approx. 26 ft) Max. 7.5 psi Max. 85 psi Max. 140 F (60 C) Max. 140 F (60 C) 4.1 Approvals SMART-FLO 3/K is TÜV-tested, report no. V Z2. SMART-FLO 3/K 9

10 Transport and storage 5 Transport and storage CAUTION Damage to the product due to improper transport. Do not throw or drop the product. CAUTION Damage to the product due to improper storage. Protect the product from shock when storing it. Store the product in a clean and dry environment. Do not operate products with visible damages. 6 Installation Install SMART-FLO 3/K between the burner and the oil safety valve, close to the oil burner. Never use SMART-FLO 3/K in ambient temperatures greater then 140 F. Do not mount the product in the vicinity of uninsulated burners, over burner opening flaps or next to chimney flues. Mount the float chamber vertically, pointing to the top, so it fits securely and cannot come loose. Use oil lines and hoses as per local codes for connection to the oil pump. Ensure that the pump is set for two-pipe operation when mounting the product. Bypass plug must be installed. Install an oil filter in the supply line in order to protect SMART- FLO 3/K. A 3/8" pipe is sufficient for most installations. In larger systems requiring 1/2" pipes (if the oil used is less than 5 ¼ gph), all parts of the pipes leading upwards should be calculated as suction height. If the suction pipes are larger than ½", this should be taken into consideration as well (even if the usage amounts to more than 5 ¼ gph). Large pipes with low flow rates may cause gas accumulations, resulting in insufficient suction in the downward sections. Mount SMART-FLO 3/K as shown in fig. 2, page 7. Remove all check valves between SMART-FLO 3/K and tank except for OSV and fusible valves. 10 SMART-FLO 3/K

11 Installation Never install a shut-off valve or other device, which can impede flow in the lines between the oil de-aerator and the oil pump. All pipework must be tested during installation. Never use SMART-FLO 3/K with pump pressure between tank and SMART-FLO 3/K. Test the completed installation for correct function and fire security before starting. Only one fuel unit per SMART-FLO 3/K connection. CAUTION Damage to the pump or SMART-FLO 3/K due to incorrect connection of supply and return connections. Do not confuse the supply and return connections (not even during commissioning for a short period of time). 6.1 Right dimension of the suction tube Tabelle 2: Standard values for tube dimensioning Volume flow in the suction tube Tubing size copper 0-13 gph 5/ gph 3/ gph 1/2 6.2 Pressure test When subjecting the suction pipe to a pressure test, the pressure connection must not be made at the SMART-FLO 3/K unit since the non-return valve integrated in the device does not allow the pressure to be applied to the suction pipe. Therefore, the device is not to be included in the pressure test. SMART-FLO 3/K 11

12 Installation 6.3 Parallel connection The built-in check valve permits connection of several oil burners to the same supply line. In this case, the total oil consumption must be used when calculating for pipe resistance. When the GPH for a single fuel unit exceeds the rated GPH of the SMART-FLO 3/K two or more can be connected in parallel. See figure 5. a Return b Supply c Tank Fig. 5: Parallel operation of two SMART-FLO 3/K units 12 SMART-FLO 3/K

13 Installation 6.4 Connecting the vent hose To prevent odours from the separated air (e.g. if the unit is installed in kitchens), a vent hose can be connected to the SMART-FLO 3/K hood. a Vent hose b Hose connection with O ring Fig. 6: SMART-FLO 3/K 1. Remove the cover using a screwdriver. Mount the enclosed hose connection. 2. Push the vent hose onto the hose connection and route it to the tank next to the suction line. 3. Fixate the vent hose with cable ties. 4. Mount the other end of the vent hose to the de-aeration line or the return connection of the withdrawal fitting at the tank to prevent clogging. 5. Use the enclosed hose connector for connection to the return connection of the withdrawal fitting. SMART-FLO 3/K 13

14 Operation 7 Operation 7.1 Oil foam Oil foam may build up if the amount of air sucked into the de-aerator exceeds the separating capacity of the product (1 gph). Possible reasons: Leak in the suction line Screw connections at the suction side not tight Initial commissioning (without separate suction pump) Suction line rating too great (observe DIN , flow rate fps) 7.2 Oil level in the float housing The oil level depends on the operating conditions of the facility and amounts to approx in suction mode. If the oil level is higher, the float housing may be completely filled with oil if the suction line is tight. This is caused by the absorption of the air through the fuel oil. Over time, this results in a reduction of the air cushion. When the operating conditions change (e.g. decreasing oil level in the tank), the air cushion is formed again in the float housing. 7.3 Pressure mode Since in pressure mode with an oil pump there is no gas formation caused by suction, it is not meaningful to use an oil vent in this mode. 14 SMART-FLO 3/K

15 Warranty 7.4 Troubleshooting Problem Possible reason Remedy Oil foam: The amount of air sucked into the deaerator exceeds the separating capacity of the device (1.05 gph). Note: In single-pipe mode, only the amount consumed by the burner is transported through the suction pipe. SMART-FLO 3/K is completely filled with oil. Leak in the suction pipe. Initial start up (system not bleed properly). Suction pipe dimensions too great. Pressure in the feed line (tank higher than burner). This won t affect the function of the pump. Check the suction pipe for leaks. Manually bleed pump till no air is coming out and a clear flow of oil is coming from bleeder. Refer to chapter 6.1, page 11. Install an oil safety valve on the feed line from the tank. The oil level will resume its normal level in the SMART-FLO 3/K. 8 Warranty The manufacturer s warranty for this product is 5 years from date of purchase. This warranty applies to all countries in which this product is sold by the manufacturer or its authorized representatives. The SMART-FLO is factory tested and sealed. Tampering will void Warranty. 9 Copyright The manufacturer holds the copyright to this manual. This manual may only be reprinted, translated, copied in part or in whole with the prior written consent of the manufacturer. We reserve the right to modify any specifications or alter any illustrations in this manual without prior notice. 10 Customer satisfaction Customer satisfaction is our prime objective. Please get in touch with us if you have any questions, suggestions or problems regarding your product. SMART-FLO 3/K 15

16 Customer satisfaction Sid Harvey's Inc. 605 Locust Street Garden City, NY SMART-FLO 3/K