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Page 10
Connect Fuel Lines
Fuel Unit By-pass Plug
Oil Supply/Return Lines
Install the oil tank and oil lines in accordance with all
applicable codes.
Size the oil supply and return lines using the
guidelines given in the fuel unit literature included in
the literature envelope. Oil line fl ow rate will equal
the burner rate for one-pipe systems. For two-pipe
systems, refer to Table 3 for the fuel unit gearset
capacity - the rate at which fuel is recirculated when
connected to a two-pipe system. Size two-pipe oil
lines based on this fl ow rate.
Use continuous lengths of heavy-wall copper tubing,
routed under the fl oor where possible. Do not attach
fuel lines to the appliance or to fl oor joists if possible.
This reduces vibration and noise transmission
problems.
Install an oil fi lter sized to handle the fuel unit
gearset fl ow capacity (Table 3) for two-pipe
systems. However, size the fi lter for the fi ring rate
for one-pipe systems. Locate the fi lter immediately
adjacent to the burner fuel unit.
Install two high-quality shutoff valves in accessible
locations on the oil supply line. Locate one valve
close to the tank. Locate the other valve close to the
burner, upstream of the fuel fi lter.
Burner Fuel Flow
One-pipe systems – See Figure 9 for the fuel fl ow
paths for high-fi re and low-fi re operation. Oil supply
connects to one of the fuel unit Inlet ports. A fi eld-
installed bypass loop (Figure 9 Item K) must be
installed.
Two-pipe systems – See Figure 10 for the fuel fl ow
paths for high-fi re and low-fi re operation. Oil supply
connects to one of the fuel unit Inlet ports. Oil return
connects to the fuel unit Return port.
Low-fi re/high-fi re operation – The fuel unit nozzle port
pressure is factory set at 300 psig.
At high fi re, full pressure (300 psig) is applied at both
oil nozzles, causing full input.
At low fi re, full pressure (300 psig) is applied at one
nozzle, causing reduced input.
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One-pipe Oil System By-pass Loop
Refer to Figure 9 (item k). Note the addition of a fi eld-
installed by-pass loop (use 3/8” copper tubing) from the
fuel unit Return port to the Inlet port. This line is required
for low/high operation. It simulates the fl ow of a two-pipe
system at the fuel unit.
Table 3 – Fuel Unit Gearset Capacities
Fuel Unit Model
Number
Gearset Capacity
(gph)
H5PAN-C100H 79
Section: Connect Fuel Lines
Factory-Installed Pump
Bypass Plug
Failure to follow these guidelines will cause the
fuel pump seals to rupture and result in oil leakage,
burner malfunction and potential fi re and injury
hazards.
Models CF2500A/CF2500/CF3500 are shipped with
the pump by-pass plug installed.
Do not remove the by-pass plug from the pump. It is
required for step-fi ring (Lo/Hi) operation.
Do not operate the burner unless a return line or by-
pass loop is installed or the pump seal will rupture.
Carefully comply with the following instructions
provided in this section of the manual.
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Install Oil Supply To
Specifi cations
Failure to properly install the oil supply
system could cause oil leakage,
equipment malfunction, puff-back of
hot gases, heavy smoke, asphyxiation,
explosion and fi re hazards.
Carefully install the oil supply lines, fi ttings and
components using the guidelines provided in this
section.
The oil supply must comply with the latest edition
of NFPA 31 (Canada CSA B139) and all applicable
codes.
Do NOT install valves in the return line.
If the oil supply inlet pressure to the pump exceeds 3
psig or for gravity feed systems, install an oil safety
or pressure reducing valve (Webster OSV, Suntec
PRV or equivalent).
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