BOCK WATER HEATERS Residential Oil Fired Water Heaters Installation Guide
- July 4, 2024
- BOCK WATER HEATERS
Table of Contents
BOCK WATER HEATERS Residential Oil Fired Water Heaters
Product Information
- Specifications:
- Model Numbers: 32E, 32PPC, 33E, 50ES, 51EC, 51PPC, 120E
- Manufacturer: Bock Water Heaters, Inc.
- Rev: 11 (1/2024)
Product Usage Instructions
- Consumer Responsibilities:
- This manual provides information on the installation, operation, and maintenance of your water heater. It is important to follow these instructions and all applicable building codes and regulations to ensure the warranty on the water heater remains valid.
- Read all instructions carefully before attempting the installation or operation of the water heater. Keep these instructions and all component instructions for future reference.
- If you are unsure about any part of the installation process, seek help from a qualified person. Local plumbing and electrical codes must be adhered to during installation.
- Multiple Burner Installation:
- When using two or more burners, ensure each unit has a separate supply line to the fuel pump to prevent issues with oil starvation. Consider using a priority control if separate supply lines are not possible.
- Selecting the Right Location:
- Choose a suitable location for the water heater following the manufacturer’s guidelines and local codes. Ensure adequate clearance around the water heater as specified on the label. Do not install on combustible flooring.
FAQs
- Q: Can water heater blankets be used with this product?
- A: No, water heater blankets should not be used on this heater as they may cause fire hazards or other serious risks.
- Q: What should I do if I encounter difficulties during installation?
- A: If you face challenges during installation and lack the necessary skills, seek assistance from a qualified person to ensure proper installation and safety.
- Q: How can I prevent scald injuries related to hot water?
- A: Before changing the temperature setting, carefully read the instruction manual. Hotter water increases the risk of scald injury, especially for individuals of varying ages and exposure times. Adjust the temperature cautiously to avoid accidents.
TO THE INSTALLER: Please attach these instructions next to the water heater.
TO THE CONSUMER: Read these and all component instructions. Please keep it for future reference. Please remember to return the registration card. Warranty, registration card & parts list included.
BOCK RESIDENTIAL OIL-FIRED WATER HEATERS
- Model numbers: 32E, 32PPC, 33E, 50ES, 51EC, 51PPC, 120E
WARNING:
- Improper installation, adjustment, alteration, service, or maintenance can cause serious injury or property damage. Refer to this manual. For assistance or additional information, consult a qualified installer or service agency.
WARNING:
- If the information in these instructions is not followed exactly, fire or explosion may result and can cause property damage, personal injury, or death.
WARNING:
- Follow minimum combustible clearance as noted on the water heater label. Do not install on com bus ti -ble flooring (see Figure 2, Page 3). Install following all local codes. In the absence of local codes, refer to NFPA 31.
CAUTION:
- The recommended temperature for normal residential use is 120°F. The dial on the aquastat does not always reflect the outcoming water temperature, which could occasionally exceed 120°F.
- The variation in outcoming temperature could be based on factors including but not limited to usage patterns and type of installation.
- Test your water at the tap nearest to the water heater. (See page 5 for measuring the outcoming water temperature).
WARNING:
- Hotter water increases the risk of scald injury. Before changing the temperature setting, read the instruction manual. Temperatures at which injury occurs vary with the individual’s age and length of exposure. The slower reaction times of children, elderly, and physically or mentally impaired persons increase the scalding hazard to them.
- It is recommended lower water temperatures be used where these situations exist. Households with small children or invalids may require a temperature setting of less than 120°F to prevent accidental contact with hot water. To lower water temperature use point-of-use temperature limiting devices.
WARNING:
- Flammable vapors may be drawn to this water heater from other areas of the structure by air currents. Do not store or use any flammable liquids in the vicinity of this heater.
WARNING:
- Water heater blankets may not be used on the heater and may cause fire, asphyxiation, personal injury, or death.
CONSUMER RESPONSIBILITIES
FAILURE TO FOLLOW THESE INSTRUCTIONS OR ALL APPLICABLE BUILDING CODES AND REGULATIONS VOIDS THE WARRANTY ON THIS WATER HEATER.
- THIS MANUAL HAS BEEN PREPARED TO ACQUAINT YOU WITH THE INSTALLATION, OPERATION, AND MAINTENANCE OF YOUR WATER HEATER AND TO PROVIDE IMPORTANT SAFETY INFORMATION.
- Read all instructions thoroughly before attempting the installation or operation of the water heater. Keep these and all component instructions for future reference.
- The manufacturer of this water heater will not be liable for any damages caused by failure to comply with the installation and operating instructions outlined on the following pages. These instructions are a guide for the correct installation of the water heater.
- If the installer lacks the necessary skills or has difficulty following the directions, do not proceed but get help from a qualified person for that part of the installation that is not understood.
- Local plumbing and electrical codes must be followed in the installation of this water heater. In the absence of a local code use the UNIFORM PLUMBING CODE and the NFPA Code. Local codes may supersede instructions in this installation manual.
MULTIPLE BURNER INSTALLATION
- When two or more burners are used, each unit should have a separate supply line to the fuel pump to prevent nuisance lockouts caused by one or both controls recommended. If this is not possible, the use of a priority
- Check new equipment to see if all components are in good condition.
- The water heater and oil burner may be shipped as separate units. The aquastat and immersion well may be packed with the oil burner.
SELECT THE RIGHT LOCATION
The new water heater requires fuel, and electricity and should be close to the
chimney and water supply. Locate the heater near a floor drain if possible for
easy maintenance and protection if trouble should occur. Allow ample space
around the heater for servicing (see combustible clearance warning, page 1).
Adequate air for combustion must be available.
NOTE: Locate the heater so it is not subject to physical damage by moving
vehicles or possible flooding.
DO NOT INSTALL THE WATER HEATER ON COMBUS- TIBLE FLOORING (see Figure 2). Refer to NFPA 31 or contact Bock Water Heaters with questions concerning proper flooring materials. Minimum clearance to combustible construction is SIDES 6″; BACK 6″; FRONT 24″. The installation of this water heater must conform with local codes and ordinances. In the absence of local codes, the installation must comply with the National Fire Protection Association (NFPA 31) Code.
CONNECT WATER PIPING
Connect the water piping, being careful not to apply heat to the heater nipples. Install dielectric unions and shut off valves on both hot and cold water lines.
Model 33E is equipped with an inlet flow diverter installed in the tank. This model contains a decal next to the inlet (shown to the left). The purpose of this diverter is to help keep the tank bottom free of sediment by aiding tank flushing. The index line on the diverter nipple must be aligned with the arrow on the decal (left) to function properly. Do not allow the diverter to rotate out of position when tightening the inlet fittings.
CAUTION!! Scalding injury and/or water damage can occur from either the manual lifting of the lever or the normal operation of the T&P valve if it is not piped to a proper drain. If the valve fails to flow water or reseat, call a plumber.
CONNECT TO CHIMNEY
- Inspect the incoming water line for check valves or water pressure-reducing valves. Any type of check valve may cause pressure to build up in the heater and cause tank failure. If the heater is installed in a closed system or if backflow preventers and pressure regulators are installed, add an expansion tank. Do not try to heat hard water. Install a water softener if the heater is being used in a hard water area (water hardness of more than 7 grains).
- An approved temperature and pressure (T&P) relief valve is factory-installed in the opening provided on the upper right-hand side of the heater. Pipe the T&P to within 6″ of the floor or to a floor drain with a free-flowing drain pipe.
- Install a vent connector between the chimney and the water heater. The size of the vent connector shall be acceptable based on the rise in height of the connector tor and the water heater input.
- If it is necessary to connect to an existing vent connector, be sure the connector utilized is large enough to accommodate the products of combustion of all units attached to it. When utilizing another connector, run in at a 45° angle (see Figure 1).
- Install a draft regulator control only if necessary. The overfire draft should not be positive. The breech draft should be -.03″ W.C. minimum to -.05″ W.C. maximum; CO2 should be a minimum of 11% with zero smoke on the Bacharach scale.
MOUNT THE OIL BURNER
- If it is necessary to connect to an existing vent connector, be sure the connector utilized is large enough to accommodate the products of combustion of all units attached to it. When utilizing another connector, run in at a 45° angle (see Figure 1).
- Install a draft regulator control only if necessary. The overfire draft should not be positive. The breech draft should be -03″ W.C. minimum to -.05″ W.C. maximum; CO2 should be a minimum of 11% with zero smoke on the Bacharach scale.
- The oil burner is equipped with a primary relay. An aquastat with an immersion well is packed with the burner. The thermostat is factory set at 120°F for residential use (see caution on page 1 regarding temperature variations). Install the immersion well with the aquastat and check the bulb length (see “Burner & Controls” section, page 10).
- Remove the cardboard core from the burner opening. Mount the burner on stud bolts and place the gasket (supplied) between the burner flange and the heater. Secure the burner to the heater with 1/4 -20 nuts (supplied). Open the inspection door on the heater and check the burner tube with a mirror before firing to be sure the opening is not blocked (see Maintenance and Service sections on page 5 for troubleshooting).
CONNECT THE ELECTRICITY
All wiring must comply with applicable codes and ordinances. The primary relay is wired to the burner at the factory. Install the aquastat well in the 3/4″ tapping at the front of the heater. Be sure the sensing bulb is inserted into the well. For Honeywell aquastats, tighten the screw on top of the aquastat to secure the control to the well. For Carlin EZ-Temp aquastats, refer to the pre-packaged installation guide for proper set-up procedures. Refer to drawings for correct models. Connect the power supply to the aquastat and run through a fused disconnect switch (attached to the heater in the field). See Figure 1.
CONNECT THE OIL LINE
- Use #1 or #2 fuel oil. For biofuel blends B6-B100, the burner must be manufactured by Carlin Combustion and be labeled “For use with oil not heavier than No. 2, bio blends B6-B100 (U.S. only).” A properly sized and rated oil filter shall be installed in the oil supply line (NFPA 31, 4.5.4)-
WARNING!! WHEN YOU INSTALL THE BYPASS PLUG YOU MUST RUN A TWO-LINE SYSTEM.
- Gravity System: The oil burner is normally equipped with a single-stage pump equipped for one-line (gravity) flow. Use minimum 3/8″ O.D. soft copper tubing and attach with flared fittings. DO NOT USE COMPRESSION FITTINGS. Install the shut-off valve and oil filter in the oil line. Follow the pump manufacturer’s instructions (attached to the pump).
- Lift System: The burner should be ordered with a 2-stage pump. Run a 2-line system (suction and return lines). Install the bypass plug according to the instructions attached to the pump (the plug is in a bag with an instruction sheet).
- For any horizontal run exceeding the maximum length specified in Figure 3, or any lift of more than 10 feet, a booster pump must be used. Booster pumps must be installed as close to the oil supply tank as possible. Suction and return lines should be the same diameter and both go within 6″ of the bottom of the tank. The return line should stop slightly above the suction line. Use a minimum of fittings.
- Make bends in the tubing with as large a radius as possible. DO NOT USE COMPRESSION FITTINGS. Caution must be used in the final connection to the burner so as not to strain the fuel unit. Before attaching the tubing to the burner, form a coil in the tubing to minimize any vibration. State and local codes must be followed.
FIGURE 3: MAXIMUM LIFT & HORIZONTAL RUN
1-Pipe Single Stage Horizontal System Pump Run
3/8” O.D. 1/2” O.D.
Lift Tube Tube
|
2-Pipe System
Lift
| Two-Stage Pump 3/8” O.D.
Tube
| Horizontal Run
1/2” O.D.
Tube
---|---|---|---
0’| 65’| 100’| 0’| 75’| 100’
4’| 45’| 100’| 4’| 64’| 100’
7’| 31’| 100’| 7’| 55’| 100’
8’| 16’| 64’| 10’| 47’| 100’
Your log (or one similar to this) must be filled out as follows:
| Date | Time | Test person’s name | Set temp. oF | Outlet temp. oF |
|---|---|---|---|---|
PLACE THE WATER SYSTEM IN OPERATION
- Fill the tank with water, opening a hot water faucet to allow trapped air to escape from the heater. Open the cold water inlet valve. Shut off each faucet as it delivers water that is free of air. Inspect for leaks. Never operate an empty or partially full heater.
- To place the burner in operation, follow the instructions provided with the burner.
- Set the pump pressure to the value listed in Table 1 based on the burner make/ model and nozzle specified.
- Adjust the burner combustion air according to the burner manufacturer’s instructions. Using combustion instruments, check the C02 and smoke. The Co2 should be at least 11% minimum with zero smoke on the Bacharach scale.
- While the burner is operating, disconnect one of the yellow CAD cell wires. Check to see that the burner control locks out in the time specified on the control. Reattach the wire and reset the control. The burner should restart. Note: You may have to wait a minute before resetting the control.
- The thermostat is factory set at 120°F for residential use. (See caution on page 1 regarding temperature variations. It is the responsibility of the homeowner and installer to verify that the installer follows the recommended quantitative testing for measuring the outcoming water temperature. To make sure that the system works properly after installation and in the future, it is recommended that the heater’s performance be measured and monitored. Run water out of the tap nearest the heater until it comes out warm. Using a calibrated thermometer, take a measurement. If the water is not at a suitable temperature for the installation, have a qualified service person adjust the aquastat. Contact Bock for further information on the thermometer if needed.
Warning: The Handhole cover may loosen during shipping check for tightness before putting a heater in operation. MEASURING THE OUTCOMING WATER TEMPERATURE
WARNING: Hydrogen gas can be produced in a hot water system served by a heater that has not been used for a long period (generally two weeks or more.) Hydrogen gas is extremely flammable. To reduce the risk of injury, open the hot water faucet at the highest location in the house for several minutes before using any electrical appliance connected to the hot water system. If hydrogen is present, there may be an unusual sound such as air escaping through the pipe as the water begins to flow. Do not smoke or allow an open flame near the faucet at the time it is open.
MAINTENANCE
- Follow the burner manufacturer’s instructions for proper maintenance of the oil burner.
- EVERY SIX to 12 MONTHS. Drain water from the heater tank and inspect for sediment or lime accumulation. Flush out if necessary. If lime has accumulated, remove it with a commercial compound for dissolving lime or by scraping through the hand hole opening (if supplied). Check water softening equipment if lime is found in the tank. DO NOT ATTEMPT TO HEAT HARD WATER. (See maintenance label on the heater.)
- Change the magnesium anode rods every six to 12 months or when they are reduced to 3/8″ diameter (see maintenance label on the heater).
- Open the relief valve test lever to flush out the tank. Make sure it reseats itself.
- If the heater is to be shut off in cold weather, drain the tank to prevent freezing.
SERVICE
- Check the fuel supply, electrical wiring, and fuses, and make sure temperature control is calling for heat.
- If the burner fails to operate, call a qualified local service provider.
WIRING
FIGURE 4: Carlin burner w/ Carlin EZ-Temp For Models: 32, 33, 50, 51, 120 (Carlin burner with 40200 primary control)
FIGURE 5: Beckett or Wayne burner w/ Carlin EZ-Temp For Models: 32, 33, 50, 51, 120
FIGURE 6: Honeywell L4103A-1142 For Models: 32, 33, 51 FIGURE 6 NOTES: Setpoint 120°
FIGURE 7: Honeywell L4006A w/ For Models: 50, 120E
FIGURE 8: Carlin burner with Carlin 90000B EZ-Temp For Models: 32, 33, 50, 51 (Carlin burner with 70200 primary control)
FIGURE 9: Carlin burner with Carlin 90300B EZ-Temp For Models: 50, 120 (Carlin burner with 70200 primary control)
PARTS DESCRIPTION
ITEM DESCRIPTION
- 1. Cold Water Inlet Dip Tube (N/A 33E)
- 2. Plastic Cap
- 3. Magnesium Anode Rod (aluminum available)
- 4. Name Plate/Rating Label
- 6. Immersion Well & Aquastat
- 8. Drain Valve
- 9. Mounting Bracket Gasket
- 10. Burner Mounting Bracket (part of jacket assembly on Models 32E through 51 Series; sold sep a rate ly on 120E)
- 11. Bottom Pan
- 12. Combustion Chamber Sleeve
- 13. Com bus tion Chamber
- 14. Inspection Block
- 15. Inspection Door
- 16. Heater Jacket
- 17. Tank
- 18. Hot Out Nipple
- 51 Series: 1”
- All others: 3/4”
- 50ES: N/A
- 19. Top Pan
- 20. Burner
OIL-FIRED WATER HEATER
BOCK TANK ASSEMBLY PARTS LIST
When ordering repair parts, always give the part name, model number, size, and serial number.
WARRANTY
LIMITED WARRANTY FOR OIL-FIRED WATER HEATER
- Bock Water Heaters, Inc.
- 110 S. Dickinson Street
- Madison, WI 53703
- Phone: 608-257-2225
WHAT DOES THIS LIMITED WARRANTY COVER?
- This limited warranty applies only to the original consumer purchaser.
General Defects and Malfunctions: This warranty covers defects and malfunctions in your new water heater for one year from the original installation date. We will repair or replace, at our option, any defective or malfunctioning component of the water heater. This limited warranty will terminate if you sell or otherwise transfer the water heater, or if the water heater is installed at a location different from its original installation location.
Tank and Heat Exchanger: We also warrant that the tank and heat exchanger will not leak due to defective materials or workmanship for five years from the date of original installation or date of manufacture in the event the Limited Warranty Registration Card was not completed and returned to the manufacturer. If the tank and heat exchanger are leaking and we have verified that the leak is due to a defect in materials and workmanship, we will replace the tank with a tank that is the nearest Bock model available at the time of replacement. If a replacement tank is provided, it will remain warranted under this section as if it were the original tank. For example, if we send you a replacement tank under this limited warranty two years after the original installation date, then the replacement tank will remain warranted for the remaining three years after the original installation date.
HOW DO YOU GET SERVICE UNDER THE LIMITED WARRANTY?
- For the warranty period to begin on the date of installation, you must return the warranty registration card attached below within 30 days of purchasing the water heater. You may also register your water heater online at www.bockwaterheaters.com. You must have a copy of the original sales receipt at the time you request service. Failure to return the warranty registration card and provide a copy of the sales receipt will result in the warranty period beginning from the date of manufacture.
- To get service under this limited warranty you should contact either the dealer or installer. If the dealer or installer is unknown you can contact us via e-mail at warranty@bockwaterheaters.com or call us Monday through Friday between the hours of 8 a.m. to 5 p.m. Central Time at the following number: 1-608-257-2225.
You can also write us at the following address:
- Bock Water Heaters, Inc.
- Warranty Support Group
- 110 S. Dickinson Street
- Madison, WI 53703
We will respond no later than ten days after we have received your service request.
WHAT DOES THIS LIMITED WARRANTY NOT COVER?
This limited warranty does not cover water heaters that are or were:
- Incorrectly installed, especially where the installation violates state or local plumbing, housing, or building codes.
- Operated at inappropriate settings, excessive pressures, or temperatures.
- Exposed to adverse local conditions specifically sediment or lime precipitation in the tank corrosive elements in the atmosphere or unacceptable water quality.
- Installed outside the United States or Canada.
- Acidentally damaged.
Also, we will not cover the following charges, costs, and losses:
- Any freight or delivery charges.
- Any removal or installation charges.
- Charges to return the water heater or part to the manufacturer.
- Water damage, loss or damage to property, inconvenience, or loss of use
WHAT WILL VOID THE LIMITED WARRANTY?
If you do any of the following, you will void this limited warranty:
- Fail to retain an original copy of your sales receipt.
- Fail to retain the actual rating plate from the water heater.
- Alter or remove the serial number.
- Transfer or sell the water heater.
- Remove the water heater from its original location and install it somewhere else.
- Fail to follow the care and maintenance instructions provided with the water heater.
- Remove the anode rods.
- Fail to inspect and replace the anode rods (you must retain and present your paid receipts as proof of anode rod replacement).
- The use of any burner and/or controls other than the ones specified for the water heater by Bock Water Heaters Inc.
HOW DOES STATE LAW RELATE TO THIS LIMITED WARRANTY?
This is a limited warranty. WE MAKE NO OTHER EXPRESS WARRANTIES CONCERNING THIS WATER HEATER. We will not assume, nor authorize any person to assume for us any other liability in connection with the sale or operation of this water heater. ANY IMPLIED WARRANTIES, INCLUDING MECHANTABILITY OR FITNESS FOR A PARTICULAR APPLICATION, IMPOSED ON THIS SALE UNDER THE LAWS OF THE STATE OF SALE ARE LIMITED TO ONE YEAR. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. WE WILL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTACT OR TORT. Some states do not allow the exclusion of incidental or consequential damages, so the above exclusion may not apply to you.
TABLE 1 UL LISTED BURNERS
BOCK MODEL| BURNER MFR.| MODEL| OEM #| NOZZLE|
PUMP PRESSURE
---|---|---|---|---|---
32E, 33E, 32PPC| CARLIN| EZ-1| 968280A32E| 0.75 X 70A| 100 PSI
50ES| CARLIN| EZ-1| 968280A50ES| 1.00 X 70A| 100 PSI
51EC, 51PPC| CARLIN| EZ-1| 968280A51E| 1.10 X 70A| 100 PSI
120E| CARLIN| EZ-1| 968280A120E| 1.10 X 70A| 100 PSI
32E, 33E, 32PPC| CARLIN| EZ-1| 968280A32E| 0.60 X 60A| 155 PSI
50ES| CARLIN| EZ-1| 968280A50ES| 0.85 X 60A| 140 PSI
51EC, 51PPC| CARLIN| EZ-1| 968280A51E| 0.90 X 60A| 150 PSI
120E| CARLIN| EZ-1| 968280A120E| 0.90 X 60A| 150 PSI
32E, 33E, 32PPC| BECKETT| AF| BK3| 0.75 X 80A| 100 PSI
50ES| BECKETT| AF| BK5| 1.00 X 80A| 100 PSI
51EC, 51PPC| BECKETT| AF| BK5| 1.00 X 80A| 100 PSI
120E| BECKETT| AF| BK5| 1.00 X 80A| 100 PSI
32E, 33E, 32PPC| WAYNE| MSR| 371-001B| 0.75 X 80A| 100 PSI
50ES| WAYNE| MSR| 371-029B| 1.10 X 80A| 100 PSI
51EC, 51PPC| WAYNE| MSR| 371-003B| 1.10 X 80A| 100 PSI
120E| WAYNE| MSR| 371-029B| 1.10 X 80A| 100 PSI
32E, 33E, 32PPC| RIELLO| 40F3| C8511167| 0.60 X 60B| 150 PSI
32E, 33E, 32PPC| RIELLO| 40F3| 20190809| 0.60 X 60B| 150 PSI
51EC, 51PPC| RIELLO| 40F5| C8512138| 0.90 x 60B| 150 PSI
CONTACT
- Bock Water Heaters, Inc.
- 110 South Dickinson Street
- Madison, WI 53703
- Telephone 608-257-2225
- Fax 608-257-5304
- www.bockwaterheaters.com.
- 23420 Rev 11 (1/2024)