User Guide

50
103876-08 - 1/19
CL Installation & Service Manual
A. COMBUSTION
1. Nozzles — Although the nozzle is a relatively
inexpensive device, its function is critical to
the successful operation of the oil burner.
The selection of the nozzle supplied with the
CL boiler is the result of extensive testing
to obtain the best flame shape and efficient
combustion. Other brands of the same spray
angle and spray pattern may be used but may
not perform at the expected level of CO
2
and
smoke. Nozzles are delicate and should be
protected from dirt and abuse. Nozzles are
mass-produced and can vary from sample to
sample. For all of those reasons a spare nozzle
is a desirable item for a serviceman to have.
2. Fuel Leaks — Any fuel leak between the pump
and the nozzle will be detrimental to good
combustion results. Look for wet surfaces in
the air tube, under the ignitor, and around the
air inlet. Any such leaks should be repaired as
they may cause erratic burning of the fuel and
in the extreme case may become a fire hazard.
3. Suction Line Leaks — Any such leaks should
be repaired, as they may cause erratic burning
of the fuel and in extreme cases may become
a fire hazard. Whatever it takes, The Oil Must
Be Free of Air. This can be a tough problem,
but it must be resolved. Try bleeding the pump
through a clear tube. There must be no froth
visible. There are various test kits available
to enable you to look at the oil through clear
tubing adapted to the supply line at the pump
fitting. Air eliminators are on the market that
have potential. Also, electronic sight glasses
are being used with good success. At times,
new tubing must be run to the tank or new
fittings put on. Just make sure you get the air
out before you leave.
Any air leaks in the fuel line will cause an
unstable flame and may cause delayed ignition
noises. Use only flare fittings in the fuel lines.
4. Gasket Leaks — If 11.5 to 12.5% CO
2
with a #1
smoke cannot be obtained in the breeching,
look for air leaks around the burner mounting
gasket, observation door, and canopy gasket.
Such air leaks will cause a lower CO
2
reading
in the breeching. The smaller the firing rate
the greater effect an air leak can have on CO
2
readings.
5. Dirt — A fuel filter is a good investment.
Accidental accumulation of dirt in the fuel
system can clog the nozzle or nozzle strainer
and produce a poor spray pattern from the
nozzle. The smaller the firing rate, the smaller
the slots become in the nozzle and the more
prone to plugging it becomes with the same
amount of dirt.
6. Water — Water in the fuel in large amounts
will stall the fuel pump. Water in the fuel in
smaller amounts will cause excessive wear on
the pump, but more importantly water doesn’t
burn. It chills the flame and causes smoke and
unburned fuel to pass out of the combustion
chamber and clog the flueways of the boiler.
7. Cold Oil — If the oil temperature approaching
the fuel pump is 40°F or lower, poor
combustion or delayed ignition may result.
Cold oil is harder to atomize at the nozzle.
Thus, the spray droplets get larger and the
flame shape gets longer. An outside fuel
tank that is above grade or has fuel lines in a
shallow bury is a good candidate for cold oil.
The best solution is to locate the tank near the
boiler in the basement utility room or bury the
tank and lines deep enough to keep the oil
above 40°F. Check environmental issues with
local authorities having jurisdiction.
8. Fame Shape — Looking into the combustion
chamber through the observation port, the
flame should appear straight with no sparklers
rolling up toward the crown of the chamber.
If the flame drags to the right or left, sends
sparklers upward or makes wet spots on the
target wall, the nozzle should be replaced. If
the condition persists look for fuel leaks, air
leaks, water or dirt in the fuel as described
above.
9. High Altitude Installations — Air openings
must be increased at higher altitudes. Use
instruments and set for 11.5 to 12.5% CO
2
.
10. Start-up Noise — Late ignition is the cause
of start-up noises. If it occurs recheck for
electrode settings, flame shape, air or water in
the fuel lines.
11. Shut Down Noise — If the flame runs out of
air before it runs out of fuel, an after burn with
noise may occur. That may be the result of a
faulty cut-off valve in the fuel pump, or it may
be air trapped in the nozzle line. It may take
several firing cycles for that air to be fully
vented through the nozzle. Water in the fuel or
poor flame shape can also cause shut down
noises.
NOTICE
CHECK TEST PROCEDURE. A very good test for
isolating fuel side problems is to disconnect the
fuel system and with a 24" length of tubing, fire
out of an auxiliary five gallon pail of clean, fresh,
warm #2 oil from another source. If the burner runs
successfully when drawing out of the auxiliary
pail then the problem is isolated to the fuel or fuel
lines being used on the jobsite.
9 Troubleshooting