EnergyLogic EL-200B User manual

Item # 98030034
Issue date: 26 March 2014
Installation &
Operation Manual
EL-200B, EL-375B, and EL-500B
115V/60Hz
ASME Certified
Designed to save. Built to last. ™

NuEra is your authorized dealer
Thank you for purchasing an EnergyLogic heating system!
We provide installation, service, parts and support for your EnergyLogic systems.
If you have any questions, issues, or problems please feel free to call us for technical
support or parts.
We also offer various maintenance programs for your new system - please have a
look at our website for more information.

i
Caution!
Before you begin installation and operation
of your boiler, read this manual completely,
and save it for future reference!
IMPROPER INSTALLATION, OPERATION, OR
MAINTENANCE OF THE BOILER SYSTEM CAN CREATE
HAZARDOUS CONDITIONS AND WILL VOID THE
WARRANTY AND U.L. LISTING
This boiler is UL listed for commercial and industrial use only.
Refer to Section 1 for safety information and precautions.
Installation of the unit shall be made in accordance with all state and local codes which
may differ from information provided in this manual. Installations in Canada shall be in
accordance with the regulations of authorities having jurisdiction and installation
practice shall be made according to CSA standard B139, Installation Code for Oil
Burning Equipment.
Product improvements are occurring regularly, so the products may vary slightly from
what is shown in this manual.
If you have any questions or concerns during the installation or operation of the boiler,
contact your local service representative or EnergyLogic.
Thank you for purchasing an EnergyLogic boiler. Record the Unit I.D. Number below for future
reference. Please register your unit to activate your warranty by visiting EnergyLogic’s website
at www.energylogic.com/register . If you have any issues registering, please contact us at
615-471-5200.
I.D. Number:
(Located on the vessel skins,
near the spec. label.)
Installed By:
(Service Company, Address,
Contact Name, Phone Number)
Date of Installation:
Ta
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C
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Table of Contents
Before you begin................................................................................................................................... i
Table of Contents................................................................................................................................... ii
1. Safety, Codes and Regulations.........................................................................................................1
1.1 Conventions Used in this Manual.................................................................................................1
1.2 General Warnings........................................................................................................................2
1.3 Safety Hazards............................................................................................................................2
1.4 Codes and Regulations ...............................................................................................................4
1.5 Fuels and Fuel Management.......................................................................................................5
1.5.1 Fuels.....................................................................................................................................5
1.6 Clearances to Combustible Surfaces...........................................................................................6
2. Installation Considerations................................................................................................................7
2.1 Technical Guidelines ...................................................................................................................7
2.2 Tools Required............................................................................................................................8
2.3 Boiler Placement Guide...............................................................................................................8
3. Assembly and Installation –Vessel, Tank, Pump and Suction Fuel Line..........................................10
3.1 Unpacking and Inspection .........................................................................................................10
3.2 Warranty Registration................................................................................................................10
3.3 Boiler Vessel Installation............................................................................................................12
3.3.1 Vessel Installation...............................................................................................................12
3.4 Preparing the EnergyLogic Used-Oil Tank.................................................................................13
3.4.1 Tank Vent Installation –EnergyLogic Tanks........................................................................13
3.4.2 Drain Valve Installation –EnergyLogic Tanks .....................................................................13
3.4.3 Low Fuel Cutoff Switch –EnergyLogic Tanks .....................................................................13
3.5 Fuel Metering Pump and Filter Installation –EnergyLogic Tank (continue to section 3.6 if you
don’t have EL tank)...........................................................................................................................14
3.5.1 Fire Stop Valve and Filter Head Installation –EL Tank........................................................14
3.5.2 Metering Pump Installation –EL Tank.................................................................................14
3.5.3 Gauge and Pump Tubing Installation –EL Tank .................................................................15
3.6 Metering Pump Installation –Non-EL Tank (skip if you have EL tank)........................................16
4. Installation of Boiler Components....................................................................................................17
4.1 Vessel Panel and Insulation Assembly......................................................................................17
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4.2 Boiler Wire Harness and Controls Installation............................................................................18
4.2.1 Low Water Cutoff Probe and Control Installation.................................................................18
4.2.2 Triple Aquastat Temperature Controller Installation.............................................................19
4.2.3 High-Limit Temperature Controller Installation. ...................................................................20
4.2.4 Vessel Wire Box installation................................................................................................21
4.3 Pressure Relief Valve and Combination Gauge Installation.......................................................22
4.4 Domestic Coil (optional accessory)............................................................................................22
4.5 Preheater Assembly..................................................................................................................23
4.6 Burner/Vessel Assembly............................................................................................................24
4.7 Pump Discharge (Outlet) Tubing Installation..............................................................................27
4.7.1 Pump Discharge Tubing Installation.....................................................................................27
4.7.2 Pump Discharge (Outlet) Tubing Installation –Guidelines...................................................28
4.8 Hydronics Connection and Boiler Mixing Valve Installation........................................................28
4.8.1 Hydronics Installation –Key Points .....................................................................................28
4.8.2 Hydronics Set Up................................................................................................................29
4.8.3 Boiler Mixing Valve Set Up..................................................................................................30
4.9 Filling the System......................................................................................................................30
5. Exhaust Flue System Installation ....................................................................................................31
5.1 Barometric Damper Tee Installation...........................................................................................31
5.2 Flue Piping Installation...............................................................................................................31
5.3 Draft Gauge Installation (included with some packages)............................................................34
6. Electrical System Installation...........................................................................................................35
6.1 Wall Thermostat and Low Fuel Cut-Off Switch Installation (Optional Accessories)....................35
6.1.1 Wall Thermostat Installation................................................................................................35
6.1.2 Low Fuel Cut-Off Installation...............................................................................................35
6.2 Fuel Pump Power Connection...................................................................................................36
6.3 Main Electrical Connection ........................................................................................................37
7. Startup and Operation.....................................................................................................................38
7.1 Do’s and Don’ts/Tech Tips.........................................................................................................38
7.2 Burner Primary Control Operation..............................................................................................38
7.3 Safety Systems and Warnings...................................................................................................40
7.4 Boiler Startup.............................................................................................................................40
7.4.1 Fuel System Priming...........................................................................................................41
7.4.2 Starting the Boiler................................................................................................................42
7.4.3 Burner System Checkout ....................................................................................................43
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7.5 Everyday Operation of Your EnergyLogic Used Oil Boiler......................................................46
8. Maintenance ...................................................................................................................................47
8.1 Service Contracts......................................................................................................................48
8.2 Safety Warnings –Lockout/Tagout............................................................................................48
8.3 Monitoring System Performance over Time...............................................................................48
8.4 Maintenance Schedule and Parts..............................................................................................48
8.5 Maintenance Procedures...........................................................................................................50
8.5.1 Heat Exchanger Cleaning / Door and Access Insulation Checks.........................................50
8.5.2 Low Water Cut Off Testing and Probe Inspection................................................................52
8.5.3 Fuel Oil Filter Replacement.................................................................................................54
8.5.4 Preheater Cleaning.............................................................................................................55
8.5.5 Nozzle Line Assembly Cleaning..........................................................................................57
8.5.6 Retention Head and Electrode Settings...............................................................................60
8.5.7 Solenoid Valve Cleaning.....................................................................................................62
8.5.8 Air Compressor Maintenance..............................................................................................64
8.6 Seasonal Shut Down & Start Up................................................................................................66
9. Troubleshooting..............................................................................................................................67
9.1 Troubleshooting Condition Table...............................................................................................68
9.2 Troubleshooting Trees...............................................................................................................69
9.3 Testing Procedures ...................................................................................................................72
9.3.1 Wall Thermostat (if equipped) and Burner Thermostat Circuit Testing..................................72
9.3.2 Water Circulator Pump Testing ............................................................................................73
9.3.3 Cad Cell Testing...................................................................................................................74
9.3.4 Metering Pump Assembly Testing........................................................................................75
9.3.5 Preheater and Nozzle PTC Testing Procedure.....................................................................77
9.3.6 Primary Control Testing........................................................................................................79
9.3.7 Solenoid Valve Testing.........................................................................................................80
9.3.8 Top Suction Kit Testing........................................................................................................81
9.3.9 Iron Core Transformer Testing.............................................................................................82
9.3.10 Boiler Control Testing / Wiring Troubleshooting..................................................................84
10. Appendices...................................................................................................................................86
10.1 Boiler Wiring and Oil Schematic...............................................................................................86
10.2 Boiler Specifications ................................................................................................................89
10.3 Limited Warranty .....................................................................................................................93
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1. Safety, Codes and Regulations
Thank you for the purchase of an EnergyLogic used oil boiler. EnergyLogic boilers are
thoroughly tested for safe, long-term operation. However, proper installation, fuel quality
control, and regular maintenance are required to ensure safe, long-term operation. Please
read and understand this manual completely before attempting to install, operate, or service
the boiler. Post this instruction manual and maintain it in legible condition. If you have any
questions, call your local service provider or the number below for EnergyLogic Technical
Service.
1.1 Conventions Used in this Manual
For your safety, this manual uses the following definitions and signal words to identify hazards:
Danger: Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury. This signal word is limited to the most extreme
situations.
Warning: Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
Caution: Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury. It may also be used to alert against unsafe
practices.
Caution (without alert symbol): Indicates an unsafe practice which, if not
avoided, may result in product or property damage. Also used for general
alerts.
Product safety labels and their meaning (labels not used on all products):
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1.2 General Warnings
The EnergyLogic burner is to be used only in the EnergyLogic boiler
provided. Do not attempt to use the burner for other purposes.
Do not tamper with the unit or controls –call your service technician.
Do not attempt to use unit with broken or damaged components.
Do not allow unqualified personnel to install or service the boiler,
electrical system, or flue system. Contact EnergyLogic for help with finding a qualified
installation and service company. Failure to install and maintain your boiler properly will
void your warranty and the UL listings.
Do not attempt to start the burner when excess oil has accumulated,
when the boiler is full of vapor, or when the combustion chamber is very hot.
Do not start the burner unless all cleanout panels are secure in place.
KEEP THE FUEL VALVE NEAREST THE SUPPLY TANK SHUT OFF
WHEN THE BURNER IS SHUT OFF FOR EXTENDED PERIODS.
Turn off power to the burner when the burner is off for extended periods.
The boiler is designed to be installed in a manner that restricts its access.
USED OILS CONTAIN HEAVY METALLIC COMPOUNDS AND
FOREIGN MATERIALS. WHEN BURNED, THESE COMPOUNDS ARE EMITTED
FROM OR DEPOSITED WITHIN THIS HEATING APPLIANCE AND THEREFORE
CARE SHOULD BE TAKEN WHEN USING, CLEANING AND MAINTAINING THIS
EQUIPMENT.
EnergyLogic recommends that the building, domestic hot water system or
process have a secondary heat source during times the boiler is down for maintenance
or service. Used oil boilers require maintenance. Also, used oil may sometimes be
unavailable or burn poorly due to contaminants (such as water) in the oil.
1.3 Safety Hazards
There are potential hazards associated with operation of this or any other boiler. In addition to
the codes and regulations listed in the following section, general safety rules and precautions
should be followed at all times to prevent accidents that could lead to personal injury, death or
property damage. Only those qualified should perform the tasks. Specific safety hazards
include:
Electricity: The EnergyLogic boiler operates on 115V/60Hz electrical power.
Turn power off at the circuit breaker and lock it out prior to performing any work on the boiler
system or any of the components. Make sure covers are in place during normal use. Use only
copper conductors.
Liquid Fuels: Used oils must be handled properly to prevent spills. Uncontained
oil leaks may contaminate the local water supply. Ensure that all national and local codes are
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followed in regards to the requirements for spill containment and SPCC paperwork. Oil leaks
pose slip/fall hazards, and pose a risk for fires. DO NOT USE GASOLINE OR ANY OIL
CONTAINING GASOLINE. Do not add any cleaning fluids or oil additives to the used oil
burned in this appliance. The use of unauthorized fuels will void the warranty and U.L. listing.
See section 1.5.1 for a list of allowable fuels. The end user of the boiler is responsible for
ensuring that all correct precautions are taken in managing their used oil.
Combustion Exhaust Gases: The exhaust products from the combustion are
dangerous to breathe. The boiler must be attached to a flue which properly vents the exhaust
out of the building to the atmosphere at all times, to assure safe and proper operation of the
burner. If proper draft cannot be established, changes to the building construction or a draft
inducer will be required in order to provide adequate make-up air.
Safe Maintenance: Used oil contains mineral additives and deposits called
“ash” that will not burn. Ash collects in the boiler and flue with regular use over time. Ash must
be cleaned out of the combustion chamber/heat exchanger and flue pipe on a scheduled
basis. Follow the minimum maintenance instructed in section 8. Wear proper protective
clothing; including gloves, safety glasses, and a dust mask or respirator whenever any
cleaning is performed, including the cleaning of the heat exchanger, flue piping and exhaust
stack.
Vapor/Dust Ignition: Do not store or use gasoline or other flammable liquids or
vapors near this boiler, as they may be ignited by the burner. Do not operate the boiler in dusty
or otherwise dangerous environments.
Flammable liquids: Do not create a fire or explosion hazard by using or placing
flammable liquids such as gasoline or solvents near the boiler. A flammable liquid is any liquid
that has a closed-cup flash point below 100°F (37.8°C), as determined by the test procedures
and apparatus set forth in 1.7.4 of NFPA 30.
Minimum Clearance –Safe clearance to combustibles (Section 1.6) shall be
adhered to.
Height, Weight, Guarding and General Safe Practices: The boilers are installed
with flue systems at heights which pose a risk for injuries due to a fall. Many of the
components are heavy, and pose the risk of injury with improper lifting and handling. Always
follow safe practices and use proper equipment. Never climb on the equipment. Do not take
risks when installing or servicing the equipment. All cover plates, enclosures, and guards must
be maintained in place at all times, except during maintenance and servicing. Failure to
observe general safety rules and to follow safety rules specific to the tools and equipment used
or being worked on may result in product/property damage, personal injury or death.
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1.4 Codes and Regulations
The installation, operation, and maintenance of the boiler system in the United States must be
performed by qualified personnel in accordance with this manual and all national, state, and
local codes / regulations, as well as the following standards of the National Fire Protection
Association (NFPA) and the American Society of Mechanical Engineers (ASME):
ASME Boiler Code Section IV
ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers
NFPA 31 Standard for the Installation of Oil Burning Equipment
NFPA 30 Flammable and Combustible Liquids Code
NFPA 30A Code for Motor Fuel Dispensing Facilities and Repair Garages
NFPA 70 National Electric Code
NFPA 88A Standard for Parking Structures
NFPA 88B Standard for Repair Garages
NFPA 211 Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning
Appliances
These standards are available from the NFPA at www.nfpa.org, and from the ASME at
http://www.asme.org/.
Similarly, the installation, operation, and maintenance of the boiler system in Canada must be
performed by qualified personnel in accordance with this manual and in accordance with all the
regulation authorities having jurisdiction, as well as CSA Standard B 139, Installation Code for
Oil Burning Equipment, B140.0 –General Requirements for Oil Burning Equipment, B140.7.2
–Oil Fired Steam and Hot Water Boilers for Commercial and Industrial Use, B214 –
Installation Code for Hydronic Heating Systems. Electrical installation in Canada shall be in
accordance with C22.1 - Canadian Electrical Code, Part I. CSA standards are available at
www.csa.ca.
A qualified installer is an individual or agency who is responsible for the installation and
adjustment of the equipment and who is properly licensed and experienced to install oil
burning equipment in accordance with all codes and ordinances.
In the United States, make sure you comply with all EPA regulations concerning the gathering
and storing of used oil, and operation of the boiler. Specifically, CFR Title 40 Part 279 covers
managing used oil. As well, make sure you comply with local codes and regulations.
In Canada, only used oil generated on the premises of the owner may be used in this
equipment unless written authorization is obtained from the regulatory authority. Comply with
Canadian regulations regarding the management and storing of used oil, as well as any local
codes and authorities having jurisdiction
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1.5 Fuels and Fuel Management
The boiler system is composed of several components and subsystems that work together for
efficient and safe operation. In order for the system to function as designed, good fuel
management practice must be followed.
1.5.1 Fuels
EnergyLogic boilers are listed by Underwriters’ Laboratories (U.L.) for the U.S. and Canada,
operating on the following fuels:
Used Crankcase Oil.
Used Automatic Transmission Fluid.
ASTM D396 No. 2 Fuel Oil.
DO NOT USE GASOLINE OR ANY OIL CONTAINING GASOLINE.
Fuel mixtures must have a minimum flash point of 140°F (60°C) and the maximum flash point
of approximately 400°F (204°C). Mixtures shall not contain hazardous waste.
Never mix inappropriate or hazardous material with the used oil. Examples of
substances that should never be added include but are not limited to:
Gasoline
Kerosene
Hazardous Waste
Anti-freeze
Carburetor Cleaner
Paint Thinner
Any Chlorinated Material
Parts Washer Solvents
Oil Additives
Animal Fats
Brake Fluid
The addition of inappropriate substances to the fuel is not approved and can
lead to poor equipment performance, premature product failure, and/or explosive/hazardous
conditions. Burning of fuels that contain unapproved substances will void the product warranty
and the UL listing. If you have any question about what is contained in your used oil, it is your
responsibility to have the oil analyzed prior to burning.
Contact EnergyLogic Technical Services if you have questions about a particular fuel type, or if
you need fuel analysis. For a nominal fee, EnergyLogic Technical Services will provide a
professional fuel analysis. You will be provided with instructions in order to collect an oil
sample to be sent out for analysis. Specify the type of analysis that is needed.
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1.6 Clearances to Combustible Surfaces
It is of the utmost importance that the installation conform to the minimum
clearances to combustible surfaces (Material made of or surfaced with wood, compressed
paper, plant fibers, plastics, or other material that can ignite and burn, whether flame proofed
or not, or whether plastered or unplastered). Consult applicable codes and regulations for
precedence. Non-compliance to minimum clearances may result in fire, explosion, personal
injury or death. The U.L. Listing specifies: “For all boilers rated for 50 psi or less and for all
water boilers, installation clearances are Form III.” & “The boilers are intended for installation
on noncombustible flooring.” The clearances for each model follow:
EL-200B EL-375B EL-500B
Top & pipe connections 18" 18" 18"
Front - (burner location) 48" 48" 48"
Sides 18" 18" 18"
Rear 18" 18" 18"
Flue Pipe 18" 18" 18"
Bottom
Must be on non-combustible flooring.
Model
Minimum clearance from:
48” Front
18” Sides, Top
and Rear
18” Flue Pipe
Non-combustible Flooring
Minimum Clearances
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2. Installation Considerations
EnergyLogic boilers are designed to operate reliably over a wide range of conditions. However,
it is important to read this section before installation to prevent unnecessary work or problems.
2.1 Technical Guidelines
1. Most components of your boiler are factory-tested to ensure proper operation. Do not
tamper with factory settings or fittings. The settings on the triple aquastat may be
adjusted.
2. Pre-assembled fittings are sealed with thread-locker sealant and do not require
additional tightening.
3. Always supply power through a dedicated, hard-wired (copper only), 115VAC/60Hz
circuit with a 25 Amp maximum breaker. Check local codes.
4. Do not use the provided thread-locker sealant on flare fittings. Use the provided
sealant on all NPT fuel line connections only.
5. Do not use Teflon tape on any fuel connections. Loose strands may block small
orifices, affecting unit operation or may damage components.
6. Route all fuel lines inside building to prevent exposure to cold weather. If this is not
practical, call EnergyLogic for application support.
7. Locate boiler and tank in a dry area above 50°F (10°C) at all times.
8. If not installing the pump to an EnergyLogic Tank, mount it according to guidelines in
the EnergyLogic Top Suction Kit packaging instructions.
9. Do not kink copper tubing. Route tubing as straight and vertical as possible to avoid
air pockets.
10. Maximize vertical run of flue, and minimize horizontal run. Allow access for clean-out.
11. Do not allow your tank to run out of fuel. If the tank runs out of fuel, air and
contamination will be introduced into the fuel delivery system. An optional EnergyLogic
low-level cut off switch is recommended to prevent low fuel operation.
12. Never use compression fittings for fuel tubing connections, as they will leak and cause
the burner to shut down.
13. Care should be taken not to over tighten or cross thread brass fittings.
14. Applying a thin film of anti-seize compound to burner gasket may reduce gasket
sticking to vessel when servicing.
15. Another source of heat is recommended for periods when the boiler may be off-line for
maintenance or for any other reason.
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2.2 Tools Required
Below is a recommended list of tools and equipment that may be used to aid in the installation
of the EnergyLogic boiler. This is a minimum list for a simple system, excluding the hydronics
and plumbing.
5/16” Combination Wrench Pipe WrenchSet
3/8” Combination Wrench Flat Blade Screwdriver
7/16” Combination Wrench (x2) 1/4” Hex Wrench or Driver
1/2” Combination Wrench Wire Cutter (to remove tie straps)
5/8” Combination Wrench Lift Device
11/16” Combination Wrench SafetyLadder or Lift
3/4” Combination Wrench (Tools Required for Flue Kit Installation)
2.3 Boiler Placement Guide
It is important to plan the boiler and tank placement, wiring, piping and flue prior to installation.
Electrical Wiring - Will the layout of your building allow safe routing and installation of
electrical wiring to the boiler? Check your local building codes. The EnergyLogic boiler requires
115VAC/60Hz power, supplied through a dedicated, hard wired, circuit breaker - 25Amp
maximum. Use copper conductors only. Electricity is very dangerous. Wiring
must be installed by a qualified electrician. In the U.S., consult the National Electric Code
(NEC) and local building codes for additional requirements. In Canada, consult the Canadian
Electrical Code, Part I.
Flue Pipe -Is ceiling/roof or wall location suitable for a flue pipe to pass through? Are any
obstacles present at interior or exterior locations? Check your roof warranty about penetration
of the flue pipe. Check your local building and fire codes.
Combustion and Make Up Air Requirements –It is necessary to ensure that
adequate air for safe combustion is provided for oil-burning appliances and equipment. Refer
to NFPA 31, Chapter 5 for requirements based on the total input BTU rating of all appliances in
the space. In Canada, reference CSA Standard B139/CGA B149.
Tanks - The oil tank is to be vented to the outside of the building. Oil
temperature should be maintained at 50°F (10°) and above. Tank shall be
at least 5 feet away from any source of heat and should not obstruct
service meters, electrical panels, or shut off valves. Check building,
environmental and fire codes for containment and other restrictions.
Minimum Clearance –Safe clearances to combustibles (Section 1.6) shall be
adhered to. A non-combustible flooring structure is required for the boiler.
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Distance from Flammable Liquids –Do not create a fire or explosion hazard
by using or placing flammable liquids such as gasoline or solvents near the boiler. A flammable
liquid is any liquid that has a closed-cup flash point below 100°F (37.8°C), as determined by
the test procedures and apparatus set forth in 1.7.4 of NFPA 30.
Access - Position the used oil storage tank to provide adequate access to filling ports, filter,
drain valve and pump. Leave an unobstructed path for shop vehicles and equipment. Consider
access needed for service (heat exchanger cleaning, flue cleaning, removal of breech panels,
burner access, etc.). Installation of system piping should not hinder required access for
service.
Vessel Placement in Motor Fuel Dispensing Facilities and Repair Garages –Heat
producing appliances shall not be allowed unless installed with provisions outlined in NFPA
30A, section 7.6.
Structural requirements (Canada) –In Canada, the structure in which the used oil burning
appliance is housed shall be no less than 4.6m (15ft) high at the point where the appliance is
situated and have a minimum length and width of 6m (20ft) and a minimum floor area of 37m2
(400ft2). In addition, the installation including flue stack height requirements and distance from
property line shall be in accordance with the authorities having jurisdiction concerning
environmental quality as well as fuel, fire, and electrical safety and Table 7 in CSA B140.0-03
(clause 22.3.2).
Other Considerations for EnergyLogic Boilers:
They are constructed with ASME certified pressure vessels (30 psi maximum pressure).
The ASME stamp is located on boiler plate on the vessel under a removable panel.
They have Canadian Registration. The CRN number is located on the boiler plate.
They are UL Listed in the US and Canada. The UL mark and specification label are on a
boiler panel.
They are fire-tube boilers. This means that hot combustion gases flow through tubes,
transferring heat to water that surrounds the tubes.
They are carbon steel boilers. With a ¼” steel shell, they are of a durable construction,
and much lighter than cast iron models. Since they are carbon steel however, there are
some restrictions on the return water temperature to prevent corrosion (minimum return
temperature of 140°F).
They are wet-based boilers. This means that the combustion chamber and tubes are
surrounded by water that keeps the steel cool and prevents chamber deterioration.
They are non-condensing boilers. This means that the flue gases are not allowed to
cool enough to create condensation. Due to sulfur in the oil, condensation would create
sulfuric acid which would quickly corrode the boiler tubes and chamber.
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3. Assembly and Installation –Vessel,
Tank, Pump and Suction Fuel Line
This section instructs installing the fuel delivery system (side suction or top suction) and
mounting the vessel.
3.1 Unpacking and Inspection
After unpacking your new boiler, make sure you have received the proper parts and quantities
shown in the checklist on the following page. For missing parts, contact EnergyLogic. If any
parts were damaged during shipment, please contact your shipping carrier.
3.2 Warranty Registration
IMPORTANT: You must register your boiler with EnergyLogic for the warranty to become
active and to receive technical service.
Please take a few minutes to fill out the Warranty Registration Card.
Note: Your Warranty Registration Card may be found in the accessory box where you located
this manual. You may fax the completed card to us at [phone], or mail it. You may also
register online at www.energylogic.com.
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No. Item Qty.
1
Boiler Vessel Assembly
1a. Boiler Vessel (with trim
kit)
1b. Boiler panels and
Insulation panels.
1c. Controls/ Wire Harness.
1 set
2
Preheater Assembly 1
3
Burner Assembly 1
4
Air Compressor Filter 1
5
Burner Gasket 1
6
Alligator Clips 2
7
Filter Head and Fuel Filter 1
8
Fuel Pump Assembly 1
9
Vacuum Gauge 1
10
Pressure Gauge 1
11
Barometric Damper and Tee
Assembly
1
12
Draft Gauge (provided with
bundles only)
(1)
13
Draft Gauge Probe
(provided with bundles
only)
(1)
14
Thread Sealant Tube (not
shown)
1
15
EnergyLogic Workbench
Tank
1
16
Drain Valve Assembly 1
17
Swing-Arm Fuel Gauge 4
18
3/8" Copper Suction Line
with Flare Nuts
1
19
Low Fuel Cut Off Switch
Assembly
1
20
FireStop Valve Assembly 1
Boiler Assembly with Side Suction Fuel Pick Up
Boiler complete (minus flue kit)
Tank Assy
Side Suction Kit
Included with EnergyLogic Boiler
Tank and Tank Options
20
17
Checklist
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3.3 Boiler Vessel Installation
Note: This manual covers the installation of a single boiler and pump. If you are installing
multiple boilers in the same building, contact your local dealer or EnergyLogic for additional
installation options.
3.3.1 Vessel Installation
1. Uncrate and locate the vessel near the desired location.
2. Once the boiler vessel is in place, the vessel may be anchored.
3. Be sure to remove the trim package that contains the fittings and gauges. This is to be
found in the rear breech / chimney connector.
4. Consider the following:
Prior to placement, a licensed electrician shall install a dedicated 115vac/60Hz
service junction box (switchable and lockable) in close proximity to the vessel
location (preferably within 5 feet).
A non-combustible platform or flooring structure is required.
Pay special attention to Codes and Regulations in Section 1.4, and all local codes
and regulations.
Refer to section 2.3 for placement guidelines / restrictions for the boiler. The
placement is critical for proper operation and efficient servicing.
EnergyLogic Boiler with EnergyLogic Tank
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13
3.4 Preparing the EnergyLogic Used-Oil Tank
If you are not installing an EnergyLogic Tank, first verify that your used oil storage system
meets all applicable codes and requirements, then proceed to the instructions for installing the
metering pump.
3.4.1 Tank Vent Installation –EnergyLogic Tanks
Once the tank is in place, install a tank
vent (not included). This requires a
minimum 1.25 inch NPT steel pipe
routed through an exterior wall,
terminated with a 90° elbow turned
down (figure). A mushroom-style cap
may be used to terminate the vent as
an alternative to the down-turned
elbow. Install appropriate Emergency
Venting. EnergyLogic offers an
emergency vent cap with capacity of
53,000 cu. ft./hr./1501 cu. m/hr. This
optional accessory can be installed into
a 4 inch NPT port (figure).
3.4.2 Drain Valve Installation –EnergyLogic Tanks
Install the tank drain valve in a port along the bottom of the tank as shown in figure. Use the
provided thread sealer on the threads during
installation. Note: Some tanks come with the drain
valve already installed. The drain valve is
necessary for draining water from the bottom of the
tank. The drain valve is shown in closed position in
figure. A plug should be installed in the drain valve to
prevent accidental spills.
After all components have been installed on
the tank, make sure that all unused tank openings are
properly plugged.
3.4.3 Low Fuel Cutoff Switch –EnergyLogic Tanks
The low fuel cutoff switch is an optional accessory that will automatically shut
off the burner if the tank is nearly out of fuel. This prevents the pump from
losing prime. The float switch operates by interrupting the thermostat circuit
when the fuel level is too low. Install the accessory according to the
packaged instructions.
Exterior Wall
Emergency Vent Cap
(sold separately).
Min. 1.25” NPT
Steel Pipe
Drain Valve
2” NPT Port in
Tank Side
Apply Thread
Sealer
Drain valve installation.
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14
3.5 Fuel Metering Pump and Filter Installation –EnergyLogic Tank
(continue to section 3.6 if you don’t have EL tank).
On EnergyLogic Tanks, the fuel pump components are mounted on the side as shown. Follow
the steps below to first install the firestop valve and filter head, and then install the pump.
3.5.1 Fire Stop Valve and Filter Head Installation –EL
Tank.
Decide which end of the tank is the best location for your
pump. On EL 250 gallon and 500 gallon tanks, the pump may
be mounted to either end. To install the firestop valve, first
apply gasket sealer to the ¼” NPT fitting and screw the fire
stop valve to the fuel filter head, fully tighten the NPT threads
using a back up wrench. Then, apply sealer to the ½” NPT
fitting and screw the entire filter head assembly with firestop
valve into the ½” NPT port in the side of the tank (located
about 10” up from the floor).
3.5.2 Metering Pump
Installation –EL Tank
Mount the pump to the
integrated bracket on the
EnergyLogic tank using (4)
1/4-20 bolts.
Fire-Stop Valve
Filter Head Assembly
Spin On Fuel Filter
Metering Pump
Assembly
Fuel system –EL Tank
Gasket
sealer here,
then tighten.
FireStop Valve
Filter Head
Assy.
To Tank
(4) 1/4 - 20 Bolts
Remove cover to
install bolts. Replace
cover after pump has
been wired.
Fuel Pump Assembly
Mount Pump to Tank
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