HURST BOILER & WELDING CO., INC. PO Drawer 530+ 100 Boilermaker Lave » Cootidge, GA 31738-0530 «Tek: 229 246.3585 « Fax: 220 346.3874. OWNER - OPERATOR MANUAL 300 HP SCOTCH BOILER HBC JOB # 1300013 SOLD TO: OCHOA PHONE: - - PO # 0399 visit, wwwhurstboilercom, email: inlo@huestboilecomIMPORTANT te aa RECOMMENDED WATER CONDITIONS. Following are recommendations for feedwater and botler water. Contact your local water treatment professional for testing and treatment recommendations. Itls very Important thata strict water management progeam be followed, Feedwater: Dissolved Oxygen.ne. less than 9.007 ppm PH Val neevnnrseevnn 3 tO 10.0 (tested at 259) "~-legsthan 0.3 ppm the fotm of CACOs none fess than 1 ppm less than 50 ppm “otal diseived Solids less than 300 ppsn Boller Water: Phosphate uminnuenn 30 0 60 pein the form of PO, Alkalinity 300 10.600 ppm as CACO Chloride. sss than 500 pp | HV {910 11 (tested at room temperate) “otal Dissolved Solids. odjusted conductivity... 2000 to 3000 ranahos “otal Dissolved Solids. (unadjusted conductivity =.-3000 to 6000 rrahos Frome fess than 1 ppm maxlimum Silcdscnenenmnevonnnetss than 150 ppm max. inthe frrn SIO, Site rrr oronere 300 60 ppm Dissolved OxygeN onan ONG em =parspermifon » CACO;=Calcum Carbonate « PO,=Phasphate « Sidy=sIkcondride 7 Grain Hardiness = 17.118 ppm - Therefore: 70 ppm = 410 grains hardness tis critica thatthe boiler pH be alkaline (5-11) when water isin the bole. Solis that enter in with the feedwater concentrate in the bolle. Dally blowdown is recommended ta help prevent the formation of deposits,Consult instructlon manuel for proper blowdown procedure, HB¢.09520 ‘9272011 Rca Eo Soe (Corosive ald and chcrine based ‘The buener union tis bode is siz to Proper feeder reatiant and ‘penis in the atmoenhere can be eet requirements o pau ts design aly londowm procedres re damaging (thie bor. isthe owner's fF horeepowar rating ne calbrated and ‘extremely mandatory i koecing ‘response have bo Bodo om {ested by tho manufacturer to assure your baler healing eutaca feo of poredcatytesiod ta assure these proper operation, Aa tn to ove-ro ‘eae ormaton, ling, xa ‘Samaging chemicals are rol present this burer nit o produce more ‘omeaion an conto osring or Damage tc botor duo ts eso factors horsepower tan tho manufactures atsd beaneng walt ‘may acount andor exemaily ff dosign ol innerenty cau darnago to iis \Whan he olor esta have fandin noform are related damages bolle Any frm of overfring this oder wl your water tasted bya protesslonal covered by no manutactyerswaranty. | voll menofecturers warantos {eocwater veetment const, he vil eoommend te proper water {teatrrant required or proton HURST sonra WwatDIRG co,mKC beter fe.HURST BOILER & WELDING CO., INC P.O Box 530 Coolidge, Georgia 31738 Phone (229) 346-3545 Attn: Sohn Winship FIELD START-UP REPORT DATE OF START-UP, fovud. JOB #__ _ PROJECT NAMI on LOCATION — BOILER MFG: BURNER MFG. _ BOILER MODEL: BURNER MODEl« ROILER RATING. BURNER INPUT: a _MBH OUTPUT. BURNER SERIAL, Ibshr; _ BOILER HEATING SURFACE, SQut. TYPE OF GAS: O Natural, OP O Other. Fuel Oil Grade No, ‘Was Boller Washed Out ALL SAFETY CONTROLS MUST BE TESTED Conivol Settings General Gas Operating control cut out seting Low gas pressure switeh Low oll pressure swith Ibs ‘Operating control cut in setting High gas pressure switeh, High oil pressure switch Tbs Limit control cut out sting Limit contol cut in sting ‘lame Safeguard Control Mfiy Model Flame Signal Pilot_ Does Owner have O&M Manuals Gas Pressure at Train inlet Bumer in Off Pesition,____" W.C/PST Gas Pressure af Train inlet Low Fire High Fire Gas Pressure at Firing Head Low Fite High Fire Gas Pressure af Pilot Test Tee Were Operating & Maintenance Procedures explained to Operator Operations Checklist jecked for Proper Operation OF. Yes No Yes___No iow water carol? oO © Baromaare damper cyt igh water cat off 0) O) Boyle room combustion sir and ventilation Flane Safeguard control gto fare can) O) provisions corect, co 0) Flame sfegaard conta main flame fre Oo) o> Oiftank vem system etecked Oy) Buyoer ais ow sitet Oo) (> Allol fines ebocked for leaks O20) Ynduced deaf fan coms OO 03 ‘alga ines checked fo leaks Oo) 0) Over fire dra contois 3 0) Gas tines al contols propery vented <0 C) Fresh at damper an toh rae 0 Other system components apes) ) CD Notified _ of following system deficiencies: STACK Height,BRERCHING: Sire > Cena a UNIT OUTLET DAMPER- % Ope ~ SEQUENCE DAMPER CONTROL: Mfg ‘Model COMBUSTION AIR INLET: Sire OW, TANK: GQ Above Burner O Befow Burner Distance trom Tank ‘Verticat Lift _ Pressure af suction side of pump, pst Snetion Line Size, Q Pipe Tubing eK ELD of riRED GAS FIRED COMBUSTION SETTINGS tow | med | migt | Low j Med | High Firing Rate cor or Sinoke or Co (ppm) NOx (ppm Stack Temp. Net °F Room Temperature °F Stack Drsét, "WC Furnace Pressure, * WC Water Temp. °F / Steam Pressure Ai Inet Shutter (inches open) Flame Signal Pilot Flame Sigeal - Main Oil Noz. Press. / Manifold Gas Pressure By-Pass Oil Pressure Atomizing Air Pressure Combustion Efficiency Running Motor Amps & Vols ul 12 13 Comments: Having read the Manufacturers’ Service Manual as to the proper installation, start-up and service ofthe above unit, I vorfy thatthe bummer fas been put invo operation as specified, and thatthe above inforipation and checks are complete and correct START-UP BY: DATE Company, Address,EXPORT, = so0Hp, FORM P-2 MANUFACTURER'S DATA REPORT FOR ALL TYPES OF BOILERS. Bate Hesopamer ‘EXCEPT WATERTUBE AND ELECTRIC ‘As Requltos by the Provisions ofthe ASME Code Rules, Section | Manufacured by Hurst Boller & Wolding Co, Inc. 21871 US. Hwy 319 North, Coolidge, Georgla, 31738, ‘hone ebdadiens cl manure) 2 Monte fr OCHOA (OX WASHINGTON F260, COL MODERIA GUAGALALAR, Jaan MEXICO _ 4. eaten tinttaton NUTRIMENTOS AVICOLAS AZTECA., PERFERIGO SUR 6108 LOPEZ COTILLA, TLAQUEPAQUE, Jalisco, 4616, ‘ame aa are) 4 Type EUROSCOTCH polain €$962-150-11 NA 1300013 19234 Year cuit, 2019) Rte) ‘es Seo) ern (orang No) ‘tan Booed Woy 65 The chemleal and physical properties of alparts mee he requirements of mateal specications of he ASME BOILER AND PRESSURE VESSEL (CDOE. The design, onsiucion, and workmanship conform fo Soction ofthe ASME BOILER AND PRESSURE VESSEL CODE 2010, settee to 2o11A (applicable), ond Code Cases, None te 5 gy Manufacture’ Partal ala Reports propely dented and signed by Commissioned Inspectors ere attached forthe following tems ofthis report NA RG a RT 6 Stellorcrums s* 155" wa, gt apec wy —— aeons tate 00) ‘at aay 7. ees wetoeo 100% __ WELOEO iat eg Rea wT a SN HTT ‘aera wae a ora Heads $4818.70 O76"THK FLAT NA ia Sp Ra Wore Fa ORIG. ps Raa Ay ——-— Tubesheel sasis70075" be Hotes (6,2.5" & (90)0" os a st ey nee (82a 10.BoterTuseeNo 96 SAATBA Steight wat Spt cay —— eine bea Oiameler ase Leng 1405" & 199.5" age i gue a eany "an 8 18S __ Gainey 14, Fumece ta 4 sie se Lengh.cach scton 146.195" Tot 449.125" oo oR Te MORISON CORRUGATED ‘Fi aaa Ro ROSE Cn CONTE TSSPSY -— it 16-70,0 Seams: Type ___wetoeo a — ree ay —eaahlen ay 12 Stybol:Na 28 Se __ 1.5" $4,675.70 45.9450, as Bari it Sent, So Ta Ped 12695" & 12.5" MAW 180 pst -eeenrans vay " 1. Stays or races Tecan [tapes Na [Tipe | No-ond Soe | munich [Fg PFTSPLA [Ob Tubes e Shel TaN fERatowites | sasrste —[owo] (ism ama" 3 ZS 2 [®)RH above uber | saers70 [onc] 15 12505" 19 2s 60 (e)FH. below es Wa_[ wa Wa WA Wk WA WA (RH: bow ube WA [wa [Wa NA WA. WA wR Tinea wars fv] cae "25 WA MA “0 ()Oone braces wa [wa [wa WA Wk WA WA 14 oer Pats. 1, TURNAROUNO WRAPPER a. WATER cowTROLS 3.__rurwanouvo sack PLATE ‘Bie ostapon- Tea Bier Per, #6) 1. ‘oH, SR51670 PLATE, ROLLE 8 WELOED 10 51°10 150731 (17 & 6) 1.25 30008 THO. CALGS, SAMA 5. "4" THK, SA-51670 PLATE, WELOEO INSIOE WRAPPEI sap) deer etre ese Oe WRAP pase Ge NIT RRR AR REY 1078125 ere: v1.70FORM P-2 (BACK) — i 4300013 19234 ex ‘orang Noy—— (wat Beara Nay Boller No. _& 6 “Sena a) 416. Oponings: (0) Steam _()6°FL6. 6° SCHan,SA406BPRE,T.SHL. (Pressure Reif Valve 2,9" 00H 7HO,CPLGS, SAS TSH, ike. Se (to. Sis say) (6) Blowott (2)1.57 0004 THO. CPLGS, SA-195, BSH (@) Feed (22° 00H THO. CPLGS, $4105, 5, SHL, ‘he, ze ype snLecten) “oS, Type. an Lcaton) {e) Manoles; No, Location TSH. (DHendholes: No, Location SHL.ATS. 16. Fusibe Plug (¥ used) NONE ‘Wa lanai, con, nes ateaton Mat) 17. Boter Supports: Me. 2 SADDLES Altechment WELOEO Boies (age THR (Gobet Weed) 18.MAWP 180psi____ Based On Peat Heating Suface 9625.8 [Code Pa sli) (oa 19.Shop Hydioslalic Test__225 psi_20. Maximum Designed Steaming Capacty 0350 sa 21, Remarks ‘OIWER PARTS: _AUIO LO FIRE HOLD ~ (1) 3/4" 30008 24D. cHLG., SA-108, WELDED S_SHL. REAR ‘2ocess — COO X 31S" THK, SA-B3-a Biwi Pips, WHLDED RTS GUREACE BLOG ——C)_ OOF THD. CPLG._ GA-105; WeISED TGHL—-Ge5-P-0 YOR BOTLeR ERTHINAL PIPING. SES E-7 FOR SRyETY VALVES REQUIRED. HYOROSTARTC. SHUT oF BOILER EXFEWAL PIPING WAS PERFORED BY WSS ‘EOLER ¢ WHIDING COL, DE, Aditonal Romaths- See Atached P, ‘GERTIFICATE OF SHOP COMPLIANCE Wi cert tet hestatemenis made nis data reper ae caver nd taal dlls of dain, mal, costuctor ard worranship fis baler canfor a Secon of te ASHE BOILER ANO PRESSURE VESSEL CODE, curCensosioa Autores ra, 17222 tnuceteS)_S_Desinatorerpies January 6, 2018 Dae_14/2272013, Sone None, Hora Boller & Wesing Co, no Wao) thiertaeepresei EI Boierconsucted ty Huret Boller & Welding Co, Ine 3 21971 US. Hon 318 North, Coolidge, Georg, 1788 \ thud, TI aR Srmon se! By te NaS oT BT SUT PESIR Vee bpecas ot engoyl ‘One insurance Compan hove paced pets f ha bole refered oc te ts a2 ‘ad hove examined te Manuals Prtl Oss Reports wre avd late that, othe bes! of my kneedge ae ble, te msefecturer has consid is bole accordanc wih Secon | of te ASME BOILER AND PRESSURE VESSEL CODE, By signing is cries nether he inspect: nx fs enployer makes any warany, cxpressd cr mpled,ccacemig he baler describes iis Manutscur’s Date Repe. Furemre, rede Ue hspesar ra his employer stl be ltlen ery manner or eny personal nury © 'g fom oreameied wh ts nspecion, Dae __s1vaa2013 Signed Conmisson 30374 ized nsec ‘Weel oad Carson Nabe nd Enaasan ‘CERTIFICATE OF FIELD ASSEMBLY COMPLIANCE ‘We cetyl he el sembly cansbucn of alas his bole canons va fhe requremens of SECTION lof he ASME BOILER AND PRESSURE VESSEL CODE, (er Cuenta ot Raattin na toucono(A) or) Designate expres Date Snel Name. Parad Repseane) Pema ‘GERTIFICATE OF FIELD ASSEMBLY INSPECTION | teunersignd, king vi comuisen sued by Ee Natanal Bos of ler and Pressure Vessel spor and employed by fis compared Slatemans Ws Manuacurars Data Repr vi the ie and sate Wao pats loved oo dale a included nthe carat of shop nspacton, tave been repecedby me and Bathe best of ny knafadze and ble, he manulcer nde a assonba is censbted {and ascenbled is her in act dane ih Le apeae sens cle ASNE BOLER AND PRESSURE VESSEL CODE. The dschted ter wae nepecod ond sbjacted to-hyretat lst of Bye ctl pate spectro ome aes any Wren, exposes me, cocrilg Weel desenbos ms Wanuleiare Data Rep, FUrthernte, sels the psce nor semper sab fable any are any econ yo opty Cenage 03 Ins of sy tein tom er comes wb ts spas. = i a outs Sted Connision, area rape) ‘ata oe aan aad EA “TRI PE PREY 1978125 ‘exe v6 70FORM P.6 MANUFACTURER'S DATA REPORT SUPPLEMENTARY SHEET ‘As Required by the Provisions ofthe ASME Code Rules 1, Manufacturer (or Engineerng-Contactor) Hurst Boller & Welding Co, inc, 21971 U.S, Hwy 319 North, Coot Ha, 51738, 2 Purcoser OCHOA (HX), WASHINGTON #1260, COL MODERNA, GUADALAJARA, Jalisco, MEXICO ‘Hees 3. Type of Baler EURO SCOTCH, 4. Boller No. eses2-t6o-4t MA 4300013 49234 ths Sena! 6 TERY Gravina Ney (atl are WOT __ 2013, "Weer aj — ‘Aone Romar: BOLLER EXTERNAL PIPING: 2) McDOSMELL-MILLER # 1578 PUMP CONTROL 6 UCO, Genrer orasy sep +7575 “88 Conmiol taco. ‘Gyar 786F AeOLO wat, vase De Ore ee NS, STO (Gy a" is08 execs a. Gare 3, REDUCING vee, M1 (2) GAUGE GLASS GROWICTOR HRNGD ‘2 WHERE, v-suare HROOMELL MILLER, W1S0-MI-i20, 7 RE-ITBR-I, W/ BRASS ROO. S)AGUASTAT W/ TROENSTON WELT, PRESSURGTROTE S174" 0-300 B51 PRESSURE _GAUOH SOR APOLLO BALL, VALVE SOE Br Secon SCH 40, GA-106-B SMES SyPHONS Pk 1a" TS0F R@buemc en's, ¥.1. ‘G2 780 pono BLL VALVE Gy 27300 Gace vate EB" FOO GHoss , gA-205 Ey2* 30001 F x ONION, “sA-108 Gaye goon on Fae ced ge 2 {1)-T=1/9"" 3008 UB SLOW BLOHOES VALVE ToifZ" SCH G0, SA-106-8 PIPES ¢ wIPPLES Date 1172272013 signed. Hurst Boller 8 Welsng Co, ne, yy ah fy Gobonse— Date 172272013, Ba. yO VhaiaNee comission, 136374 armen ‘ain od Casi nal eo Erase PREY 1070725 exe: 6170FORM P-7 MANUFACTURER'S DATA REPORT FOR PRESSURE RELIEF VALVES ‘As Required by the Provisions ofthe ASME Cove Rules, Secon 1, Boer manubered by Hurst Boller & Welding Co, Ing. 21971 U.S, Hwy 319 North, Coolie, Georgia, 31738 2. Baller manufacivted or OCHOA (MX), WASHINGTON #1280, COL MODERNA, GUADALAJARA, Jalisco, MEXICO ane a Seon Tp A 3. Location ofistalaion NUTRIMENTOS AVICOLAS AZTEGA:, PERFERICO SUR 6108 LOPEZ COTILLA, TLAQUEPAQUE, Jalisco, 45645, ‘ans ana saa fel aalaatataecte EURO scoTcH ID Nos, €5962-180-11, NA. 4300013, 19234 TE TART Specter, WetowaT OOHRUAI, REY irs Sanaa)” TERN Drawing Rey — “Wa Beart OT 5, enietion of Prossure lle Vaives eawo, | Site | oventy] soe Merueure Nana |Dageor Type a. 2 faa frou easenceot "Materia (1) SA-218, WOB. (2) SA217, WCB. (8) SA-217, WOS, (4) SA182,F 22. (6) Other "Connector type: (A) Groove Weld. (8) Socket Weld. (C) Threaded. (D) Flanged. 6. Unit Relieving Capacity ‘crault Ri Reed Famibed Baler i) cy [Economizer Superhester [Rebestar Inlet Reheater Outlet [omer 7. Detemivaton of Unt Refeng Capaty 1087.24 1 oppable lo ths baler? Ores Aoproach ake o acess capacty C] PO-er2.14 [] Poor2142 PREY 1878125 xe VEA7OFORM P-7 Nia 962-150-411 NA 1300013 19234 PTB ies Sra eT TERRY Pravin Nay THAT Boe NOT CERTIFICATE OF COMPLIANCE ‘We cortly the stoloments of thls Manufacturer's Data Report for Pressute Reel Vales to be correct and thal al delle conform fo Section fof the ASME BOILER AND PRESSURE VESSE1, CODE. (Our Cortfeate of Authorization No, 172s tousethe(S)or(t) —_g Designator expires _ 01/08/2015, Ahly Gobaso— Date_ 227013 signed oy Fata Rope) PREY T376725 exe: VE17OHURST BOILER GARRATT-CALLAHAN BEFORE OPERATING THIS BOILER IT IS NECESSARY TO CLEAN THE ENTERNAL SURFACES IN ORDER TO REMOVE OIL, GREASE, MILL SCALE, AND OTHER, FOREIGN MATERIALS THAT RESULT FROM THE MANUFACTURING PROCESS. HURST BOILER RECOMMENDS THE GARRATT- CALLAHAN COMPANY, A NATIONALLY RECOGNIZED WATER TREATMENT COMPANY, FOR THIS AND ALL OTHER INTERNAL TREATMENT FOR THEIR BOILERS. TO LEARN MORE ABOUT GARRATT-CALLAHAN CALL 1-888-203-4900 OR GO TO www.g.c.com_M tae Sate Mesa frome yur om dof sien, al wil be epaced bythe etry, pat “ng ie deve put Girt etrnd epi by le coset. Defective etl wil le placed y the sell, bueno far clan asoeve allowed no the Seer enjoy oter fhe Uibliy fm acount of wach defcive ati No cat ebaremen wl be alowed tc dfetve parts tured, oral any rp serie, ola, lowed witha tes eran fom the cry. ood tke ‘ancractareSld by "HBC" aero pane by "HC beyoed it mnufatres Wainy. “HBC does NO waranty the vs plication, ine, cleraonct design cx enginensig oto bles, burr cml oreter den pple, attachment of range any of ese or CLAD: Munufcrer's espensiity fo dnage or xs ceases whe sent ssp fry ce, ‘Goods sol ena excoly balve igning the right oe, Bogor mm requ he car to make ation on eg lf any dems msi pat ald Buyer must ake lal fr seme agin ar SPECIFICATIONS: Manufscizerseres he right tn chang pcelficaons of pods wie ate, itterenes with waren, eae to plano acho, dslays ia unasparaon or donage fears fle fea svar of Seller's soles reeds See oo, sa, or cures ben sell’ eon alte feo neue Sr dea in making mpm, ‘Boilers betcn ee sbjet to tbe seid hyosati oll cette ta they ave bee sintoy ‘ened un mae ihr beloee shigenentis soe a oa surance compen. Selle esses ne ep ‘iy or stsequens sess fer ters eft ee lant Slr sa pte espa for tena, sping, switeking or deme changes loa ole ris aod 7 bck pon of clvey Easing ole oe aad pst of dlr oj sto nding ‘oder os rigng Des on feamtaions dayage at destino; oF icomvenes Aye, o pase ‘ued yt liar trek omy st Galen chipnet pomp ths eb te ding the Purchaser's eae hos, Al of het aro te Purchatrs expense an espns, "TAX: Any tn nposnl by any zeta rue lof he Fed, Stato ter goverment aunty on ‘tr, nora ae ouipment td tal eden he sept oo pid y he pce HURST BOILER & WELDING COMPANY, INC, 0, Dever 30 100 Belemater Lane cecligy cA 317380830, ‘ls 929) 3463545 » Pe (20) 46.3874 ‘al fagtodercinHurst Boiler & Welding Company, Inc. P.O. Drawer 530 - Highway 319 North Coolidge, Georgia 31738 877-99HURST - Toll Free 228-346-3545 — Local 229-348-3874 — Fax www hurstboiler.com This manual contains important information regarding the operation of and the maintenance required on your HURST boiler. Failure to read and follow the instructions contained herein can lead to damaged equipment, or injury to those personnel involved with the daily operation. WARRANTY ISSUES. HURST will gladly assist you in the retum of items for warranty consideration, Our policy for handling such retums is stated below. The first step for returning items for warranty is to call 229-246-3545 ext. 1104 and request a “Return Goods Authorization” (RGA) number. When making this call, you need to have the following information available: ‘Customer name Job location Job number Date equipment was installed Reason for return — specify the problem ‘Where to ship replacement To whom billing is to be directed vrvyvyy All replacement items are shipped on a Net-30 day schedule. Payment is expected within this period, Any warranty will be credited upon teceipt of credit from the vendor for the defective part. All RGA shipments to HURST must have the RGA number on the outside of the shipping container. Any item not received at HURST within 21 days of the RGA request, will be deemed “not retumed” and no credit consideration wil! be made. Hurol Balle & Neting Company tne, ‘Start-Up, Oporation & Mabvonanco Gas or Ol Fad Packages Solers swanuburstbal.cos Page ot at Rev O40?GENERAL FEATURES OF YOUR HURST BOILER ‘Your Hurst boiler has been designed, constructed and certified to meet the requirements of the American Society of Mechanical Engineers (ASME) Code for boilers. HURST maintains its own quality control personnel with all the necessary equipment and instrumentation to verify constructions standards equal to or greater than those required by the ASME. All units are first inspected by HURST personnel and then by a “third party” inspector who is a member of the National Board of Boiler and Pressure Vessel inspectors to verify compliance with all Code requirements. Then, he witnesses the hydrostatic pressure test performed on the pressure vessel and authorizes the stamping of the proper ASME symbol on the vessel A manufacturer's Data Report is then completed and the unit is registered with the National Board. A copy of the Data Report is avaliable from HURST or from the Nationa! Board. After completion of the pressure vessel and the addition of certain other features of the unit, a burner and associated fuel train are added to the package. The bumer may have the UL or cUL Label, and may have the Factory Mutual (FM), GE Gap (IRI) or other agency identifications. Many state and Jocal authorities have laws/codes governing the installation or operation of boilers and pressure vessels You should verify with those local authonties regarding compliance with their requirements. ‘ars Boer & Welding Compary re. Stor Up, Operation & Mainenanca - Gas ex 04 Fred Packages Boers wee m Page? of 31 - Rov O07BOILER IDENTIFICATION PRESSURE VESSEL: Each boiler is stamped with a Serial Number and a National Board Number. These numbers can be found on the identification piate that is attached to the front door of the boiler and they are stamped on the boiler shell near the front tubesheet on the right hand side of the boiler. Besides simply identifying this unit, the Serial Number and National Board number identify the characteristics of this boiler for Maximum Allowable Working Pressure (MAWP) and temperature, if applicable and the Fireside Heating Surface available, Both of these numbers are unique to this particular boiler, so when inguiring about your unit regarding warranty, service or parts, having these numbers available for reference will speed the service we can provide. BURNER: If supplied by HURST, the burner on your unit will also have a recorded Serial Number that is unique to this unit. Should you need to make an inquiry regarding this bummer for service or parts, it is helpful to HURST for you to provide this serial number. Other bumer plate information will include maximum BTU throughput and the UL registration number for that burner. INSTALLATION The installation of your boiler should have been planned long before you take delivery of the unit, Drawings and specifications are often prepared by individuals familiar with steam or hot water systems, ‘This document assumes that the installation has been planned out and documented. Here, we only suggest some approaches to issues that might need a little additional detail General: The boiler should be placed on a fat, level concrete slab or on housekeeping pads that run the full length of the base rails. Hf the boiler is not in a building, be sure that all the controls, the control panel and the bummer — ata minimum — ate designed for outdoor operation. if the unit is inside a building, the space allowed on either side, at the front and at the back of the unit must be adequate to maintain the required maintenance and operation of the boiler. Minimum dimensions for these clearances are set by UL and perhaps by other local codes. Be ‘sure to determine whether your unit meets these ordinances before you place the unit. Most codes require @ minimum of 7 feet clear of obstruction above the manway for access on high pressure boilers and 5 fest clear on low pressure boilers. These obstructions include piping, catwalks or building structure. Your local codes may be even more conservative. Hurst Bote & Wielding Comper nc, ‘Stat, Oporatlon & Maintannes - Gas or Ot Frod Packaged Boers sovmnpursibalen. cn Poge dof Rev 7Building openings: ‘We suggest one opening large enough for the boiler to pass. Additionally, one man door and adequate openings for admission of combustion air (see Combustion Air Requirements in this manual) are absolutely necessary. Other openings may be supplied as the owner sees fit. Be sure to check with local authorities for building code requirements. Lighting: Adequate lighting is a must for proper operation and maintenance. Be sure to include enough lighting in the boiler room so that the operator can sead nameplates and instructions on the equipment without the use of supplemental fighting. Power: ‘The motor(s) and controllers that are part of your boiler system all depend on a constant supply of electrical power. The interconnection of these devices is accomplished through the pre-wired electrical contro! panel that has been furnished with your unit. Normally, the power supply will only be required to be made to one point on the control panel. That power requirement is specific to your unit and will be specified by HURST. It is the responsibilty of the customer to supply that power to the panel. Steam boilers typically have a feedwater system supplied with electric motor driven pumps that requires a separate power supply to the panel supplied with it. Piping: No piping should be at or near the floor level to cause tripping accidents. Floor drains and pipe trenches are essential for maintaining an orderly, clean facility. Piping may be placed in drains $0 you will not need separate trenches. These trenches should drain to a point outside the boiler room of to a sump to be pumped out as required. All trenches should be covered with adequate grating or floor plate Connections: There are several connection points on the boiler that must be connected to other systems within the scope of the installation. Some of these connections are common to both steam and hot water systems, Others will be designated as “steam” or “hot water’ 4. Safety Valve: The safety valve(s) will be located on the top centerline of the boiler. The outlet of the safely valve must be piped to a point of safe discharge, and it must be the size of the valve outlet or larger. NEVER reduce the discharge line size. 2, Vent Stack: This is the large opening at the end of the boiler through which the gases from the combustion process must be vented to some point outside of the boiler room. When using factory manufactured stacks, we recommend the use of stacks rated for pressurized systems. UL Listed double wall slack systems may be a good choice. it must be gas-tight to eliminate the chances of leakage into the boiter foom. Check with local authorities for any requirement they may have for height requirements above the roof. Hurt nie & Weng Cexspany, ne Start-Up, Operation & Msintnaroe - Gas ov OR Fred Packaged Balls ‘rshurtboter com Paget of 1 Rov MOT3. Fuel: The fuel connection(s) will be for natural gas, manufactured gas, light oll or heavy" oii. The connection points are on the sides of the boiler or near the bummer (for oil). The gas piping must be approved by the local gas company and will be inspected by their personnel, Oil piping must be appropriate for the application and insulated if fring oil that requires heating 4, Supply: This is generally the largest opening on the boiler, and it wil be on the top. This is the opening through which steam or hot water is allowad to exit the boiler to enter the extemal system. This must be piped as required by local jurisdictional requirements and as good construction requirements demand. In multiple boiler installations, some of this piping may need to be constructed and stamped according to the ASME Code. Connections that are specific to Steam Boilers: 1. Feedwater: This is the opening on the side of the boller through which water enters to re-supply water lost through evaporation. This must be connected from the feedwater supply system. The design requirements for pressure in this line must be greater than the MAWP of the boiler. 2, Bottom Biowdown: This opening or openings are in the lowest part of the boiler at the bottom centerline. There will be one or more bottom blowdown openings. See Blowoff-Blowdown in this manual 3, Water Column Blowdown: This refers to the piping directly below the water column/gauge glass. This is the valve through which the unwanted contaminants will be expelled from the Low Water CutoffPump Control device. See Blowoff Blowdown in this manual 4, Surface Blowoff: This opening is generally on the top centerline of the boiler and is the opening through which surface contaminants will be expelled. See Blowoff- Blowdown in this manual. Connections that are specific to Hot Water Boilers: 1, Return: This opening will be focated on the top centerline of the boiler and will generally be the same size as the Supply Nozzle, Water returns from the system and re-enters the boiler at this point to be reheated. 2. Drain: ‘The drain connection on a hot water boiler is similar fo the bottom blowdown ‘opening on a steam boiler, and it will be located at the lowest part of the boiler at the bottom centerline, This discharge should be piped to a point of safe release such as a blowdown tank or pit. 3, Water column Blowdown: Some hot water boilers may have a blowdown connection on the water column. This should be piped to a point of safe discharge. Hust Ballo & Nesing Company, be ‘Start-Up, Operation & Mstenance- Gas or OR Fed Packaged Bere ‘a hurts com Pago of 1 Rov 08/07COMBUSTION AIR The bumer on your boiler requires oxygen to support combustion of the fuel, This oxygen supply comes from the air in the boiler room, so an adequate supply of ‘combustion air” is, essential for efficient operation of your boiler. Allow 8 cubic ft per minute (cfm) of air for each rated boiler horsepower up to 1000 ft elevation, and it is suggested to limit the velocity of the air movement in the boiler room to 250 ft per min (fpm), Above 1000 ft elevation, add 3% additional volume for each additional 1000 ft. ‘Two (2) air supply openings should be supplied in the outer wails of the boiler room, preferable on opposite ends or sides of the boiler. Fans are not required nor recommended, but simple louvered openings are suggested. These openings may be covered with wire mesh, but the mesh should have at least %” openings. Example: 250HP Requires 250 x 8 = 2000 cfm Then 2000 cim/250fpm = 8 sq ft opening So, 2 openings of 4 sq ft each in opposite walls are required Even for the smailest boiler, the air supply opening should be at least 1 sq ft CLEANING ~ BOIL OUT ‘After the installation of your boller has been completed, and before any operation is begun itis highly advisable to clean the water side surfaces of the boiler and the piping system to which the boller is connected. The piping system may contain oil, grease, welding slag. thread cuttings and other contaminates that should not be lett in the system piping. If ieft in the piping, it is only a matter of time before it will find its way to the boiley. Slag and thread cuttings can block or damage gaskets, valves and control devices. A new boiler is likely to have oil, grease, or other protective coatings that were on the metal parts during the manufacturing process. These contaminants mist be removed prior to beginning operation since any one of them may cause priming, foaming, inefficient heat transfer or contamination of the process to which the steam Is directed. Most boiler chemical suppliers can supply the chemicals and the expertise to affect an appropriate method for cleaning your boiler. However, in the absence of such consultation, suggested procedures are outlined below ust Boler & Webira Company, in. ‘Sart-Up, Operation & Mantonance - Gas ¢¢ Oi Fred Packaged Bollors woven trata ett Pages of 31 -Rev O40?Before beginning any internal cleaning procedure, you must determine the experience level of anyone who will be assisting in the cleaning procedure and make suitable safety garments available to each of them. Itis preferable that ail personne! be familiar with the procedure and vwhat the results could be if they are not careful with handling the chemicals involved. Asa minimum, the safety equipment should include face mask, goggles, rubber gloves, and apron. Severe burns can result from improper handling of caustic chemicals. PROCEDURE: Please read the entire procedure before beginning any part of the procedure. Steam boilers: 4. Close all external valves, such as feedwater, steam supply, chemical feed, and lowdown to avoid loss of chemical and to isolate the boiler internal parts Remove the safety valves. Remove the manway cover, if so supplied and if itis in the uppermost part of the shell Fill boiler with fresh water to a level 2-3 inches above the top of the top row of tubes. Just basic tap water is acceptable for this filling. 5. Determine how many gallons of water the boiler will contain when completelly filed. 6. Mix Tri-sodium phosphate and caustic soda (Sodium Hydroxide) in the amount of one (1) pound of each for each 100 gallons of water content in the boiler. Add the chemicals slowly into @ bucket or barrel with water as necessary to dissolve them. Stir constantly to be sure that the chemicals are thoroughly dissolved. 7. Add the dissolved chemicals carefully through the largest opening available in the top of the bolle. Compieie filling of the boiler to the top. Begin firing the boiler at the lowest rate possible and Intermittent, as necessary to get the water temperature just above 200 degrees F. During this early firing, the water volume will swell and tend to overflow the openings in the top, so operate the bottom blowdown as necessary to maintain flooded condition in the vessel while minimizing overflow. 40. Continue this low heat input for a minimum of 4 hours, and shut the bumer off 41 Allow boller water to cool fo a temperature of 120 degrees F or less, and drain to a point of safe discharge. 12.Remove ali handhole plates or other inspection openings and wash the interior thoroughly with high pressure water, On large boilers, a fire hose is recommended 13.IF interior surtaces are not clean, you may repeat the above procedure. 14.\f you determine the water side to be adequately clean, proceed to replace the safety valves, re-close the handhole and manhole pilates with new gaskets, and refit the boiler with treated water from your feedwater system. (Additional information about treatment of boiler water is in another section of this manual) 15, When filled to the normal level, the boller should be checked for leaks and may be fired normally. Allow the trapped air to escape the boiler during this initial filing. BON om Hurst Bolle 4 v¥eeing Company, ne. ‘Start-Up, Oporaton & Réanenarice - Gas oF Ol Fed Packaged Boers swell com Page 7 of 1 Rev 04707Hot Water boilers: Close all external valves, suchas feedwater, Supply, Retum, and drains to avoid loss of chemicals and to isolate the boiler internat parts. Remove the saiety valves: Remove the manway cover, if so supplied and if itis in the uppermost part of the shell Fill the boiler with fresh water to a level 2-3 inches above the fop of the top row of tubes. Just basic tap water is acceptable for this filing. Determine how many gallons of water the boiler will contain when completely filed Mix Tri-sodium phosphate and caustic soda (Sodium Hydroxide) in the amount of one (1) pound of each for each 100 gallons of water content in the boiler. Add the chemicals slowly into a bucket or barrel with water as required to dissolve them. Stir constantly to be sure that the chemicals are thoroughly dissolved. 7. Add the dissolved chemicals carefully through the largest opening available in the top of the boiler. 8 Complete filing of the boiler to the top. 8. Begin firing the boiler at the lowest rate possible and intermittently, as necessary to get the water temperature just above 200 degrees F. During this early firing, the water volume will swell and tend to overflow the openings in the top, so operate the bottom drain as necessary to maintain flooded condition in the vessel while minimizing overfiow. 10, Continue this low heat input for a minimum of 4 hours, and shut the burner off. 11.Allow boiler water to cool fo a temperature of 120 degrees F or less, and drain to a point of safe discharge 42.]f interior surfaces are not clean, you may repeat the above procedure. 13.1f you determine the water side to be adequately clean, proceed to replace the safety valves, re-close the handhole and manhole plates with new gaskets, and refill the boiler. {Additional information about treatment of boiler water is in another section of this manual) 14.When filled to the normal level, the system should be checked for leaks and the boiler may be fired normally. Allow the trapped air to escape the system during this initial filing an Son Hurl Bolo 8 Neidng Company, to ‘Start-Up, Opaatlon & Iinionanoe - Ges or 02 Fired Packaged Boles mu nuttboten come Page 8 of t= Rev O07PRE START-UP — STEAM HURST assumes that everyone involved with the start-up or operation of this boiler has some training or experience with similar equipment. If not, he/she should not be allowed to be directly involved with the operation or maintenance of the unit. Training is available and should be pursued. Satisfactory operation of your boiler system depends on attention to details. The following steps should be attended to at initial startup and after any period of shutdown. 1. Check the Feedwater tank (deaerator) to verify that water level is correct and that feed valve that supplies water to the tank is open. 2. Pump suction valves are open 3. Power is available to the pump(s) 4, Main steam supply valve(s) is open 5. Safety valve(s) is correct for this boiler design for pressure and capacity 6. Boller water is at correct level and Feedwater valve(s) is open 7. Verify low water cutoff operation by opening water column blowdown valve until alarm sounds and feed pump starts 8. Verify that Auxiliary Low Water Cutoff is operational. (You may close feed valve and open bottom biowdown for this check. Be sure to re-open feed valve after you close blowdown valve.) Pump should start and bring water fevel in the boiler back to normal operating level 9. Verify water treatment system(s) is operational and valves are open 40.All control cabinets should be clean ~inside and out — with completely functional doors that are closed 14. Equipment guards should be in place 12 Fuel valves should not be open at this time PRE START-UP — HOT WATER HURST assumes that everyone involved with the start-up or operation of this boiler has some training or experience with similar equipment. If not, he/she should not be allowed to be directly involved with the operation or maintenance of the unit. Training is available and should be pursued. Satisfactory operation of your boiler system depends on attention to details, The following steps should be attended to at initial startup and after any period of shutdown. Check that feed valve that supplies water to the system is open Supply and return valves are open’ Safety valve (s} is correct for this boiler design for pressure and capacity ‘System water is at correct level Verify low water cutoff operation \Verify chemical treatment has been performed and is satisfactory All control cabinets should be clean ~ inside and out — with completely functional doors that are closed Equipment guards should be in place Fuel vaives should not be open at this time ©@ NOORONS Fst Boter Weng Company, Ine ‘Star, Opevafon & Matenanes- Gas a Ol ed Packaged Baers acu nucsaier on Page Gof 3¢- Rov 04/07STARTING FROM COLD HURST assumes that everyone involved with the start-up or operation of this boiler has some training or experience with similar equipment. If not, he/she should not be allowed to be directly involved with the operation or maintenance of this unit. Training is available and should be pursued. Be sure to sead PRE START-UP in this manual before attempting any start up. When all points in the PRE START-UP have been completed, you may proceed to start the unit Open the vent on top of the boiler to allow trapped air to escape as pressure is building in the boiler. This may be accomplished by opening the vent valve ~ if supplied ~ or by removing the plug from the top of the water column balancing fine. See the manufacturers manual for the particular bummer on your boiler for instructions regarding initial fring Set the firing rate controller to the lowest firing rate possible. This will allow the bumer to begin heating the water at a rate that will minimize stresses to the metal parts, it will also allow the lower, colder, zones to warm at a rate more consistent with that of the higher, hotter, zones. The firing rate should not be increased until after steam pressure is evident on the steam pressure gauge Remember, there is some refractory in your boiler that has not been completely cured. Therefore, the initial firing should be at a very low rate for a minimum of 2-3 hours to completely drive out any free moisture that remains in the refractory. When steam is detected at the vent valve, close the air vent. Maintain this low fire rate as steam pressure begins to build after which the firing rate can be increased and fueliair ratios can be adjusted for optimum combustion at various rates per the manufacturer's instructions. Subsequent firing, from cold, may require a cursory re-reading of the manufacturer's instructions. Uniess changes have been made to linkages, valves, or other components, further starts, afier shutdowns should only require assuring yourself of the points found in PRE START-UP. Verifying combustion conditions should be made at time of start up and periodically thereafter using a combustion gas analyzer. No other special fools are required, ‘ust Baller & Welding Company, ne. ‘Stat-Up, Operation & Maintenance ~ Gus of 0 Fed Packaged Bolrs sean ursboles cam ‘Pago 10 of 3t- Rev O07FUEL INPUT To know the rate of fuel consumption in your boller is important for maintaining cost records and to know when you are under firing or over firing your unit. OIL FIRING: To determine oif cons umption rate, you need to place an oll meter in your fuel train and simply record meter readings at specific times. By doing this, you can calculate the of consumed within that period of time. Example: Assume you are firing No. 2 oll (140,000 Btu per gallon) 8,00 AM meter reading = 1020 galtons 9:00 AM meter reading = 1048 gallons Difference= 28 gallons Time = 1 hour, So, 28 gallons in 1 hour = 28 x 140,000 = 3,920,000 Btuh (input) At 85% efficiency, = 3,920,000 x .85 = 3,332,000 Btuh (output) 1 Boiler HP = 33,475 Btuh (output), So, 3,332,000/33475 = 99.5 HP if you are firing a 100 HP boiler, your firing rate is almost perfect. GAS FIRING: To determine gas consumption you must have access to @ gas meter — which your gas supplier probably has already installed in your gas fine, If the boller is not the only load on the meter, you may have to further isolate that supply or stop operating the other equipment while measuring boiler input. You need to verify the gas pressure and temperature at the meter and determine the inlet gas pressure and temperature that was used to calibrate the meter. Your gas supplier should be able to help you with all of this information. You will need pressure and temperature correction factors as shown on the following chart bases on the values determined above. Example: 8:00 AM meter reading 9:30 AM meter reading Difference = Time = 4.5 hour (90 minutes} Hast Bier & ioidng Company, ne, Stan-Up, Operation & Mantenance - Gas or Ot Fhed Packaged Boers sal tuesiber om ‘Pago 11 of 31 Rev OM‘Assuming a value of 1000 Btu per cu ft of natural gas (typical). Your gas supplier can be more specific about your particular gas. Assuming a pressure correction factor or 1.324, ‘Assuming a temperature correction factor of 1.020, Using 3800 as the number of seconds in one hour, Multiply 40 x 3800 x 1.324 x 4.020 = 194,469 Then divide by 90 = 2160.8 CFH 2160.8 x 1000 = 2, 160,800 Btu (input) At82% efficiency = 2,160,800 x 82 = 1,771,856 (output) 4 Boller Horsepower = 33,475 Btuh (output) So, 1,771,856 / (33475 x 1.5) = 35.3 HP If you are firing a 35 HP boller, you are firing it about 1% over rating. Hurst Bote &weiing Company, ne Start-Up, Oporion & Minenance - Gas or Of Feod Packaged Balers sonbsipibolle com Page 12 of 9 How 0807i { GAS PRESSURE CORRECTION FACTORS PSIG Meter Base Pressure at doz, 80x 10 0Z, 7ib 2 Lbs. Meter Civic) (14 ic) (17.5iwe) | (28.0iwe) | (56.0 iwe) 3 o.863 0.055 0.988 0835 o878 118 +000 0.983, 0978 0.954 0.803 2 4.017 “1000 9.902 9.988, 9.908 5/8 4.026 4.008 000 0.976 0916 7 105? Te “1025 “1900 ‘Og39 2 atte 1401 +002 +1088 4.000 3 1g 1168 1188 130 1061 4 +256 1338 4225 4188 4122 5 1324 302 1201 +260 1383 8 +1302 1368) 388 328 ‘aaa T 3464 1.838 ‘az 300 1308 8 11520 1.503, “aot ass, 11368 9 4807 4870 1587 +1520 sar 10 +1906 1.938 ‘tsa 1.584 1408 12 “ie02 TT 787 Tra 510 4 +1939 4.908 11220 eae 4792 18 2078 2040 2.023 1.974 1854 18 2212 274 2186 2104 3978 2 2348 2.209, 2.200 224 2.008 5 2408 Daas 2423 2364 2220 24 2621 277 2.560 2.404 2aat 23 2768 arn 2089 2623 203 28 2.998 2848 2002 2763 2.505 30 3.031 2.980, 2.085 2.083, 2707 38 3.372 3318 3.288 ‘3208 3012 40 ams 3.054 3621 3.582 8317 4% 4.055, 3.087 3.953 3887 3.022 50 4398 4322 4.286 4182 3.907 30 3078 4.995 4052 4634 2597 70 8763 5.604 S617 saat 5.146 a Baas 6336 8203 6.130 8758 % 74128 7.007 eae e779 6.368, +00 7809 1s78 7614 aso | 6.78 170 3.495 B20 8280 ‘8078 7888 120 e174 9.020 2.945 8727 3.195, 130 2887 eat eat os77 6.008 140 10.540 10.60 40.280 40.030 oats +50 44.220 14.090 20.949 40,800 19.020 “60 T1000 7.70 i810 47.300 79.830 170 42.590 12580 12270 +4970 11.240 80 43270 13.080 32.040 321820 11.850 199 13.950 13.720 13.600 13.270 12.460 200 14630 14.300 14270 13.020 13.070 Hut Bole &. Weidng Commary, ne, ‘ec turer om ‘Star-Up, Operation & Maintenance - Gas or Ol Fred Packaged Boils "Page 19 of 3 Rev O07GAS TEMPERATURE CORRECTION FACTORS Gas Meter Calibration Temperature Temp oF 60" F 65°F 68° F Jo" F 72°F 6 4.130 4441 1.148 1.162 1.187 5 1.118 4.129 1.135 1.140 4.144 40 1.108 417 4.423 1.428 1.432 45 1.095 1.108 4.112 1.116 4.420 20, 4.083 4,094 4.400 1.104. 4.108 25 1.072 1.082 4.089) 1.093 1.097, 30 4.061 4,071 4.078 4.082 1.086 35 4.054 1,064 1.087 4.071 1.075 40 4.040 4.050, 4.056 4.060 1,064 45 4.030 4.040 1.046 1.050 7.063 60 4.020 1.029 1.035 1.039 1.043 55 4.010 1.019 1.026 1.028 4.033 60 4.000 1.010 1015 4.019 1.023 85 0.990 1.000, 1.006, 4.010 4.013 70 0.981 0.994 0.996 4,000 4.004 75 0.972 0.981 0.987 0.991 0.994 80 0.963 0.972 0.978 0.981 0.985 85 0.954 0.963 0.969 0972 0.976 90 0.945 0.955 0,980 0.964 0.967 95 0.937 0.946, 0.951 0.955, 0.959 100 0.929 0.938 0.943 0.946 0.950 105 0.920 0929 0.935 0.938 0.942 110 0.912 0921 0.926 0.930 0.933 415 9,904 0.913 0.918 0.922 0.925 120 0.897. 0905 | 9.910 0914 0.917 ATMOSPHERIC PRESSURE 14.4 PSI BAROMETER 28.31 INCHES Hurst Boder &Netding Company, nt sew hustler com ‘lar Up, Opecton & Maintenance - Gas or Oi Fred Packaged Balers Page 4 of31- Rev 0807OPERATION ~ STEAM (Gas or Oil fired) ‘The design of your HURST boiler is such that In general operation, the starting, ramping up, slowing, and stopping is alt controlled automatically. (See START UP in this manual) ‘Some of the devices you may find on your unit are the Burner, Firing Rate Controls, Feedwater Controls, Low Water Cutoff, Auxiliary Low Water Cutoft, and High Level Alarm ‘As with any automatically controlled device, the key to continued successful operation is to maintain the correct operating characteristics of the devices that are doing the controlling Lwco. This is especially true with a floattype low water cutoff (LWCO). This device wilt protect your boiler from firing when the water level is too low, but there are several things that can go awry and cause this device to fail The first, is allowing the interconnecting piping from the boiler to the device to become plugged with sludge, “Sludge” is an all-encompassing term for materiat that has settied out of the water and blocked normally open paths where water or steam should pass. This sludge may also enter the float chamber of the LWWCO and block the float from properly responding to changing water levels in the boiler. DAILY attention to controling this sludge buildup by blowing down and physical inspection is a must Modifying the electrical or mechanical characteristics of the LWCO in any way may cause it to incorrectly sense boiler water level. If there is any question as to the proper operation of the LWCO, you should shut the boifer down and correct the malfunction. ALWco The Auxillary Low Water Cutoff (ALWCO), if fitted, is a back-up device in the event of failure of the LWCO. However, it is never a good idea to simply begin to rely on the ALWCO if you know something is wrong with the LWCO. A fatlure of the ALCO could also occur leaving you with no safety devce to shut the bumer off in the event of low water. The ALWCO may be a float- type device or it may be a probe-type controf, FIRING RATE CONTROLLER: The unit firing rate is controlled by pressure (temperature) sensitive devices that have limits within which they cause the burner to respond. The limits of this control must always be within the range of the safety valve(s) setting, Example: 150 psi designed bolfer, 150 psi safety valve setting, and Operating Control range not higher than 135 psi (about 90% of safety valve setting with a High Limit control set at 138- 140 psi. The High Limit Control is another backup device that only functions if the Operating Control fails, Hurst Bole &Heting Company, oe, ‘Start-Up, Operation & Maintenance - Gas or Fd Packages Boters mos nurstholercom Page 15 of et = Fev 04707‘The Operating Control starts and stops the bumer in response to pressure in the vessel. I fitted, the Modulating Contro! varies the firing rate of the bumer within the range of the start- stop action of the Operating Control. The full modulating range must be lower than the upper limit of the operating contro! The High Limit Control is a backup to the Operating Control, so that in the event pressure in the boiler continues to go higher than the Operating Control set point, the High Limit contro! will shut down the bumer. This contro! generally requires operator involvement for manual re-set before the unit will recycle BURNER: ‘The burner on your unit is a “forced draft’ design meaning that thie combustion air fan provides ‘oxygen to the combustion process in a pressurized fasivion and pushes the products of combustion through the boiler and out the exhaust stack All modem forced draft burners are supplied with an automatic ignition device and a flame safeguard control. These devices sequence the buming of the fuel in a proper, systematic fashion. No effort should ever be made to bypass any of these devices. FEEDWATER CONTROL: As steam is allowed to escape the boiler, water must be forced into the unit to maintain the Normal Operating Water Level. This make-up water is normally supplied from a pump that is dedicated to this one unit The starting and stopping of the feedwater pump (on smaller units) is typically controlled by the same device that acts as the LWCO. When the waier level drops fo a point just above the LWCO point, it starts the pump and allows it to run and pump water through the feedwater line until the upper level limit is satisfied. Then, the pump is allowed to stop until the next cycle is required. (On larger units, the water is normally fed continuously to the boiler through a Modulating Feedwater Valve allowing only the amount of water to pass as is necessary to maintain the Normal Operating Water Level in the boiler. This means that the feedwater pump runs continuously. The Modulating Feedwater Valve may be pneumatic or electric and it monitors the water level in the boiler to control the rate of water allowed into the unit. HIGH WATER ALARM: ‘On some units there may also be a High Water Level Alarm. Normally, this control does not shut anything down, but sounds an audible alarm to alert the operator that a higher than normal water level exists in the boiler. High water level can lead to wet steam and may cause problems in the system by the introduction of water into the steam lines, ‘We urge the use of Operational Logs to maintain optimum operational efficiency of your boiler system, Maintaining regular, systematic recordings of operational data such as steam pressure, stack temperature, Feedwater temperature, fuel meter readings. boiler water Hurst Soler & Weiting Company, ne Star-Lp, Operation & Mainionance - Gas or Ot Fed Packaged Boers ‘wavy burton com Page 16 of 3 - Rev 04/07chemical levels, and any other data ~ even the outdoor temperature — can be very helpful in analyzing problems that may arise. Some owners/operators prefer hourly recordings, while others may feel dally recordings to be appropriate for their operation. Remember that during periods of cold weather, the piping that supplies fresh water to the system must be protected from freezing. Hurst ale & olng Company, he ‘Ster.Up, Operation & Maintenance - as or 08 Fired Packaged Sots ‘wag hurtoolan cam Page 17 of 8 = Rov O40?OPERATION ~ HOT WATER (Gas or Oil fired) ‘The design of your HURST boller is such that in general operation, the starting, ramping up, slowing, and stopping is all controled automatically. (See START UP in this manual). ‘Some of the devices you may find on your unit are the Burner, Firing Raie Controls, Feedwater Controls, Low Water Cutoff, and High Temperature Cutoff ‘As with any automatically controlled device, the key to continued successful operation is to maintain the correct operating characteristics of the devices that are doing the controlling, Lwco, ‘This is especially true with a float-type low water cutoff (LWVCO), This device will protect your boiler from firing when the water level is too low. DAILY operational check of this device is a must Modifying the electrical or mechanical characteristics of the LWCO in any way may cause it to incorrectly sense boiler water level. If there is any question as to the proper operation of the LWCO, you should shut the boiler down and correct the malfunction. FIRING RATE CONTROLLER ‘The unit fring rate is controlled by temperature sensitive devices that have limits within which they cause the burner to respond. Example: Operating to maintain 180 degree F bulk water temperature within the boiler. {Temperature range must not exceed 250 degrees F). Operating contro! will be set af 180 so that any time the bulk temperature drops below 180, the bumer will fire to bring the temperature back up to 180 at which time the burner will shut down. If fitted, the Modulating Control varies the firing rate of the bumer within the range of the start- stop action of the Operating Control. The fui modulating range must be lower than the upper limit of the operating control HIGH TEMPERATURE CUTOFF: ‘The High Temperature Cutoff is a backup to the Operating Control, In the event temperature in the boiler continues to go to a higher temperature than the Operating Control range, the High Temperature Cutoff will shut down the burner, This control generally requires operator involvement for manual re-set before the unit will recycle. BURNER: ‘The burner on your unit is a “forced draft’ design meaning that the combustion air fan provides ‘oxygen to the combustion process in a pressurized fashion and pushes the products of combustion trough the boiler and out the exhaust stack. hast Baile & welding Company, ne ‘Start-Up, Operation & Maintenance - Gas or 0% Fred Packaged Boers saz turstboder cam Page 18 of t= Rev O40?All modem forced draft bumers are supplied with an automatic ignition device and a flame safeguard control, These devices sequence the buming of the fuel in a proper, systematic fashion. No effort should ever be made to bypass any of these devices, FEEDWATER CONTROL: ‘As water is allowed to escape the boiler, water must be forced into the unit to maintain the Normal Operating Water Level, This make-up water may be introduced at the boiler or in an ‘expansion tank and may be available from a pumping system or other system that delivers at a pressure adequate to overcome system pressure ‘We urge the use of Operational Logs to maintain optimum operational efficiency of your boiler system, Maintaining regular, systematic recordings of operational data such as supply temperature, return temperature, stack temperature, fuel meter readings, water makeup meter readings, chemical additions and any other data ~ even the outdoor temperature ~ can be very helpful in analyzing problems that may arise. Some owners/operators prefer hourly recordings, while others may feel daily recordings to be appropriate for their operation, BLOWOFF-BLOWDOWN Steam: Part of a water maintenance program will include “blowing off” or “blowing down" Bocause of the nature of intreducing hot water under pressure to a point outside the boifer, it is advisable (0 utilize @ blowdown vessel or pit to minimize the obvious hazards, Blowoff/Blowdown is required on all steam boilers and will help maintain the quality of boiler water that is required for proper steam purity, control of dissolved or suspended solids that are in the boiler water that can lead to encrustation on the heated parts of the boiler. No water treatment program can completely eliminate all undesirable substances from your boiler water. ‘The most efficient method for removal of sludge that may accumulate in the bottom of your boiler along with some dissolved solids suspended in the boller water is through Bottom Blowdown. This is an intemmittent, manuai opening of the water space to the outside. This exercise will generally be performed once every & hours of operation, but the final schedule should be determined by your water quality consultant Functionally, the typical unit will have one or more “slow-opening’ globe valves and one “quick opening’ vaive mounted to piping that is connected at one or more points along the belly of the boiler The operation is such that the "quick opening” valve is opened first, followed by opening of the globe valve(s). As soon as the globe valve is fully open, begin immediately to close it. When it 's closed, close the “quick opening” valve. This process should probably iower the level in the gage-glass approximately one-half inch, Hurt Baller & Welding Compson, ne ‘Stat, Operadon & Mainisnance - Gas or 08 Ftd Package Bots mowuturinolerem Page 19 of 8 Rew 007Surface Blowoff is a common method for removing oil and other impurities that accumulate at the surface of the water in the boiler. Functionaily, this method utilizes a collection pipe or pipes that are mounted just below the normal water level in the boiler. This piping culminates just outside the boiler with a control valve that controls the rate at which water is allowed to flow depending on the analysis of the collected water. This analysis may be intermittent with manual valve adjustments or it may be automatic with instrumentation that will adjust the valve accordingly. The ultimate discharge of this water must also be directed properly to avoid contact with property oF personnel. Water Column Blowdown is another procedure for controlling or eliminating sediment from the low water cutoff device and the associated piping. This procedure should be executed at least one time every 12 hours of operation. The operation of the pump control and the low water cutoff should be verified each time this blowdown is executed. The importance of this procedure must never be underestimated and is probably the most important function you can perform to help eliminate low-water failures in your boiler. Hot Water: Normally, no blowdown is required on a water boiler because there js little make-up of water in a closed system. However, water quality should be checked periodically to determine need for adjustment to your water quality program. ars! Boor & Weld Compny, fe. ‘Start-Up, Operation & Maintenance - Gas ar Ol Fred Packaged Bodors ‘ow huzstballe com Page 20 of 94 = Rev 0807SHUT DOWN ‘Steam Boilers: Short term: If you intend to shut your boiler down for a period not to exceed 3 days, (72 hours), you may simply tum off the power, close the valves and jeave the water at the normal operating level without further preparation. Long term: if you intend to shut your boiler down for a petiod exceeding 3 days ~ up to 14 days, you should tum off the power, fil the boiler completely with water, close all the valves, and take no further steps of preparaton, However, in both cases sited above, if there are other boilers connected in the system with this unit, precautions must be taken to ascertain that no bleed-over is taking place thet would pressurize the idted boiler either through the introduction of feedwater or steam Extended period: For periods of shutdown beyond 14 days, you must consider either 2 “wet layup” or a “dry layup". Wet layup means to fil the boiler completely with treated water, close all valves on the boiler, and to carefully moritor the quality of the water at least weekly during the layup period. You must also verify weekly that leakage or other influences have not lowered the water level in the boiler. Ifitis not full, you must add water to maintain @ condition of full. The success of this storage method depends largely upon eliminating any air coming in contact with any of the water side of the unit while maintaining good boiler-quality water inside. Dry layup means to drain all the water from the boller, wash and flush as necessary to remover all sludge from the water side, and use whatever method is available to ‘COMPLETELY dry the water side of the unit. ‘Then, when the unitis completely dry inside, place moisture absorbing material inside on pans, if possible, and seal fhe water side as tightly as possible from the outside environment. The absorbing materials must be checked weekly and replaced when they become damp The success of this storage method depends lergely upon eliminating any moist air from coming in contact with any metal surface inside the boiler for the entire period of lay up. If you are in an area subject to freezing temperatures, be sure to disconnect and drain all connecting lines. ‘Horst Bode 4 Weidng Company ne. ‘Start-Up, Operation & Maiegenance Gas ar Oi Fred Packaged Boters| wa tases ca Pago 21 of St - Rev 0407[ | For this extended period of shutdown, itis recommended that all gas-side surfaces be orushed to remove all soot or other foreign deposits which could lead to corrosion of the metal parts during the time of shutdown, Hot Water Boilers: Wet and Dry Layup procedures are the same for hot water systems (as steam systems) that are to shut down for extended periods of time. Danger of freezing with wet layup is of particular concern in a water system because of the volume of water involved and the piping system that may extend to no-heated areas of the facilites, MAINTENANCE ‘The importance of maintenance cannot be overemphasized when discussing boiler operations, ‘The cleanliness of the entire boiler room will impact how long some of the controls will continue to function and how accurate that functionality will be. DAILY: ‘Sweep or wash down the floor Wipe up oil spills Clean the dust from top of control panels and other flat surfaces Blow down water column every 12 hours to prove functionality (steam) Blow down bottom blow ever 8 hours (steam) Record stack temperature. This & helpful in determining the need for cleaning the fireside of the boiler. » Note feedwater temperature (and tank pressure, if system is pressurized) (steam) > Note by visual inspection that the water level in the boiler is at te normal operating level. (Steam) > Note steam (or water) pressure gauge reading > Perform water quality analysis and record results, > Check for leaks at all piping connections and inspection opening on the boiler. Reduce boiler pressure to below 15psi before attempting any tightening of handholes, gage glass fittings or the like, Replace gaskets as soon as practicable. » Check softener tanks and re-supply, if applicable >» Always be sensitive to tube leaks. Water dripping fo the floor at the front or rear of the boiler especially when the unit is shut down, or when steam vapor in the stack, this should be investigated immediately. Do not attempt to expand tubes while the boiler is under pressure. vrvvry burst Baler &Wiolng Compare Stor-Up, Operon & Maintonance - Gas or OH Fkod Packsged Boters nos pustoales com Page 22 of 81 = Rev 08/07WEEKLY: Verify the operation of the steam pressure controls (steam) Perform water quality analysis and adjust surface blowoff rate, if applicable (steam) Check softener supplies and re-order as needed Check handhole and manway gasket inventory and re-order as needed Compare stack temperature reading records and note trend in temperature gradient (Increasing temperatures may indwate a need for fireside cleaning), vrvyy Remember, many motors and other moving components start and stop automatically. Be sure to disconnect power before servicing to avoid possible injury to yourself or others. ‘Steam and hot water can severely injure or kill, Do not attempt adjustments or repairs while system is “hot” and under pressure. ‘SEMI ANNUALLY OR ANNUALLY: » Plan ahead for the periodic insurance company or jurisdictional inspection. Have manpower and tools available to minimize the time required for this important inspection > Be sure to have new gaskets available for ali the gasketed openings that must be disassembled. All jurisdictions and insurance companies require periodic waterside and fireside inspections. These vary with the states and companies, so you need to determine their schedule requirement so you will be prepared. These inspections can usually be carried out at the same time to minimize down time for your operation. » Each time the boiler is opened for an internal inspection, use this time to note any sludge buildup on any surface, especially in the belly of the boiler and wash this out thoroughly, » Also, note any suspicious area of pitting or chemical buildup on the tubes or furnace. Involve your chemical supplier for a possible re-evaluation of your water treatment program, and after his inspection, thoroughly wash these areas clean. > Note the condition of the fireside of the boiler. The furnace, tubes, front and rear smokeboxes and the stack should all be brushed, or vacuumed as necessary to remove any foreign materials. Note especially any evidence of tube leaks on the front and rear tube sheets and in the tumaround space, if so fitted. This is the time to contact your local boiler service company and have those leaking tubes repaired. Hurst Bator &viesing Company, ne. ‘Star-p, Oporaton & isnionanoe - Gas of Ol Fred Packaged Baters ss urooon cam Page 23 of 31 Rev OWWhen preparing for a waterside inspection, stop all fuel input at least 18 hours prior to the inspection. Allow the boiler to cool siowly to minimize stresses in the heated parts. On steam boilers, blow the bottom blowdown frequently during this cool down period to introduce cooler water and flush out settled sludge. About 6 hours before the inspection, open front and rear doors. As soon as boiler pressure has gone to 0 psig, close feedwater valves and remove manway. Open top air vent. Turn off all power to the boiler. Open all bottom blowdown (drain) valves to begin draining the boiler. As water is drained, you may begin washing down as you see fit until internal parts are clean. WATER QUALITY ‘The life expectancy of your boiler is greatly impacted by the quality of the water you place into it. If you take steps to assure the water to be free of contaminants and solids and to have the correct pH, only periodic waterside inspections are necessary to maintain an efficient, long-life operation STEAM BOILERS: ‘When the water that you place into your holler is converted into steam; that steam leaves the boiler, but the contaminants that were in the water stay in the boiler and have the potential to form studge and scale. Sludge is generally a soft, settieable material that over time will drop to the bottom of the boiler and may be removed through bottom blowdown. It can impact heat transfer since it will also build up on furnace the tubes. Left uncontrolled, it can contribute to foaming and priming thereby compromising steam quality Scale however, is that material that will cake on the fumace and tubes in a hard, baked-on Jayer that will lead to poor heat transfer and may cause overheating of those surfaces to the point ofrupture. Ultimately, this scale must be removed, so it is better to take steps to eliminate the very formation of the scale. Removal of scafe from the water side of a boiler can be very labor intensive and costly. PH is the measure of how acidic the water is. If the pH is not properly adjusted, the metal surfaces can experience conditions that can lead to corrosion, pitting and uitimate failure, Sludge, scale and pH are all controllable. The condition of the raw boiler water must be analyzed and corrected before it is introduced into the boiler. Filters, softeners, dealkatizers and chemical feed systems are some of the pre-treatment methods used to create suitable boiler water. Additional chemical treatment is sometimes required to be injected internaily into the boiler A water quality consultant can make an analysis of your boiler water and make recommendations for treatment, Hurst Bolles & Weng Cenpany, ne ‘Stat Up, Cparaon & Mainienanoe - Ges or 02 Fred Packaged Boies ‘lu hurboie com age 24 of 1 Rav O47‘Some recommendations for conditions of acceptable boiler water are Oxygen <.007 ppm Total hardness <5 ppm Total Alkainity (CACO3) <700 ppm Total Iron (Fe) <0 ppm Silica ($102) <150 ppm Suspended Solids <300 ppm — (up to 300psi) <250 ppm — (300 - 450psi) <150 ppm — (480 - 600psi) Total Solids <3000 ppm pH 75-11 Hot Water Boilers: At the time of filling the system for the first tme, the water quality should be checked and treated. Chemicals to prevent scale formation, elimination of dissolved gases and control of pH should be of particular importance. Although these systems are considered “closed”, there are conditions that can lead to water losses which must be made up. Leakage through handholes, threaded pipe fitting, pump seals, and a variety of other issues in the system can lead to make-up water being required in the system water. ‘A meter on the make-up water line is a good method for determining the amount of water that has been added to the system over a given period of time, This will alert the operator to verify system water quality and adjust treatment as necessary ‘Shottype feeders are generally the method used for introducing chemicals into the system. Hurst Bodar & Welding Company, nc. ‘Star Up, Operation & Maicnance Gas o¢O8 Fred Packages Botere ‘som hues com | ‘Page 25 of 31 Rev O47SATURATED STEAM PROPERTIES ‘i303 | ovisre Ts0.8 | OS15s ‘isan | 18106 | 6957 | 10778 | Diadé | ooi6r7 Tiest | o3201 ieiy | ier.st | e020] 1070s. 2ie24 | 0.01681 71563 _| ost7 “Lia5) | 163.96 | 687.6 | 1001.2 25067 | 0.01685 rig 2 | 0.8095. i7oso | 13873 fas | 10828 | 2549 | 0.91659 ‘fp.0 | 05466 ‘yan | rant | emo] 1039 ‘24007 | 01682 ES “rise | aes | o768 | 1086.1 i 244.36. | 0.01696, 1162.0 _| 0.3804 ‘rare | 21267 | 8736 | 1088.5 | ee foresee oer ee eee pies | coe Tee rir tar Pais four ines sen | aaas eee [oss [ae i tire Hae tose See ee eon: a2? | O01 mee | 11682 | 0.288% 15826 | 25114 | 650.8 | 10908 26572 | corr ta ‘ay | sien2 | 030m | 12006 | t6res | Zaas5 [a572 | 1096 2a i4 [oor wae | 11702 [0300 | 12003 | 1974s | 272 | a0 | 10024, Dee bere Sere omer tea | aon ear | aaa | Donezt Se ee ee eer oe pa oo eee er veer air you Lew [eee we Tivre [ours ao] 1a) fot | aos | tact | aes | doa mo ‘0228 | 001725 ‘Sasa | visa [oat | 1aaaa | tessa | zaizy | seas] 10958, 25a To | o0ts0 | 5.062 Beret iivo2 | aawes | 12577 | 465se | 2570 | ana] tose t Bei or | ONT | ie sie} 1176.9 | oatos | 12316 | 1e80s | 2852 | eae | taser Ea 3 est | ooirae | 1529 79] 11788 | 0429s | 1208 | (o4se | 20840 | aser | oer : Hurst Bole & eiing Company nc, ‘Start-Up, Operon & Mainlonarce - Gas or 02 Fred Packages Solers i vote cor Page 28 of31 = Rov O400.0t735, ira | 31768 | 0420 "nag ‘OoT7s8 ais | tvs] 04270 “0.9 ‘ota | 6987. aig] tie2 | oaavo 1098-4 foarraz | 8.763, m3] v7ee | 24508 266.24 1098.8 ‘otrae | 5.560 | zeess | o1as | i104 | 043s. 206-34 10093 urs | 6.378 woes | vtao0 | ooas zo | e294 | 1098 ‘o.or748 | 6.26. Sor] T1806 | OAADG | 1.1005, zrs8 | i378 | 11902 ‘o0is0 | eae sient | ase05 | 1 1057. 2rais | W255 | 13008. ‘1752 | 5600 si] ters [oaana | 11300 2re25 | a7 | T3010 ‘S.orrea | 5749. nazi | nadbe | 1 1764 | 2iate | #253 | tite ‘01765 | 5604 ‘tas | 0.4508 | 1.5720 2ra06 | 827 | MOLT ‘Sore? | 5472 test | asst | 1.1676, ‘er.76 | 2203 | 11027 ae [ee Srepee See ee ee ee ae cree Ete Teia | ose | 151 Zaeae | s61 | T1084 caret sor Tes | o7ean'| rie16 fae ar | nese cores ae res [oder vari ear | ste | 1087 ae Ee i eer eee re ee ae Le ae “ess [oor | asi? Tees | 04721 | t 1320 | eons [eeb7 | 808.2 | 11069 waa [ow | dase | 2 arora | o4rao | 11206 | tears | zon0a | ors | 11082 W925 | 000778 | 4360. Tiare | os7eo | iizsi | teow | zoos | bone | 11054 seaws [oor | 4271 era | oa77s | 11216 | i504 | 30103 | soar | HOET Huot Blo & Wosing Company, be. ‘StanUp, Operation & Malnienance - Gas of Of Fred Packages Baers Page 27 of 81 Rev 007‘osrre | 4232 ‘7a? | 1.1190 ‘ours | ator 4608 | 1.1108 ‘otrat | 08a oases | 1t38 nose | 4016. asso [7.1104 oores | scar 9.4868 | 7.1059 .0¥7es | 5.862 ‘uaars | 11037 otra | 3.810 “oanet {11007 eae Tae Ti ooiren | aes eae | 10047 “ea ee oan ie tore hae ES a ‘aoiret | 3595 oaurz | 10860 Tes ae fgets a tora sore htm | 12508 "ey 0ov7es | 3381 ei ‘sots | torre | 1.6750 "7687 ‘oreo | 3.335 0.5059 | tarda | 1.s7at TT ‘ootect | 3.287 2 ‘047 | 10722 | 1.5769 | sz.59 | 7057 ‘oteon | 3240 ‘601 | 1.0808 {1.5757 Ti “07803 | 3.198 sore | 1og5u | 1 57as 7368 Dove | ates Bso00 | towed | 15768 "Tee Ge te Spo opie aie a oe Shee Pose eet ae ‘ooreid | 3077 O.is1 | 1.0500 [1.5003 78 Hurst Bolle & Wieiing Company ne, ‘Start-Up, Operation & Maintensres - Gas or 08 rad Packaged Batre saint cu) Page 28 of = Rev OWToot Sots Toa? ome DoT Tate Tes ror OTE Ota S018 ODT Sate ote? D018 ‘o.st8s? 0.01863 ‘00188 ‘ota: ae ‘91876. ‘00188 ‘001687 a G10 ‘Ot908 AIS 236 Zio Te as 20002 7 ‘ase es ira iat 328 12500. asta ry nes nao 63 er 1968) ad 7 070 er are ac Tigre T1982 "198.7 "a3 Ss ae oe = ona Te 202.7 12031 12056 to Di saite ae C108 | 10004 e0 | 13080, ‘95319 | 19228 0.5596 | 1.0158. 015859 | 10768) ea ‘osa81 | 10118 co ‘sats | 1.0076 ao sees | LoD aseo1 | 0967F ‘Osse2 | 0.9880 caset | 087ae tae ar tae ae tos" [ote Telia oret | ose jaait Psu? Seen [ome osaie | a5t69 ‘Case | o.cas a8 38774 3153 E06 40240 410. iiite ite iy. Tite 522 Wied 36 Te Tat 41133 1136 11140 ania = tid i883 1135.6 11490 a Tes ae 11158 188 a0 a4 3178 Hurst Bole & Welding Company, ne non bursoten com Slart-Up, Operation & Msntenanea- Gas oO} red Packaged Bollore Page 29 of 4 = Rev 04/07Gorsis | eaze0 ‘o.or021 | 1.2560 a Goi020 | 1.010 Dorea | 11350. 0.0184 ‘0188. “00196. 0.0197 ons | Te Sear Ta cose [oo 4253 [ess "cor aa a5 | o8s2 “abo | 4a52 | o734 Hurst Soller & Welding Company, ne anufusiboter com ‘Start-Up, Operation & Mélnjenance - Gas or 08 Fired Packaged Bolles age 20 oft Rev OUTCirculation Rates - Hot Water Systems BOWER ‘System Temperature Drop - Degrees F BOILER HP output (Btu/tr/1000) 28 418s) 837 as, 279 208 250 8025 1005 503 335 251 200 5695 1239 670 446 335| HURST BOER & WELDING CO,, INC. P.O, DRAWER 530, 100 BOILERMAKER LANE, COOLIDGE, GA. 31738 PHONE: 229-346-3945 — FAX: 229.346.3874 Hot Water Boiler Design Parameters Minimum outlet temperature = 170°F Minimum retam temperature = 150°F ‘Minimum circulation rate thru the boiler= 1 gpm per boiler horsepower. The 50°T ‘temperature differential below must not be exceeded. ‘Maximum temperature differential = 50°F A constant 20°F temperature differential (3.35 gpm per boiler horsepower) across the boiler is preferred for tong boiler life, and Jow maintenance, ‘When starting 4 cold boiler the water temperature should not rise more than 1°F per minute, Pressure drop across Hurst Hot Water Boiler waterside is less than 1.5 psi.| | STANDARDS ‘American Society of Mechanical Engineers (ASME) 345 East 47" Street New York, NY 10017 212-705-8500 ‘American National Standards Insfitute (ANS!) 41 West 42” Streot New York, NY 11036 212-642-4900 Canadian Standards Association (CSA) 178 Rexdale Boulevard Etobicoke, Ontario, Canada M@W 1R3 416-747-4044 Canadian Gas Association (CGA) 86 Scarsdale Road Don Mils, Ontario, Canada M3B 2R3 416-447-6465 National Board of Boiler and Pressure Vessel inspectors (NB) 4056 Crupper Avenue Columbus, OH 43229 614-888-8320 Nationa Electric Code (NEC) 1 Batterymarch Park Quincy, MA 02268 Underwriters Laboratories (UL and cUL) 333 Pfingsten Road Northbrook, !L 60062 Underwriters Laboratories of Canada (ULC) 7 Crouse Road Scarborough, Ontario, Canada M1R 3A Hurst Bor Wek Comary, no. “Sar. Operation & Maborance- Gas oF Ot Fred Packaged Blea mbssteater om ‘Saget ora Rev O07PRECISION INSTRUMENT COMPANY BIMETAL. THERMOMETER 90° BACK ANGLE TYPE STANDARD FEATURES * All Stainless Construction With Glass Lens Anti-Parallax Dial Vibration Resistant (No Needle Flutter) Fast Response To Temperature Change Hermetically Sealed (Moisture Proof) +h 4 % Full Scale Accuracy Stem Welded To Connection Zero Adjustment on Back of Case oor ereve E ‘STEM PART oD 2 B — LENGTR* NUMBER, a ; 3° DIAL | §* DIAL T c B32 | _BSB2 Biba BSBe A B3Be_|__BSBG R T B3B9 BSB9 a BaBI2_|_BSBI2 4/2"NPT 5 BIBIS_ | BSBIS is B3BIs | BSBIR 2 B3p24 | B5B24 B De STANDARD RANGES* e SMLENGTT ao 38 CODE RANGE Dial STEM LENGTH im | 976 ‘AA “AO0F EC ” STEM LENGTH or ae BB, ~0/160F &C Diat ‘STEMLENGTH Toss | 936 EB ‘O50 &C = GG. 0200 F & C ‘Note: u 207340 F €C + Other Ranges, Stem Lengths And Configurations IL ODs0F RC Are Available Upon Request. ha 30R00 F&C + Thermowells of all sizes and materials of “PP TO400F eC construction are available also. > RR 50550 F&C Please Call With Any Inquiries. SS 1S0/710 F&C Tr 0o7OoH FEC |THIS PAGE IS INTENTIONALLY LEFT BLANK.UNITED BRASS WORKS, INC. 714 S, Main St, Randleman, NC 27317 alae ‘Tel: 800-334-3038 Fax: 800-498-4696 www.ubw.com !$09001 rorasr cours Model 34015 ¥%” Short Shank Gauge Fixture Set w/ Ball Check 250 WSP @ 406°F Max 400WOG Rising Stem Aluminum Hand Wheel Ball Check to Prevent Leakage, if glass breaks MATERIAL LIST NO. | DESCRIPTION | MATERIAL ' Upper Finture See Sheet Tr 2 Protector Ros Stel 3 Lower Fistue Bieiposs or *A To determine proper glass length, subteact 1 1/8” from center to center dimensions of the installed valves.70B-140 series Power Piping Bronze Ball Valve Job Name: “Contractor: Job Location: ‘Engineer: DESCRIPTION The Apolio® 708 Series has the seme rigged features as the standard 70 Series vales but with ASTM B82 bronze ‘shell somponents. The 708 has trusted performance along vith a wide range of options o aul evary application. FEATURES Stainless Stoo! Ball & Stem Blow-Out Proot Stem Design Adjustable Packing Giant MPTFE Seats and Sting Box Ring Cero 100% Facion Tesieg a ra scya0n 85-5-5-5 Relainar & Body t _ PERFORMANCE RATING DIMENSIONS + Maximum Pressure 600 pslg GWP. 250 psig SP Roel Se [panes We 2) Maximum Temperature S007 Number | (iny TAT [eT o ib) 3 Vacuum Serio 0:29. Hp ToBrares] va [OT | 109] z0eh LS] aa | 060 Pop iaeea | 38" | 0.37 [7.03] 2.08] 175] 387 | 0.88 MODELS roerasea| iz [080] 172] 225| 17s] 3a | 068 70880 St sain te Lover Taiaca ae [om olswoleat ear ie ast ton [alas sar Toerasea| TH Fo Zon] sof aap sao] 3.25 STANDARD MATERIALS LIST wopiareay Tie L126] 218} a7 208] 200} A [oon eT Pee wobietsa] 2 | 1s0f2ss}ase] avs] a0) 80 stm Pacing [PTFE Sion Booty —[RrTE ast asm OTE Sear ay [were Noone sesame eT 1862-C83600 (1 1/4". 2°) t [Semthaa—Yasocasne — sen fps azra te @APORT [over Nut [Steel Zine Plated ¥ [sear osa-Cenco0 APPROVALS + MSS SP-110; Bat Valves Threaded, Sooke Welding, Solder Join, Grooved and Flared Ends + GRN: Oc10808.66. + ASME 831-1, POWER PIPING” Conca nsusbog, Ino. 70 Mathews nt Fill, Hatthowe NG 28106 USM: jute nollosaives cam: 708-847-6000 “hie spateatan provi etane av, Cobra av ieee ay pre i pect eat nate an a cag gen 2 {one scones o Coss sic oda ences 551029 6 1009 Page 1 270B-140 series Power Piping Bronze Bail Valve OPTIONS 1 (42) Stem Groundes Ey (03) 1 2 08 Stom Exension (04) 2.4 CS Stem Extension 5] (07) Stoo! Tee Handle {E0e) g0*Raversed Stem {610} 3S Lever & Nut £44) Side Vented Bali (Un+Directonal) (45) Whee! Handle, Steel £18) Chain Lover-Vertical £24) Graphite Packing [(27)SS Leteh-4.cx Lover & Nut [-30) CameLock & Grounded (-32) SS Tee Handle & Nut [-39) SS HERise Looking Whol Handle & Nut (40) GytLce & Grounded (4) Lass Lever & Nut (C48) Lach Lok LeversLek Closed Postion Only (47) SS Oval Latch-Lock Handle & Nut (48) SS Oval Handle (No Latch) & Nut {L49) Aveombied Dry (50) 2-114" OS Locking Stem Extension (57) Oxygen Cleaned (658)chain Lever Horizontal (660) Static Grounded Bal & Stom P01) BSPP (Paral) Threaded Connection Pot} BSPT (Tapered) Threaded Connection poooooonooosoodanasoo Conte nis, ne. 70% Matta Met Ml Re, Mathews NO 26106 USA; wan apslovalvas com ; 704-844-6000 cvttc eases cn scorer tote res et ove sigh i tl ee temo wo a es wees SS Sree ea Sat e e ynceesar 0A pss een rau roe ee Hay 15510230 1009 Page 20%2BALL VALVE WITH MOUNTING PAD ale deg in enty secon ape totum hades or np penal mown. “Treadad end somwotone win PTFE eats and ein Sox hs. FEATURES 24" ot mals (S60 7/ aes esH#-) «Fund hans 160 GWE pron ing ‘paste packng ‘Blowctpea ston 250 LB. BRONZE STEAM BALL VALVE [Dorr fr reatia operon oa igh pressure sea systems ae ts Sul of wy vying terperanes kas or use mh Fgh oral expan ets. ‘Stalnace set bl and eer alana. Talla son. FEATURES tangs stool or sam + Spel heparan MTFE stm pack Ni ted PTFE ae 250 SF SASTM Se once oy Rote ans brorae cot Rotel Ginsends esae as “Woteoae SED oh ate (amare 7187 Sates) comesennineman “Apolla” vaives| TT McDonnell & Miller Installation & Maintenance instructions MM-217(I) Series 1508 and 1578 @) @ (Snap Switch, Ail Models except 157S-RB-P) Low Water Cut-Off/Pump Controllers For Steam Boilers and Other Level Control Applications Typical Applications: ~ Primary or secondary pump controtter/ low water fuel cut-off for steam boilers ~ Low water cut-off ~High water cutoff — Alarm actuator Sorios 1578 4 WARNING + Before using this product read and understand instructions, + Save these Instructions for future reference + All work must be performed by qualifled personnel trained in the proper application, Instal- Jation, and maintenance of piumbing, steam, and electrical equipment andior systems in accordance with all applicable codes and ordinances. + To prevent serious burns, the boiler must be cooled to 80°F (27°C) and the pressure must be 0 psi (0 bar) before servicing. * To provent electrical shock, turn off the electrical power before making electrical connections. > This low water cut-off must be Installed in series with all other limit and operating controls instalted on the holler, After installation, check for proper operation of all of the limit and operating controls, before leaving the site. + We recommend that secondary (redundant) Low Water Cut-Off controls be Installed on all steam boilers with heat input greater than 400,000 BTUMour or operating above 15 psi of steam prossure. At least two controls should be connected in serles with the burner control circuit to provide safety redundancy protection should the boller experience a low water condition. Moreover, at each annual outage, the low water cut-offs should be dismantled, inspected, cleaned, and checked for proper calibration and performance, + To prevent serious personal injury from steam blow down, connect a drain pipe to the control ‘opening to avoid exposure to steatn discharge, + To prevent a fire, do not use this low water cut-off to switch currents over 7.48, 1/3 Hp at 120 VAC of 3,7, 1/3 Hp at 240 VAC, unless a starter or relay is used in conjunction with It. Falfure to follow this warning could cause property damage, personat injury or death,OPERATION Maximum Pressure: 150 psi (10.6 kafem?} Electrical Ratings Tee DIFFERENTIAL earn) BuRNER oN —t sumer - ATCASTUNE maKeon ES Ful Rag pee] Tarn Gea tg aor asp Voltave | FultLoad | Locked Rotor | Pilot Duty _ Voltage | Aris Vaitaye Hp 120 VAG. T4 464 345 VA at 420 VAC. i 420. VAC 18 nage [37 m2 | wor edovec| © ame fae wove [8 Enclosure rating: NEMA 1 General Purpose Settings and Differential Pressures Values are +" (3.2mm). Series 1505, 1575 Model 4508-M0, and 157S-MD Tana 7 ippoaae Distance Above: Distance Above et Lie | Dieta ast Line | Dien Pressure | Setting in. (mm) | tm (ram) Pressure | Setting in (mm) | in. (mm) | [Pumeot | He aa) | y, ‘Ops: | Pumpot | Ke G4 8) Ste (16) iy [une on | Fe te is @) (oky [Pome on | Se ta (6) fm) [Buneron| Se 0 la, ap em?) [Bumer oi 0 (0) WA Burner Gi | Vs (6a) “a0 pst [Fumo oH | WEG Loy 99) Pump Ott 5 {10.5 ko/ {Pump on | whe (17) Ye (19) aay | Bue a om?) | Bumer of | -ae (16) | WA me) | Bummer On | 2) Toe pay Buiner OF] 8) 150 psi (10.5 kglem?) Levels 150 psi (10.5 kg/cm?) Levels 78" ae ON eenm prtentna, ume | (46m) ena Pump eal agers eh, ae ot ca se ug ye soon oF Sen oper 2g" (9.5mm) BELOW oe me rect Cio ue oe repel aR faa aneoret— - reSettings and Differential Pressures (continued) Values are & {6" (3.2mm). Model 1585 Modo! 1585-MD Approximate Distance Above ee Castine] Ovforental ast Line | Diterntia Pressure | Soting | tn. (eum) | fn, (mm) Pressure | Seting | tn. (oam)_| In. (mm) Motorized | Tie (28) Vawtoned Osi | Fumpos | Tit 26s 46) Ost boned Seay (@ko/ [Pump On| hw (14) (okay | J em?) Paumeror | 0 | WA Gime) | Yate Onan - auneron |% iy ga ‘0 psi [Pump [He GT a0 Siero Pee (10 3r[Fumn on { ioe | He oy Sumer of [a8 coo) [WA Valve Glosed 150 pst He 159) Wotorwed | 8s (76) 10.5 ky fem?) Lovel (108. on 450 psi (10.5 kglom?) Lovels tuner On| We (2)! he" i 2 frumror poo | ont, moroazen| NORMAL BUER 450 psi (105 kglom4) Levels et HERE || sumer ,— -- DPEERENTIAL nn or” t SuNER CUTOFF LeveL" 3h. (oars) BOW caste ue seen money ue vat DFE motorizen {amr ‘ae | choseo —t wororses NOTE: Due to the slower operation of some wee motorized valves, compiete valve opening or closing will occur at slightly different WF levels than indicated above DIFFERENTIAL ean) puRNERON —_ aumER OF — 7 eich Sarr eye Arcam ne NOTE: Due to the slower operation of some motorized valves, complete valve opening cor closing will occur at slightly different levels than indicated above,Settings and Differential Pressures (continued) Values are + %" (3.2mm). Model 1595 oprxinaio stance Above Cast Line | Differential Pressuro | Setting ja, (mm) | to. (oun) | (Pome off rs en) by | See em) [Pan F208] Sea) y Furpazont ta ea? Pump #1 Off] 12/8 (44) 4 450 pst Fee i Bal Fe ae (18) (10.5 ko) ° cm?) 6 7 eB] men 150 psi (10.5 kg/em2) Levels “36 orion. ae rue | NSE = PEER pues | Ope i ON Susea2 ov AT CAST UNEINSTALLATION _ _ TOOLS NEEDED: IMPORTANT: Follow the boiler manufacturer's Two (2) pipe wrenches, one {1) fathead screw instructions along with all applicable codes and driver, snd pipe sealing compound. ordinances for piping, blow down valve and water gauge glass requirements. STEP 1 - Determine the Elevation at Which the Low Water Cut-Off/Pump Controller Must be Installed If the control will be the primary low water fuel cut-off, size the steam (top) and water (bottom) equalizing pipe lengths so that the horizontal cast line on the bocy is 196" (35mm) below the boller’s normal ‘water level, but not lower than the lowest, stroman safe permissible water level, as deter- === mined by the boller manufacturer. west OR If the control will be the secondary low water fuel cutoff, size the steam (top) and water (bottom) equalizing pipe lengths so that the horizontal cast ine on the body is at or above, the lowest, safe permissible water level, as determined by the boiler manufacturer. meror r STEP 2 - Installing the Low Water Cut-Off a. Using a pipe wrench, unscrew the plastic float blocking plug (A) from the low water cutoff body (8), Series 1808 Models 1505-8 Sories 1875 (except Mode! 1508-8): b. For Model 150S-B and Series 1575 (For all other models, proceed to Step 3) Screw the %” NPT ste! plug (C) (provided) in tapping (A). A CAUTION Models 1505-6 ‘Series 157S “The plug must be reinstalled before control is shipped installed on the boifer, and removed ‘when boller is installed after shipment. Fallure to follow this caution may damage float and operating mechanism. ¢. Mount and pipe the low water cut-off (D) on a vertical equalizing pipe (E) at the required elevation level, as determined in Step 1 Install a ull ported blow down valve (G) directly below the lower cross of the water equalizing pipe (F) Note: 1" NPT tappings are provided, with ‘the exception of some 157 and 1575 models which are 14" NPT. 2, Install a water column (H) (not included with product) forall models except Series 1575 (with integral water column). bs Install a water gauge glass (J). Note: Gauge glass and tr-cooks not included with product,STEP 4 - Electrical Wiring ‘AA WARNING VAG, unloss a starter of relay is used in conjunction with ft. the site. holler system, property damage, personat injury or death. ‘Switch Operation Taprenta fe date tip peut ac euro rar T AAT ipa TAG oA pa AMY | - Teper ocr im fe sees power ba mag oct omectone «Bik news sacanant op tars inean ai ater inst apratcComrl aad on he Heatran eet eminence barat tent hee op « Mgdteton of sch ase beter ser ntl con cme deg alr enor Failure to follow this warning could cause electrical shock, an explosion andor a fire, which could result in For all Models except 1588 and 1598 Boiler feed pump of, burner on, alarm off oo O58 | a Boiler feed pump on, burner on, alarm off. @5S Boiler feed pump on, burner off, alarm on. Qe For Mode! 1588 Motorized valve closed, bumer on, alarm off Motorized valve open, burner on, alarm off, Motorized valve open, burner off, alarm on. ©Qe O56 [529 5S 53 G3|| 53 GS For Model 159S Pump #4 off, Pump #1 on, Pump #1 on, pump #2 off. pump #2 off pump #2 on BG 8 a. Using a fathead screwdriver, remove the Junction box cover (K). Pe ifp, Following the appropriate wiring diagram, (refer mm to page 9) based on your application require- IMPORTANT. There must be ments, and using BX armored cable or Thinwelt a minimum space of 1/2" electrical metal tubing connector fittings, make (enm) pee connector ‘lecirical connections to the junction box (L). metal parts. lectrical live ‘Snap Switches (Sories 1508 and 1578) Automatic Reset Automatic Reset {All models except 1588 and 1598) Model 1585 Automatic Reset Model 159 : Manual Reset Manual Reset {All models except 1588) Model 158S-MWIRING DIAGRAMS For Motorized Valves, refer to the valve manufacturer's wiring instructions. Low Water Cut-Off Only }1. Main Line Switch - For burner circuits within the switch’s electrical rating, $2 288 Reto oR 2. Pilot Switch - To holding coil of a starter when the bumer circuit exceeds the switch's electrical rating one LOAD Pump Control Onty 1, Install a starter or retay in pump contro! circult, as shown, to prevent damage to snap switch and help insure proper switeh/control operation. NOTE: For Model 1596, use terminals 6 and 6 from starter or relay for pump # 2. 1, Main Line Switch - For burner circuits within the switch’s electrical rating, ‘SEE PUMP Sie, ig ae rt oo o o TO NEUTRAL eT TONE ‘TO BURNER CONTROL CIRCUIT Combination Pump Control, Low Water Cut-Off and Alarm Failure to do 80 may shorten the life of the une switch when actual amperage exceeds _— - switoh rating [i i 2. Connect wires from holding coil of pump starter or relay to terminals 1 and 2 as shown, 29 988) g | — tone NOTE: To help insure most affective operation, balance baller feed pump(s) to deliver required wator feeder rate to match bolle steaming requirements. Alarm Cirouit Only [1 Low Water Alarm 2. High Water Alarm AR oR NEUTRAL ner 23 288 2, Pilot Switch - To holding coll of @ starter when the burner circult exceeds the switch’s electrical rating, SEE PUMP panne Lise @ PAS CONTROL, ‘ » se 388 b6. Re-altach the junction box cover (K). i Note: Cover must be installed correctly as shown STEP 5 -Testing This control is factory calibrated for specific applications, The following testing procedure Is only meant to serve as a verification of proper operating sequience. Dimensions provided are typical for a boiler not being fired and/or not at pressure. Actual operating anges are shown on page 2 in the “Operation” section, IMPORTANT: Follow the boiler manufacturer's start-up and operating instructions along with all applicable codes and ordinances. Note: Water fevels stated below are only for 150 psi (10.5 kg/cm?) operation a, Turn on the electric power to the boiler. With the boiler empty the pump should go on and the burner must remain off, A WARNING ‘Wthe burner comes on, immediately turn the boiler off and make the necessary corrections, 72, | Feilure to follow this warning could cause an explosion or fie anc Lil, | 18% ropery damage, personal injury oF death bb. The boiler should begin to fil with water, Watch the gauge glass (J) unti the water | evel reaches approximately 74” (22mm) above the horizontal cast line (M) on the low water cutoff IMPORTANT: if water dogs not start filing the boiler, immediately turn off the the boller and make the necessary corrections, 0. For automatic reset models only. When the water ‘Snap Switch Models teval reaches approximately 7” (22mm) above the horizontal cast line (lower for MD models) the burner (> should come on (pump #2 should shut off with Se Model 189) @—! oR For manual reset models only. When the water level reaches approximately 74° (22mm) above the horizontal cast line pros the reset button (N). The burner should then come on, d. Continue watching the gauge glass (J) to see that the water continues to rise to approximately 196" (85mm) {4#/te" (37mm) for MD models) above the horizontal cast line (M). The pump should shut off (tho ‘motorized valve should close with Models 28 158 and 1585, or with Models 159 and (am) 159, pump #1 should shut off ee A CAUTION |_| To prevent serious personal injury from steam pipe blow down, connect a pipe to avoid exposure to igc| steam discharge, Fallure to follow this caution could cause personal injury e. Blow down the control when the water in the boiler i at its normal level and the bumer is on. Follow Blow Down Procedure found in Maintenance Section on the last page of these instructions. INSTALLATION COMPLETE7 MAINTENANCE SCHEDULE: Blow down control as follows when boiler Is in operation. + Daily if operating pressure is above 15 psi. + Weekly if operating pressure is below 15 psi. NOTE. BLOW DOWN PROCEDURE: ACAUTION “To prevent serious porsonal injury from steam pipe blow down, connect a draln pipe to te , antral opening fo avold exposure to steam tlischarge. Failure to follow this caution could cause personal injury. More frequent blow-down may be necessary due to dirty boiler water andlor local codes. + Remove head assembly and inspect water side components annually, Replace head assembly if any of the intemal components are worn, corroded or damaged of if contrel no longer operates properly. + Inspect the float chamber and equalizing piping anfually. Remove all sediment and debris. NOTE The cleaned more frequently on systems where there is the potential of excessive scale or sludge build-up. This includes systems: * With high raw water make-up + With no condensate return + With untreated boiler water + Where significant changes have been made to the boiler-water chemical treatment process + With oil in the boiler water jrol may need to be Inspected and | Replace head mechanism every § years. More frequont replacement may be required when severe conditions exist. Replacement parts are available from your local authorized McDonnell & Miller Distributor. ‘The use of parts or components other than those manufactured by McDonnell & Millor will void all ‘warranties and may affect the units compliance with listings ar rogulating agencies. {00% Aas Ae ah ser a66s70 _ TOV fe ear sons Crowes ‘When blowing down a control at pressure, the blow down valves should be opened slowly. The piping needs to be warmed up and stagnant water in the drain piping needs to be pushed out. Suddenly ‘opening a blow down valve causes steam to condense, which can create water hammer. Damage to components can occur when water hammer occurs due to improper blow down piping. For these reasons, McDonnell & Miller recommends a dual valve blow-down system for each control, Blow down the control when the water in the boller is at its normal level and the burner is on. NOTE: Refer to page 2 for switch operating points. + Open upper vatve (#1) + Slowly open the lower valve (#2) + Water in the sight glass should lower. + As the water in the sight glass lowers, the pump shiould turn on. + As the water continues to lowor in the sight lass, the burner should tum off, + Slowly close the tower valve (#2). + Close the upper valve (#1) «The water level In the sight glass should riso, frst fuming an the bumer and then tuming off the pump, NOTE: On manuel reset models, the resot button will naed to be prossed after the water Jevel has been restored before the bumer will operate, - NOTE 7 if this sequence of operatlon does not occur a8 described, immediately close al the valves, tum off the bollor and correct the problem. Inspectionéleaning of the float mechanism may be required to determine why the control was not working propery. Retest the control after the problem hes been identified and corrected, i‘ int in Sa. 1008. 210384Series 750 Low Water cutorr ‘@-@- <> For Use With with Remote Sensors I T T McDonnell & Miller Installation & Maintenance Instructions MM-213(G) = Primary conductance type control for commercial or industrial hot water boilers where remote level sensing is required. ~ Secondary control for commercial or industrial steam boilers. 4 WARNING + Before using product, read and understand instructions. + Save these instructions for future reference. + All work must be performed by qualified personnel trained in the proper application, installation, and maintenance of plumbing and electrical equipment andior systems In accordance with all applicable codes and ordinances. + Boller manufacturer schematics should always be followed, In the event that the boiler manufacturer's schematic does not exist, or Is not available from the boiler manufacturer, refer to the schematics provided In this document. + To prevent serious burns, allow the control and surrounding equipment to coo! to 80°F (27°C) and allow pressure to release to 0 psi (0 bar) before servicing, + To prevent an electrfeal fire or equipment damage, electrical wiring insulation must have a rating of 167°F (75°C) ifthe liquid's temperature exceeds 180°F (82°C). + This low water cut-off must be installed in series with all other limit and operating controls Installed on the boller. After installation, check for proper operation of all the limit and. operating controls, before leaving the site, + When using mixed voltages, do not jumper from terminal 1 to terminal 3. + To prevent electrocution, when the olectricat power ts connected te the control, do not touch the termainals, oF eieetrical wires. “To prevent electrical shock, tum off the electrical power before making electrical connections. Failure to follow this waming could cause property damage, personal injury or death.SPECIFICATIONS ons The Series 750 control box connected to a vmaete 8 open remote sensor provides protection against tow wa TD stee Series water conditions for commercial and industrial \. applications. The Series 750 controt box is fully CSD-1 compliant and can be used as the primary LWCO on hot water botlers and as the secondary LWCO (manual reset) on steam boilers. Automatic Reset Models SD-1 Code Compliance Whenever water is below the lovel of the probe, the On Manual Reset units, if the control is in a low control will go into a tow water condition. When the water condition (water off probe) when there is an water level has been restored, the control will auto- interruption of power, the control will remain in a low ‘matically return to a run condition. water condition when power is restored. The reset ‘bution will need to be pressed when the water level Manual Reset Models ig restored to a level above the probe, fa low water condition occurs (water off probe), the manual reset button must be pressed once the water lovel is restored to a level above the probe, Control Unit Temperature Ratings: Storage: ~40°F to 185°F (-40°C to 57°C) Ambient: 92°F to 135°F (0°C to 87°C) Humidity: 85% (non-condensing) Electrical Enclosure Rating: NENA 1 General Purpose Electrical Specifications is is agp TOW aac | amnaannt Zee Tae | atzoe Hz: 50/60 Control Power Consumption: 3 VA (max.) Probe Sensitivity: 20,000 ohm (water/glycot mixtures up to 50% concentration may be used)STEP 1 - Where to Install the Remote Sensors Determine where to install the remote sensor based on the following requirements: a. The tip of the probe or xtension must be installed ag = above the minimum safe zn water level, as determined by the boiler manufacturer. b. Probes must be installed ver- tically if they are more than 5" (427mm) long, ¢. There must be a minimum 1/4" (6.4mm) clearance between the probe and any grounding IMPORTANT: Remote sensors MUST surface inside the boiler. ‘bo installed in a tapping on the boiler. Table 2. Remote Sensors ‘Sensor Boiler] Sensor | Sensor Pressure | Sensor Temp, Catalog No. |PartNo.| Tapping _| Housing Rating (psig) Rating °F RSALP [176203 [34° NPT [NEMA 4 [760 (water\/18 (steam) 250° RSA-BR4"| 179524 | 1"NPT | NEMA4X| 250 (water & steam) 406° * Requires probe extension (See table 3) REMOTE SENSORS jions* PEAR Re1aRY Table 3. Stainless Steel Probe Extensions’ teacher st barca cr Catalog No. | Part No.|Length, inches| 189 Fes HotWater, Mex) Hot Water, Max) RS-13-88 176208 | 4-1/2 PS--8S 179530, 2 G-2-8S 4179156 24 G-3-SS 479157 36 *To be used with remote sensor (RS-1-BR-1) mounted in vertical position only. stale iss sree BROBE EXTENSION (GSI THROUGH 834STEP 2 - Installing the Remote Sensor For the Model RS-1-BR-1 sensors, only: a. Cut the probe to desired length, Screw, clock- wise, the threaded stainless steel probe exter sion (A) into the remote sensar (B). Carefully tighten the locking nut fo approximately 1 feb (1.7 Nem), Do not cut the clear plastic protece tive tube. For All Remote Sensors b. Apply a small amount of pipe dope to the first threads (L) of the remote sensor. IMPORTANT: Do not use Teflon? tape or thread 1 sealant. 6. Insert the remote sensor {B) inte the boiler tapping (M) as determined in Step 1 ernest (Sth Mranicnm 4. Using the adjustable wrench (N), tighten the brass hex adapter (P) on the remote sensor {B) to approximately 63 ftlb (85 Nem). DO NOT TIGHTEN BY TURNING THE SENSOR HOUSING. a. Retnove the sensor housing cover (9). 1. For Model RS-1-BR-1, using a flathead screwdriver (R), remove the four (4) screws and separate the housing cover (Q) from the { sensor (B). 2. For Model RS-1-LP, using a fathead sorew- diver or nut diver (R), loosen the two (2) screws and separate the housig cover {Q) from the sensor (B), Model RS-4-BR-1 Model RS-1-4LPSTEP 3 - installing the Control Box + Mount Control Box in a suitable location near ae sat the boiler's main electrical panel. NOTE [When installed as secondary LINGO on steam bolt Jers, the boller sight glass must be visible from the location of the control box Using the flatblade screwdriver or nut driver (C), loosen the two (2) screws (D) and remove cover (E), b. Using the four (4) 3/16" (4.8mm) mounting holes (F), attach the control (G)to the boiler Jacket, entry plate, or other suitable location NOTE: Mounting hardware is not inclucied Bi ©. Install an electrical conduit (H) to the conduit knockouts (J). Wite-ways should be able to i accomodate the 120VAC supply eireutt, the remote probe circuit, alarm feeder oirculf, and burner circuit NOTE Refer to ahd follow local codes and standards ‘when selecting condutt and electrical fittings. Wires from Probe Housing and Control Box must be In their own condult. If they are run in conduit with other wires, there may be interference that Can affect the performance of the contr. + Install electrical conduit between Probe Housing and Control Box. NOTE. Wire musi be 18 AWG stranded with giase bralded| silicone jacket (UL 3074) suitable for high temper ature (200°C) service. NOTE, Refer t and follow local codes and standards ‘when seiocting condult and electrical fittings. Wires from Probe Housing and Control Box must ‘bein their own condult, they are run in conduit ‘with other wires, thore may be interference that can affect the performance of the contrSTEP 4 - Electrical Wiring A WARNING 4& IMPORTANT To proven elactcal fre or equipment damage, | |”aoller manufacturer schomatles should akvays be followed clectscal waning rust have arating of 167°F || In the ovent thatthe boller manufacturer's schematic does (75°C) if the liquid’'s temperature exceeds: not exist, or Is not available from the boiter manufacturer, 180°F (82°C), refer to the schematics provided in this document Falluro to follow this warning could cause property damage, personal injury or death NOTE Probe wires should be minimum 18 ANG stiandod| with glass braided Silicone Jacket (UL 3071) suit- able for high temporature (200°C) service. Wiring Diagram Legends 1. Bold lines indicate action to be taken in Step shown. 2. Dotted black lines indicate internat wiring, Remote Sensor Wiring: + Connect wire from probe and to Terminal + Connect wire from remote sensor green ground screw fo chassis green ground screw Control Wiring: Same voltage for control and burner circuit + Connect hot wire to terminal 1 + Connect neutral wire to terminal 2 + Connect jumper wire from Terminal 1 to Yerminal 3 i + Connect wire from beginning of Bummer circuft rf (thermostat, gas vaive, limits, ate.) o terminal 8 + Connect wire from end of Burner circuit to terminal 2 Control Wiring: Different voltage for control and burner circuit + Connect hot wire to terminal 1 + Connect neutral wire to terminal 2 + Locate Boller Burner Safety Circuit and connect wires to Terminals 3 & & a8 shown to interrupt circuitSTEP 5 - Testing and Diagnostic Procedures Series 750 LWCO with Green Power On LED and Red Low Water LED Start-Up 4, Before filling the system, turn on the electric power to the boler, 2 ag 1. Upon initial power up, the Green and Red lights will flash arco 0 tb siroultaneously 4 times. mw ape fees 2. The Green and Red lights will urn "ON". 3, The burner wil never turn “ON” during power up, If water is off the probe, 1 b. Now fill the boiler with water. os {auto reset units only) Ta 1. When water touches the probe, the Green fight will remain "ON" i 2. The Red light wil tum "OFF" and the burner will tun “ON" as fong ‘as there is water on the probe. {manual reset units onty) (Wan water returns fo the probe, nothing will happen unti the manual reset button Is depressed.) 1. After depressing manual reset button, the Green and Red! lights will fash simultaneously 4 times, 2. Then the Green light will tum *ON" and the Red tight will turn" OFF”. 3. The burner will tun"ON" as long as there is water in the probe. Manually Testing Control ¢. Slowly drain the boiter of water. (both auto and manual reset units) 1. When the water drops off the probe, the Green light will romain” ON” 2. The Red light will turn "ON" andthe burner will turn "OFF", if water is off the probe. ‘Testing Control Using “Test Button” 4d. Depressing the test button with “water on probe” (auto reset units only): (Must depress and hold fest button to activate test cyde ) 1. When test cycle is activated the Red and Green lights will flash simultaneously 3 times, 2, The Red light will turn "ON" 3. The burner will tun"OFF* 4, The Green light will continue flashing as long as the test button is depressed (Release test button, if water is stil on probe. ) 5, The Green lights will stop flashing and turn "ON", 6. Then Red light will tunOFF*. 7. The burner will tun" ON" as long as there is water in the probe. ¢. Depressing the test button with “water on probe” (manual resets units only): (lust depress and hold test button to activate test cycle. } 1. When test cycle is activated the Red and Green lights will flash simultaneously 3 times. 2. The Red light wil turn ON’ 3. The burner wit tum" OFF". 4, The Greon light will continue flashing as long as the test button is depressed. (Release test button, You must depress the manual reset button to unlock the low water cutoff) 5. After depressing manual reset button, the Green and Red lights will flash simultaneously 4 tmes. 6 Then the Green light will turn ON" and the Red light wilt tusn’ OFF”, 7, The burner will tn" ON" as long as there is water in the probe. f. Depressing the test button with “water off probe” (both auto and manual reset units): (Since contro! is in Yow water” the Green light will flash and the Red light will remahn"ON", The burner will omain"OFF* CSD-1 Compliance (On manual Reset units, ifthe control is in a jow water condition (water off probe) when there is an inter- ruption of power, the control will remain in a low water condition when power is restored. The reset button wil need to be pressed when the water level is restored to a level above the probe.ITT McDonnell & Miller If control fails to operate, perform the following diagnostic checks. 1. Check to be sure the water level in the boiler is at or above the level of the probe. 2, Re-check all wiring to ensure proper connections as specified in boiler manufacturers wiring diagrams or these instructions. 3, Check to ensure that Toflon® tape has not been used on the threaded connection of the electrode to the boiler. 4, Re-check the electrical ground connection for the remote sensor and control unit, 5. Check the qualliy of the holler water to ensure adequate conductance. MAINTENANCE SCHEDULE: + Inspect probe annually or more frequently for scale build-up and clean or replace if necessary. ‘Make certaln there is no scale or build-up on the probe or t's white Tefion® insulator, Be careful not to damage the Teflon® insulator. + Test the low water cut-off annually or more frequently, if required by code. A CAUTION Replace Probe + Tefion@ insulator is cracked or wom, + Probe Is toose. Failure to followthis caution could cause property damage, personal injury or death, + Replace probe every 10 years. More frequent replacement of the probe is required if it's used in locales ‘where significant water treatment is required, or in applications with high make-up water requirements + Replace the low water cut-off every 15 years. NOTE lean probe by wipina with non-abrasive Goth and rinsing with clean water. DO NOT tse sharp instruments to remove any accumulations of rust or scale £20017 comrortion Prine S810 750290 1220001 ast Ae eran Grove, 69053 tak Bersear00 town ncsonnatecomKUNKLE Features + Osing seats avalible fo xcopiona take free perenne, recused materanes Cen mug cjclee ws sto, imprest bina. + Wide hex on valve nozalo xcs vrorching servi erence fr ees instalation ‘ul conto rings otter exoy _achustal ity for proceo opening wit, ‘anim prsopan Sioa xt Spoon sna + Plvot between se and spring corects mBatgimert and eorpentes fe xm sce rust + Grooved piston modet dite resuoes $Sing ores and ton Model Descriptions ‘Model 6810: So ovo. Fus nazie design ‘tn branzetraas ten Avalon ih Ong Soate For ersnationa inakitoe pocermarcn, Mors! 621: Same as Model 8010 wth “eflonn (PFA es nga For excepto ‘Rallies partrmanco fuse a slaar Oo Mode! $080: Same se Model 2010 oxoael SS thm fezale ane ea) Avoese wth Sieg sete for exoopboral oak toe pevtmanee dio! 6182: Yop eutot Ful nazz design ‘hin bronaafaas im. C-ing seat eval {or excepto ask oe porormanes, ode! 6121: Same os Mode! 6182 wlth “elon (PEA) cles naort For exzopor| nofsak porormance (uss on seam or) Model 6130: Sere as Mode! 8182 exaspt SS {in (p01 and dss), Oving coat walle ‘er excoptana lank ea parermanes Model 6186: Top outst, Fu nezalo design Win eonaforae tm 450 pig (#0. bar] maximum st pressure, Replacos Model & (Gxigial equpment oy). Model €283: Oveesiod ede outlet Ful ogala design bronznfrasa tm, Mosel 6221: Same a8 Modo! 6283 wits Toton® (PAR) disc inser For skcaptora Isakthoe porormaren ua on sie ty) Model 6250: Same 28 Modo 6289 cot SS im (nezze ana de), Model 6993: Sore a8 Mode! 6970 except ‘celles ir ASME cae Socton 1. om Dressicestaen heating bolle vt a 18 psig Fo barg ont Moret 8934: Same as Medel 2025 axcart ‘erie or ASME code Seston V.Loor respite staom hsaliag bales stot 1S pla Froborg ony. tyce / Flow Controt Total Fiow Control Solutions ™ Series 6900 ASME Section | and Vill, Steam, ‘V’ and ‘UV’, ASME Section Vill, AirfGas ‘UV' National Board Certified. Models 6933, 6934, and 6935 are ASME Section IV, ‘Steam’, ‘HV’ National Board Certified. PED Certified for Non-Hazerdous Gas. LL Model 6928 Same as Mosel 8940 axcapt ‘intGas Sorvice ‘ililed or ASME cada Secton W. Low ‘310 300 psig (0210 20.7 bon) pressure sioom heating bots se at Spsig——“AUrIO DEE [S110 208°C) Eobsrs} oni. Models 6030, 6130, 6250 Steam and AifGas Servieo Applications “Sto'300 pag (02 16 20.7 bara] + Siosm Boles ond Generators, Seo WoaloF PSI io 2eC) + AkiGas Composter -recipoestng or Scr An pee sees cere reet-conngsean ar? Rlrienedeitensy orm ‘or non-hazardous. gas. Including tanks, (ove page 14) LORRSETUEEET maw ene monk oe + Prossuse Recuchg Stations - grotection Font se Nemours Comps Sereeteao cis soar gees lant nar» at pte Pressure aod Tomperstre mite SS Reh Sra Yrimecnigaesieeantet GICTRytee ‘3 to 280 palg [0.2 10 17.2 bara) product names or trademarks belly fa Hye ro hoiters. 50" 405° 51” to 208°C}ee uel italiane acs Series 6000 Parts and Materiais 8 Models 6010, 6030, 6283, 6230, 6932, 6935 Models 6121, 6221, 6934 Teflon® Seat Configuration Models 6010, 6030, 6283, 6230, 6933, 6935, Optionat Soft Seat Models 6182, 6121, 6190, 6186 ‘Top Outlot Configurationeet earan Series 6000 Materials ‘BRS 8285-C48500 fr D Orica? BRE 6062 Ethel.) Ono Sess es Brags 896 SO SOAs vee rz abee-caatno Brass B16 AOR FRAN a” [BRS 8176 Aoy 2008 BRS BIE! ozs ate BRS BG ier and Eolas PLY RZ B784-C24400 fe Fou J Oia eee Novos 63 ot, 552 na 694, SSisn Sata Caeser omes Semen oe! 2. Seton en 5. Mate S500, 6190, 6290 and 6935 ae Beenisrcrs, 4 Mou 6950, 6130, 628 and 68 ae Be ara.ode (tir Ontos or SS Barons. Oreo). cele 6020, 6130 and £220 we SS Beira casSeries 6000 Series 6000 and Models 6932-6935 ASME Section | and Vill, Steam, ASME Section VIll, AlriGas National Board Certified. Motels 6932-6935 are ASME Section IV, ‘Steam; National Board Certified Model ‘Connections Numbort ANS! Standard in fmm) Inet ‘Outlet a 8 frum] in (en) ve 27) a 9g} ae a EROS Bae THM ie 27) Gils SCO: e618) eae F ve 6 a S80 6 i Bs one : s # # 2H SR BS: Rte BHO) SoA 1 Sea Ta one 2 ee Herne oI He P6B? oie oe su “ai ee si 1 Royce ate th dened ose numb ebloe deste seat 2, Mod 609 valet ony ee TES ana ncn 832m, Weise Bd edie tice Ween Pilz oe etna et me nits 54 2 Mosel 6993, 6994 an 605 hae eae Uinenssne est otaHESS eee 1 cae ap or Non ramepice bat pmo Series 6000 Capacities Fe eueistilas grille x (0263) {1.444) eee 358 ‘i 1588 ‘a ee am 90) 4238 oe “ait sor ar sais a0 ast aris. 082 eSSeries 6000 Capacities eae ee F fo.701) [1394] _ 12.180) 1352 ogg. 1622 188 yeu. 220 ee 20388178 we soar cera 703 1623 sous Reese ya anon{1 No cine stamp or ‘Boagoat Pie erence Cure Series 6000 Capacitios Set Pressure | (psig) D E e 6 H 4 (azn (0210) ar “68 B seo rare at a7 152 ere 08 sr pias se uae 8 6 ST ta Sas! 42 oe asia cae m8: ‘ar Tora ao “073 SsteA 8305) wrap asia wo TO 11489 apr ogni moos Tet tas90. ‘Sigg 7 basa 2 fou ayaa eee 5 ssie 15709 gaan 2 Cyne oa ome toe 37118 aaah Sotaoerg Ce rar $3908 18823 sits ‘aeore aT0# 12188 gases poset a8, ston ass HP eo gabe erate ia aaa?Series 6000 Capacities 28 563028 ae eee sm 8 TA aa 1854 ie 07 ee ‘509 oe 1871 ae Sse yo 258 ‘2500 goes 5082 Seg oe “68 gps 1085, Hoo! 1125 sua 5050 ‘87 : f aor ie Ram 2 gaan: ioe zoe oN). 82S nae Syriana Sate osSy es Series 6000 Capacities Ee ‘Set Pressure (esio) ° E é 6 # 3 (0.4121) (0.216) (0.338) __(0.554) (0.883) _ (1.414) 73 783 “08 AERO 204) oa “aia 270. preen eeR 200 72518619 a0 ee ae 00 49mg aon ta6t8Series 6000 Capacities 4 d 5.507) 19423} 165 ie HRY 867 930 sesh oR TIGA: red 26f8 Sud aaa BOATS mae 8217 ease a8 Models 6933-8935 ASME Section IV, Low Pressure Steam, ‘HV’ National Board Certified psig) Tag] 0.121 0216 0.338 lezen 11388 fet 130 388 ss HO (0) SayPeers Series 6000 Specifications ASME Section [ and Vill, Steam, ASME Section Vil, Air/Gas National Board Certified. Models 6930, 6933, 6935 ASME Section IV, National Board Certified Intet Size Gesblech [F27] G=1Nsined 8.5] Boveinch [180] H-2nch [50 Es taneh (254) J 2frneh 535 FiWeineh (31.8) ‘Seat Material Mt = Maia £- ePR = Mone Variation (01 through 99) 31- Pai over 0B. Plan fever beatin dampen (03 Path lever wth 295, 50- BSP Thresas Design Revision mS Indeate nen inrchangeckleravaton. Dash Wee dln. | Valve Service ‘A Steam ASME Sexton | K Anas ASME Section Vil LL Steam ASME Saxton VIL 1G Stoam ASME Socio I (Models 6983, 0084, 6035 only) P - Stam Noncode Ni Nenad ‘Spring Material M=8s Set Pressure (015-15 pg [1.0 bag) ony for Medes 6953, 8034, 6985,Series 6000 Facility Phone: 828-669-3700 Tyco Valves & Controls wvackunklevalve com “Sapp cna rasa Peta Fa heel hwo mormiin pt honghalarte seam BE ap ng avast uum nS pean mee GReaaote Grae tet recs aan enact rl sarc aeasies oCerstamotin cer neta ck ctea clon muecae ve ie Scene es Se SEN SI MORES Te SE Eran te orcs wo NEST Panes ren Sar Siypane Rercenerae 115D SERIES GAUGE These 4%”, 6” & 8 %2” gauges have been designed and built primarily for the industrial market, They are well suited for ail applications where bronze tube and socket are suitable for use. Some typical applications are; air, water, gas, oil and steam” ("a pigtail / siphon should always be used when putting any gauge into steam service) STANDARD FEATURES « Heavy Duty Black Steel Case (Epoxy Coated For Rust And Corrosion Resistance) * Plastic Lens* (To Resist Breakage) (Glass on 8 "Dial Size) * +/-1% Full Scale Accuracy (ANSI Grade A) * Single Scale PS! only Standard (Dual Scale Available upon request) + Removable Back Flange (For More Diversity From Stock) Part Number Wajor ] Minor ayn er 8%" RANGE. inc_| ine || Note: TiSD-464A | 71SDROAR—[TISD-B64K [SONG VAC |“ spq | 2h | Tisbasecd | risb.a0400 | Tieb-esdcd_| 30030 | best] Tesi] All typical accessory type TISDABACE | MIBBADICE | Fiebseace | s0u/t0g | 1oPSI_| 1 PSh it fh TiSb-a54cF | TBOSOACF | 1 f80-854cF ‘sor0/igo [25 PSI_| 25 PS) items such as gauge Fisbasas | Vteb.soa | Veb-aseb OAS cock’s, pigtail/siphons, isoaeiG—[Tigb-s0e6 | Viso-a5aC ‘a6 5PS_|_ TPS asikisab | isb-abas | Tisp-seat eo [ors rpsi-]) Snubbers, needle valves Teaasie | Tiepame — [iene aioe} iors TPs] | or diaphragm seals can TieasdF [Tibor o aba (7166-20 PSi_|2 Psi pages viebsoaG 10a Sae——Larect per) be provided with gauges Tiss | 60-600 | 1180.864H 77300 SOPSI_[ SPSL upon request. “rppasak— Vis0-50eK | T1S0.854K 01600 feo PST [70 PSI 4%” Dial size 8 A"Dial size Jn. MN aor | 126 [695 [151 | 856 | 216 [sar 18 [eer | tre sar | 140 | 742" | 188 are | 12 | eat | ts 1.40" ES 161" | 41 xe [a7] 40" | a7 we) 45) ee oni) oye} > Page 46‘See PED etaternent below {ion not inca, ‘The Union Insert (UY) valve isthe threaded pipe counterpart of the Flange Insert Valve, Designed to be inserted into rast standard ground Joint unions, t provides the simplest and most eaonornical vay to install a check valve in a threaded pipe system. A check valve may be installed anywhere in the system where tere is a union, The valve works equally well in sither @ horizontal or vertical position with proper spring selection, Each Union Insert valve Is furnished with @ metal tay, ‘hich is quickly attached te the union when the valve is installed. This provides a permanent visual notitication thatthe union contains a check valve, NOTE: Bore of union must be equal to .D. of schedule 40 pipe. Use ground joint unions with 45° seat only (union not included. PED Conformance Statement: Due to the unique design of the Union Insert Vaiva, this serias is not considered a pressure vossel but rather a gasket. According to PED Guideline 1/8, gaskets are not governed by the Pressure Equipment Directive, As a resull, the UIV series is available for sale in the European Community and no CE Mark is required. ‘allay Non-Shack Prassure-Tamperature Rating == 3000 PSIG @ 100° {£500 PSIG for ocng seats) Senstantaed | Sart acoy far ese other materiale ‘®See page Bator material grade information. CHECK-ALL YALVE MIF, CO, Phone: 518-224-2901 Fang 815-224-2826 26Union Insert Valve For Water at 72°F Note: Al fow curves and Gy vluas posume the valves aa fully opan with V2 PSL cracking pressure springs. Consul the fctry for more information, [TCU Gy VALUES & VALVE WEIGHTS SE ALL MATL x oer a “Gier t Te be Ta Bos ae E308 z rE See page 48 for Flow Forauiae Valve weights are eppreximate, PRESSURE OROP- PSI VfrER FLOWRATE < HOW TO ORDER CHECK-ALL STYLE UV (UIV) “yiDwe See. Tope in ne 16%. 125 PS! anal ommended or installations With low ve ® Seat materials other than metal-to-metal Nave'8aximant pressure rating of 1500 P' TEE seals are tot 86 40 ot allowable leakage rales : lwwrezeheckall.com sales@checkall.com 1S0 9001-2000 CERTIFIED 2008, 27UNITED BRASS WORKS, INC. 714 S. Main St., Randleman, NC 27317 Tel: 800-334-3035 Fax: 800-498-4696 www.ubw.com Model 425 Quick Opening Blow-Off Valve Class 300 * ANSI B 16.34 * 650 psi Working Steam Pressure @ 500 F 750 psi @ 100 F * 100% Pressure Tested * Threaded Ends * Epoxy Coated (E-Coat) Max Pressure for Boiler Blow Off 490 PSI per Sec. 1 Table A-361 CRN 0CO7135.2, 24, 25, 26 CRN QEO2171.7, 79, 70, 78, TAY, 71, 7N ‘The United Brass quick opening boiler blow off valse hus been designed for the ragged service of boiler treatment and scale. The cast siee! knife gate valve conforms to Class 300 of ANSI B16.34 snd features a stainless steel seat and disc hardened to Rockwell 60, ASME Boiler and Pressure Vessel Code Section 1 PG- 2.4.12 and Power Piping Code ASME B 31,1 Table 126.1 reference steel valves to ANSI B 1634, The sliding dise provides 2 “cleaning” action that keeps the seating area clear of scale and debris, DESCRIPTION MATERIAL Body, Sieal AIG WCE [Gover Steel A216 WOO ‘Gasket “Tanged Graphite 17-7 Stainless Steal Sed Ale WCC 410 Stainless Seat Ste Rive Cabo Stsi Ste Spring 177 Stainless Sih Packing Grp {Packing Nat 410 Stainless Steet Handle @ TU) Ductile ron (Per) tS Fin Pied Sel Body Bolle Steel Grades Tex Nuts | ‘Name Pat Stinkss Set__| Drive Serews Suns Se Sze] i x S20 | oso pb [s2 | 52 | sa | ios0 © [iso | ioe | aes0 | tenn D wo | @ | @ | Few | [ow | aw | ean Weise | ao ao | 300 | wooUNITED BRASS WORKS, INC. | @ 714 S. Main St. Randleman, N.C. 27317 an Tel: 800-334-3035 Fax: 800-498-4696 www.ubw.com Model 325U “Y” Blow-Off Valve Complies with MSS-SP-80-2013 CRN 0C07135.2 Class 300 + Non-Shock Service 100% Pressure Tested + Threaded Ends | Rising Stem + Swivel Dise Holder Seat & Disc 400-500 Brinnell Stainless Steel ‘Max Pressure 390 PSI @ 500° F + Max Pressure for Boiler Blow-Off 312 PSI “Contains Lead. Not Intended for Use in Potable Water Systems* Care must be take tn Bas dows piping so that no water Bammer effect ‘causes shock tthe" blow down valve, expecially in cases where a boiler “as two blow-down lines. In xch cases both lines should he piped to @ common set of blaw dawn valves or each blow off line should be pived separately tothe blow down separator. Excessive water hammer or Shack ‘ean stray valves an piping and could coese injury. (0. | DESCRIPTION i Tam at | : Hand SEE | 4 Packing Nut . Ss Packing Gland . | 6 Packing 7a Bonnet 8 "Bonner Nut 9 Tosk Ne Base 19 Disc Stainless Sed ~h Body Bronze 2 Seat Biatles Sea Te PE TEP] ‘ as S56 | gas [778 co Ba [00 Tas (Ship Wi. tbs.) 475. 6.25 8.60 | 15.11 Qy.Uereck [ 4 [4 | 2 | 2L404F,T,V PressureTrol” Control APPLICATION L404F PressureTiof® Controliers provide operating contol ‘with automatic imi protection for pressure systems of up to 2070 KPS, oF 300 pai. LADAT.V PressureTrol? Controllers are for ase on oll bums systems for aressures up fo 1035 kPa or 150 psi Honeywell lers FEATURES + Models available in a series of control ranges, and pressure scales in KPa and psi, + All models automaticaly reset and have an adjustable differential + Models have snap switch to open or close a circult on a pressure rs + Case has a cloar piastic cover se sotpoints can be observed. + 414 inch—18 NPT connection for pipe on diaphragm assembly. + Ground serew terminal. LaoaF: + Coptrotfers may be used with steam, ait, or noncombustibie gases, oF fluids noncorrosive to the prosoure sensing element. Laoat: + High pressure iimits, Break a citculton oll pressure ‘ise above setpoint Levey: ‘makes a elrcuit on oll pressure Contents ‘Application Features Specifications Ordering information RSRIABON seer Seitings and Adjus ChockoutLAg4E.1.V PRESSURETROL® CONTROLLERS SPECIFICATIONS Model: LADAF.TY ProssureTio! Controllers, See Tabla 1 Table 1. Modets with KPa—psi. ‘Waximam Biaphragm Operating Ranges Subtractve iterentia® pressure Model Number | RPa eal az al we iaoarr0c0 SOT ZT www Fee 7 ae TaGiFIO7e —_|Sbi0 360 Bios bw i060 500 5 iaoariows "fab 2075 Bem faves [aes (aA aa ADFT TOW IO fw oe mo ow Lapartaig? [810700 20% Fated [08 70 5 iLacarraaae [8810 350 Bes [Ow 100 Bete 1805 ioe Lage aay 70 098 THI wae a Lanariass [Ow 2070 fae aT SIE TORS sate Soe 4 Lega taoa® STS sete t80 aod aa Fied [1580 as oer _ [os Tt oo sae peso 25 (aoaeraaa ove 380 ons ow 100 [sie 0 as ae Bio ~~ row 130 Yibo 2 88 Eg Taare roe 2560 Toisas [tease pT 350 [L404F 1367 [7 to 85 te 5 0 14 [0.75 to 2 ie 25 iaoutio7e? 5810 380 Ey ido 100 ‘bio ta oe L404 3837 TO to 1038 110 t0 180, \70 t0 150 1010 22 1550 )226 Laowrroei a S70 Bois 300 fide eas ow fafa faoarta0a? [B10 Zoe isa Zi6 770 ig [bioari055”— fasv6 350 560 wise [pe 580 LACT OEE [70 fo 1035, 1 to 150 [7010 180, ite 7550 aoavi0a7® [70 to 1085 Ot 185 70 150 10 tn 22 7580 Ihaoav10989 ew 55 a0 1 ew 4 se * Nominal at midscate operating range. » Brags bollows instead of staniess stool dlaphagm. Models with 14-19 BSPT thread instead of 14-18 NPT thread. 8 Make-co-tise models wth terminal Boned for miswiring compliance, ORDERING INFORMATION When purchasing replacement and mademization prodats from your TRADELINE® wholesaler or distributor, refer to the TTRADELINE® Catalog or price shoots for complete ordering number. Ifyou have additonal questions, need further information, or would ks to comment on our products oF services, please waite or phone: “Your local Honeyarel Automation and Control Products Sales Office (check wile pages of your phone dizectory) 2 Honeywell Customer Care 11805 Douglas Drive North Minneapolls, Minnesota 95422-4986 in Canada~Honeywelt Limfad/Honeywell Lintée, 36 Dynamic Drive, Toronto, Ontaio MAV AZ8. International Sales and Service Offces in al principal offse of te workd, Manufacturing in Austrade, Canada, Fitand, Franco, Germany, Japan, Mexico, Netheriands, Spain, Talwan, United Kingdom, U.S.A. rasp 2‘Table 2. Conversion Tabto, LA04R TV PRESSURETROL® CONTROLLERS. Pressure Sensing Eiement: Stainless steel diaphragm (140 {0 2070 kPa models) has brass ballows. Maximum Ambient Temperature: 85°C (150°F), Also, refer To note under Mounting, ‘Adjustmont Means: Screws ontop of contol case, Seales are ‘masked in psi oc KPa. ‘Mounting Means: 1/4 inch-18 NPT connection on dlaphragin ‘assembly; oF surface mounts using holes in back of case, Dimensions: See Fig, 1 —="Gperating Range Conversions ‘Subtractive Differential Conversions kgiom? | kPa Ps kgiem® kPa psi Des LICR Pay NTStoOF Teas Zoe oaieas fastoa50 Toto g0 (Gamo labo 106 aw 18 0.7 io 10.0 |70 to 1035 10 to 156) Ores [7ot0 166 [30 to 22 eae iow 20rd faove ao [iswas 160 19300 ite Table 9. Switch Ratings (Amperes), Switching Acton Snap sich breaks FEB closes RW) on Hae pressure is. Makara Govicas omit fetrinal Fravtoed a a GGrouncing Means: Ground sre terminal marked with a lloaed Ra a8 Soe sid ground symbol Accessories: ‘50024585-001 Brass Steam Trap, 14026 Steel Steam Trap. 118025 Stoa) Sipam Trap for BSPT Modls, 838128 Knurted Knob--fts on tap of adjusting sorews. 4120564 Range Stoo—rarge stop sorew, Part No, 107194, and ‘wrench, Part No, 28468, to limit setpoint range, Approvals: Underwriters Laboratori inc, Listed file no, MP466, vo. 10, ‘guide no. MBPR, Canadian Standard Association corlifd: fle no, L620, ‘guido no. 4008-0, 123019 ——~a] siecle a Fig 4, LA04R,T.V approximate dimenst INSTALLATION When Installing This Product... 4. Read these insisuctions careful. Fallure to follow them ‘could damage the product or cause @ hazardous ‘condivon. 2\ sro miesare wre sous coms cn, EAR VIEW fons in inches {milmeters in parentheses). 2. Gheck on the ratings given in the insructians and rmatkad on the product a make sure the products ‘suitable for your aplication. Installer muel bea trained, experienced service technician. ‘Aer instalation ts complete, check out the product ‘operation as provided in hase Instnuctions. ry2429-08LADAR TV PRESSURETROL® CONTROLLERS IMPORTANT When making pipe connections, use pips dope sparingly fo soa the joints: any excess dope may clog tho smal hole inthe fing and prevent the controler from operating property Location and Mounting (L404F) Locate the LAO4E whore tho ambient ternpersture wit not ‘exceed 66°C (180°F). The LA04F can be mounted near the prossute gauge, a @ remote location, ina fiting provided by tho boller manuiacturer, or in a spect mounting on tow wator Cuffs, The LADSE should always be mounted abovs the water ling in steam bolle appications. NOTE: Foraccutate opsraton, supplemental hast should be ‘added {0 installations wnere temperatures fa Delo 26 (20°F), 'A steam trap must be connected botween the L494F and the ‘boiler (see Fig. 2} f9 prevent boder scale and corrocive vapors fem attacking the elbows or diaphragm, oils ta| are pew cu. tanersxremna spenos Fig, 2, Steam trap mounting Pressure Gauge Mounting “To mount beside = pressure gauge, reve the gauge, and Inslat ins place he steam tap wit ates oa top. Mount the Pressuret:of unit and pressure gauge on the side of the tae by moans of nipples and elbows (ee Fig. 2) Paka ot ‘ Remote Mounting Exoacsve vibraion at ine boter may affect he operation ofthe AGAR, In these cases, the LAO4F should be reretely located, Subject to Be foloweng 4. All piping must be sulabic and property pitched te drat allcomiansation back te the bober, 2 Tho remote mounting musi be soi. 3 A.stzam trap must be used al one end ofthe piping Boiler Mounting IFits not eoavoniont fo mount the L404 adjacent to the pressure gaugp install a steam trap 2 the lation Focommonded by the toler manufacturer, fen sore the device dectly 0 he steam trap. Location and Mounting (L4047,V) Location NOTE: For most accurate operation, supplemental heat should be addod to nstabiatone wnere to temperature fall below 20°F (28°C). These ‘controllers ean bs mounted at any location in the oll supply Hine, depending an the application. Typieal locations are shown in Fig, 3. The low ol pressure controller should be located upstream trom the safety Shuto valve(6), ln @ dawnstrear locaton, there would be zero prassure when the burner [sot ‘nnn ar the safety ahutot valve(s)is are} closed, ‘This could prevent startup or require manual reset ‘everytime the bumer is started. The high oll pressure ‘oontlier should be located as near fo the burner as possible, Mounting Mount the ol pressure controler directly on the man pins. Inarta fee in tre pe Ene, and connect a pipe aippe of ‘ate size to tne to9 (600 Fig. 4), Sere the hexagonal fing [1418 NPT internat tvead) of the pressure contre to tha pioe nipple. To avoid leaks and damage to the case, uso 8 arate avr wtench on the hexagonal iting close tothe pipe Fipple. Bo not tightan the pressure controler by hand by hrlting the case, ‘Make all pipe connections In accordance with approved standards. Use only 2 stall amount of pipe compound to soal the connection joints Exeass pipe compound may clog the ‘orcs In the pipe fing and prevent tha controller from ‘operating propertyLAOGE.T,V PRESSURETROL® CONTROLLERS n “eit” nore Gl: etremine wecncine bessiee Mano, Bum feovemvsotu same areteey wou Fig. 3. Typical locations of pressure controllers in an oli burner system, : WIRING | ae Electrical Shock Hazard Sekexs Can enuse severe inry, dest or property damage ~ [Bisconneo! the power supply before beginning witing. voxocnas ’ ‘More than one power supply dssconnect may be | ae uf rexured. ermine Alig must comaly vith sopcabe codes and ednances " ‘All modats have terminals (on the MleroSuntch® snap-acting say Snitch) mie the cover ang knockouts for cord nd cate Ae, Rotor o menutacrer nealtion and wing hsttulons, avaiable, and lo spice hookups shown ln Fig. 8 10. ohn vk Fig, 4 Mounting an oll pressure controtlor directly on the main pipe, Using with Preheated Oil ‘When used with preheated of, a siphon loop must always bo ‘connected between the oontraer and the main pipe (620 Fig. 85) to provide thermal buffering estat Aggarggreoer evenooinont Avss ues siren cores on arson ase ete eae" sensory we Fig. 6. LA04F in ow voltage relay cieuit. A gresguamureramaamsge™ Fig. 5. Mounting ofa siphon loop, with approximate ‘dimensions In i nm). 5 Pipa| : LAGAF,T.W PRESSURETROL® CONTROLLERS A el os veut Avgorggegnner won monrorce Averemamemes cans en serst RGMEnts Morea SiBeMeD Fig, 7. LA04F Ina typleal 2-wira control circuit. = _ SSR fear | |salw =slw SHB B homirteD) 14047, Laoay eaySOn PRESCURE ers cree Fig. &. LAOAT.V terminal blocks and internal schematics, Beivcoh OF coin Fig, 9. Hookup of an oll prossure controller used om a ‘single burner system with an integral oil pump. vrzeca—oe ‘ oamessine umes.) uh Ee Eteuo tet ea zo C4 Fig, 10, Hookup of an off pressure controlier used on 3 sitigte bummer oF muitiburner systom with an external oii pump. SETTINGS AND ADJUSTMENTS When the pressure atthe contzol rises above the L408 setpoint, 9 circu pans between the RB terminals, During a pressure fl, RB wil lose at tne setpolnt pressure minus tke Sich atferontil For example, contrltr fs set to differential B (s00 Fig.11) with 2 contiallr srpoitof A, RB wil open when the pressure ‘ses 0.8. Then curing @ pressure fll, the B-B terminals wil ‘lose when the pressure drops to G {A minus diferent B. For make on Hse apptications, the switch is wired to RAW terminals, The FEW acu wil lose on pressure to the efpail. RW will opon again on a pressure drop past the sich differential [Elevates ccosee sir cenracrs cod Fig, 11, Operation of switch on pressure rise and fall Setpoint Adjustment “Tur the pressure adjusting ren on the fap ofthe conor {Fig 12) fo acjad te satpint Turn the dare acing Screw io the destod preseur diferanice between etch pering and suroh celng NOTE: When the main scale setting is al the fowor ond of the ‘operating range, the diferetial range wil be tess ‘han the difareriial eating by approximately 20 poroont.presse anne sexe Satie Be Fig. 12. view of L404 PressureTiol® Controfier. Scaleplate Adjustment “The LADEF,T.V has boon carefully calorated during ‘manufacture and sheuld not require recalibration, 4046 T,V PRESSURETROL® CONTROLLERS However, if recalibration is necessary, remove the cover and Joosen the satscrews which hold the scaleplate, Adjust he Baie up or dow, as required, o bing the device inio Callbzation. Tighten the setscrews securely and replace the CHECKOUT Aller the contcollor has been insaled, wized and adiusted, ‘should bo tested with the system in operation, Fre, alow the ‘systom to siabliza. Then, opsurve the operation ofthe controller whe raising and lowering its setpoint. Pressure should increase when the seipeint is raised and decrease When the setpoint is loweres. Also, check the make end break poinis ofthe controle. if they do nok agree wih a separate, accuralely caSraimd pressure ‘gauge, a sight adjustivet of the scaleplato(s) may be necessary, Use accurate prassure testing equipment when checking out the controler, Do not ealy on Inexpensive gauges. The ‘entrollers are carsfuly Calibrated at the factory restLOHR T,V PRESSURETROL® CONTROLLERS Automation and Control Solutions Honoywel International in, Honeywell Lirted-Honeywal Limitee 1985 Dougies Drive North 35 Dynamle rive Golden Valley, MN 56422 Toronto, Ontario M1V 423 castemer Roney com Honeywell U5 Regie Fc tas anon areal ne came car Peaaacoe Mis Re cr FestsL4079A,B,W PressureTrol” a ee eee APPLICATION ‘The L4079A 8, and W PressureTiof® Limit Controls are high pressure lit slices which break electri reals whos pressure rises 1 @ preset vate. ‘The L4O7@A and B oan be used with seam, at, noncombustibie gases, and fluids noncorosive io the sensing clement LAO7OW is for use on oll bumer systems, Honeywell Limit Control “FEATURES + L4079A has two ganged spst switchos; breaks two. Clreults (may be both sides of the power supply) simultaneously. + L4079B has ono spet ewtch. + L4O79W is the same as 140798, but with seats for oii applications, + MICRO SWITCH® snap-acting switches are visible through transparent cover. + Switches open automatically, but must be reset ranually. + Tiip-ree reget mechanisms do not pormitthe tinting role of the PressureTrol® Control to be defeated by jamming the reset lever. + Controt does not need leveling. + The L4079 is unaffected by moderate vibration. Contents Application Features .. Specifications Grdering information Installation wing Checkout i 2 2 3 3 4 ad140798,8 W PRESSURETROL® LIMIT CONTROL SPECIFICATIONS Modbls: Prossure an Sloctical Specifications: Gee Table 1 ‘Table 4. Prossure and Electrical Ratings. ~ “Maximum = Fiatings in Amperes Diaphragm —T Range Pressure | 120Vac 240 Vor —T" ‘Locked Locked Model Number | ps won| psi_| uea_| Futtoad | Rotor_| Fulltoad | Rotor laorented ESS Tsar se ee es me 4076 ws ssioa50 jesse _—iBB a aa 1Oro 180" jTO%e 103s {225 1560 188 4.9 ae Caoyeniaei [Boe 00 aoe BOT a) paaio” (8 ae aa [aorontooo® 0730 ows eS Es TRB ae ae Ratings apy to enoh of wo soparie aus © One elroult anly Suithing Action: Dimensions: See Fi. 1. iZo79A Snap stitch, Breaks two dou automaticaly on Dressute re, Each cout mus ba manual reso. : se . 140798,W—Snap-swiich. Breaks one circuit automatically on i te " pressure rise. Circull must be manually resel. yp arsre “ Adjustment means: Exeral aghstent sore. Seats vel TT] calibrated in psi and KPa, i th, Maximum Ambiont Temperature: 150°F (65°C), ‘Mounting Means: Pipe filing 14-18 NPT, Connection on diaphragm assembly ‘These devices may be elt baller mounted drecty t0 bailar fiting, or may be surface maurted, such as on a wall, by using the Knockouts in the case, Approval: Tees Prev torres ve (UL Used Fle No. MPA, vac ‘Guide No, MBPR. 7 woes cansuian Sonar Assocvton (5A Fe No, LROS229, ‘ ctrl Limit Conte reste 720880 Fig. 1. L40708.8,W Prossureio Limit Conte Recessories: ‘50024585-001 Brass Steam Trap. 44028 Stoel Steam Trap. 393128 Koutied adjustment knob, ORDERING INFORMATION When purchasing replacement and maderization products from your TRADELINE® wholessier or distibutor, refer to the ‘TRADELINE® Caialog of price sheets for complete ordering number, Ifyou have additional questions, need further information, oF would ike to comment on our producls or servoes, pl phone: +) Your lal Honeywell Automation and Contrel Preducts Sales Otic (check vite pages of your phone directory), 2, Honeywell Cusiomer Care 485 Douglas Drive Nort Minneapolis, Minnesota 55422-4986 tn Canada-Honeywoll Limled/Honeywell Limitée, 35 Dynamic Drive, Toronto, Ontario MIV 4Z8. Intemational Sales and Service Offces In al principal cies of tho world. Manufacturing in Ausiralia, Canada, Finland, France, ‘Germany, Japan, Mexico, Netherlands, Spain, Taven, United Kingdom, U.S.A. ase write oF eo 2t6t os 2INSTALLATION When Installing This Product... ‘Read these instructions carofuly. Falla to follow them ‘could damage the product or cause a hazardous ‘condiion. 2, Check on the ratings given in the inssuctions and ‘marked on the produc! to make sure the produc is ‘suitable for your application. 3. Inslatler must be a trained, experienced service technic, 4, After lnstalation ie completa, chack out the preduet oper alin as provided in these instructions. Location PressureTrol™ Limit Contolless must be mounted above the ‘water lina in steam oles. They can be mounted alongside the pressure gauge, ata remote location in fting provided by the bollor manufacturer, or in spacial mountings on lowewoter cutots, Mounting See Fi, 1 or mounting dimensions ‘A stoam trap ust always be connected between the PreseureTrol® unit and the bovar, The steam tap prevents boiler scale and corosive vapors from attacking the diaphragm. Pressure Gauge Mounting: ‘To mount the limit contro! beside a pressure gauge, remove the gauge and instal nice asa rap wth ate ofp. fount tho Pressure Tra unt and pressure gauge on the ide ofthe ee by means of nipples and abows Remote Mounting: Ifexcessive vibration seems ike o affect the operation ofthe conto, may be located remctely, as ong as 38 piping is ‘suite and property ptched to drain ail condensation back to ‘he bol Boiler Mounting: if Ris not convenient to mount the conta! acento the preesuto gauge, instal a steam trap at locaton an the boler Tecommened by he bor manvfactuet end screw the unk ‘Steal tothe star ap, WIRING AXWARNING Electrical Shock Hazard. ‘Can cause severe injury, death or property damage, isconnec the power supply before beginning wiring, ‘wre tian one power supply disconect may be roguiked. ‘Allyeing must comply with local codes and ordinances. See Fig. 2 for internat schematics and ving 140794 BW PRESSURETROL® LIMIT CONTROL 9 ° TeERMOSTAT Fig, 2. Schematics and wiring. L4079A broaks both sides of power supply; L40798,W breaks hot side only. Setting ‘Toset the control, tm the pressure adjusting scrow (see Fi. 3} unl the pressure sating Indicate on the front of he caps is ‘nline with the requted contol pressure setpoint, The Indicator setting isthe porn al which the svtch breaks contact rreace Ba ! at F.3.Cotls an inet on LATO, L479. ‘same except for having only one reset button. soz168-08| LAOTOA,BW PRESSURETROL® LIMIP CONTROL Manual Resetting ‘hon tho Greats have broken atormabety, they must be Tanbaly set. fer te pressure returns to noma, analy {Deut daprossing the race eee outon() frm and ‘Glooea. the reat snot compat unl tp rasa ton is {blessed The ebvtes mana Tost mochanom prover he lrnt conte om operating as an automate conor (ol Touolieg oven f the anual eset tion hes baen Yo! down Automation and Control Solutions Honeywell ternational Ine +1985 Dougias Drive North Golden Valley, MN $5422 customer honeywel.com 35 Dynamic Drive US. Ragileed atoms ‘Toronto, Ontaria MAY 4Z9 CHECKOUT [Alter the conto! hes been installed and wired, ‘ost 2s follows) Note the boiler pressure by checking the boiler pressure ‘gauge (toler pressura should be near the mig ofthe Pressure Tro! pressure sosie fo perform this test propery) Rotate the PressureTio® prosauroadjuning sor (668 Fla Shunt the pressure sting cater on ho fet ot ho case hrrespond fo the ber presse gauge raging “The limit eonirol should braak tho contol cruit(s) when the boiler pressure gauge reading equals or sighily exceeds the PressuroTro!™ prasture seling. Ire limit conto ie oparating propery, manually reset i anc adjust the pracsure adjusting Sorow unk the pressure setting ineator isin ine with the required hii stot. Honepwall Limited: Honoywo Limite Honeywell (©2007 Honeywc iserrional no, @ Pag sre So eased M8 Rac O507 (eeewerbmeritanHoneywell L91A,B,D Proportioning Pressuretrol’ Controllers APPLICATION 91 Preporioning Pressurtr!® Contre aro Saios 80 Madulatng Prossuro Controle that proviee ditect contol of modulating motors or valves used on automatic burners or ‘steer heating systems, ee ‘TDAIN FEATURES + Models available for pressure systems up to 300 pst (2068 4a). + May be used with steam, air, noncombustible gases, oF ‘other fluids noncorrosive to brass or phos-bronze (300 sl model) beilows, + When used with stoam boilers, a stoam trap (siphon loop) is recommended. + Wiper on controller potentiometer moves In response to pressure changes. + LO1D has two potentiometers for unison control of two motors. + L818,0 models have adjustable proportioning {hrotting) range to allow selection of desired rossurw control rang + Adjustments made with screws on case top. + Large, easlly-ead scale piates in both US. customary {o2isa, in, pst, or in. Ha) and metric (kPa, MPa, or mm Hg) uns. + Steel case with clear plastic coverto observe pressure ‘settings and potentiometer action. + Futing with 1/4 18 NPT threads aliows rapid Installation, + Surface mount with screws through knockout holes in case back. Contents. ‘Application Features... Specifications Critng information Wiking “ Checkout Service Information TmL944,8,0 PROPORTIONING PRESSURETROL® CONTROLLERS SPECIFICATIONS __Table 4. Modets Avaliable - T ~ asian Sarge Proportoning (Throtting) Range at Mdseate Pressure potentiometer ‘custonary Model] “Units” | metic units | PartNo? | Adjustabie| —Unils. | Metric Unite | psl_| kPa Toa Diep ow Tae _[astreoR No sepa isawaze {172 Sto 150 pal [O08 9 108 MPa\zaITECR Soa ies “0 to 300 ps? (00716207 MPajzsi7éce 2 par i2a03 [BiB [Dt We oslsann. [Oi 7 kPa zatreck ives 2 to $8 ozleg in. {0.8 to 164 KPa at [oto 4 pat “lasiecr Yes “|S to 38 ozisgin. [2210 16.4 KPe | lat [Oto 15 ps i25376F ives iSite ips (1010 BS kPa i io Tao Seka S8I7eC [Yes «(Ste SZ pa [Sato Z2t KPA (5 | ds ie Los Pa[sai76C8 Yes Sto psi_—(s8ts TeOKPa_[zas [7557 Sowa pit ODT OROTMPA|zgT7008 Vee ——«iA to aS para SAT RFA aT G10 500 pai (07 to BOF MP a,23176Cr i St Tiopa [aT CENA ars jiSth owe iS psi lot 10a kPa (23 78CF ves (Stci2psi iOmeakPa ie] Si too pa [008t0 10S Pa lzarTGcr Nes SW EE pal [oa OSE NPa|oas [SST ho oto pst orto Za7Ma[zaTTeOF Vee bie Tiga zt wUTEHIS S50. ® Soalepates aro marked tn both customary (az/e3 in, pst, erin. Hg) and metic (KPa, MPa, oF mm Hg) units > Length af active winding Is 7/64 in. (2.8 men) for pari no. 231T6CB, and 1/4 In (6.4 om) for pat no. 28176CF. © Model avatable wih 1M In, BSP-TR interral threads (Brlish Standard Pipe Threads) for mounting. Models (Table 4): Lota: Singla potontiometer, nonadiustable proportioning range 91: Single potonlometer: adjustable proportioning range. LO2D: Twe potentiometers allow unison contol of motors, ‘adjustable prapartoning range. Elootrical Rating: 24 Vac, Potentiometer Action: Wiper moves toward W on pressure lea, fawatd B on pressure fal. Potentiometer Feld replaceable. Potentiometer Resistance: 140 ohms (norninal) for L91A, 8, ‘and B mode's. ORDERING INFORMATION Pressure Sensing Element: Brass bellows, 10-300 psf mod ‘els phos bronze bellows. Mintmum Amblont Temperature: 32° F (0° C) Maximum Ambient Temperature: 150" F (8° C) ‘Adjustment Means: Sorows on controler casa top; knurled ‘knot for maln soalo setting on 10 10 300 psi (0.07 to 2.07 MPa) models. ‘Setpoint: Atlow prossure end of proportioning (throtting) range. ‘When purchasing replacement and mosemizatin preduets from your TRADELINE® wholesaler or distil, refer to the ‘TRADELINE® Catalog or price sheels for complete ordering number, It you have addtional questions, need further information, or would ike to carnment on aur products er services, plese writ OF phone: "Your local Honeywell Automation and Conta! Products Sales Olle (check while gages of your shone directory. 2. Honeywell Customer Care 4855 Dovalas Dive Nort Minneapolts, Minnesota 55422-4385 In Canada—Honeywel LimitedtoneyrlLimitbe, 38 Dynamic Drive, Toronto, Ontario MY 4z8. Intemational Seles and Sendee Ofiezs tn al princlal cles of the wold. Manufacturing in Australia, Canada, Finland, Frence, Getmany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A eozsee6‘Main Scaloplate: Marked in bath US. customary (aztsq, in, i o in. Hg) and metric (KPa, MPa, or mm Hg) units, Proportioning Range Scaleplate (L918, only}: Graduated fom Ato F with 2 MIN (imu) valve below A (See ‘Table 2 forthe value of wach division.) Mounting Means: Fitiog on belloves hae 1/4 - 18 NPT throes {extemal on Oto 16 ozs. ina 0 14 pei, and Oto 15 5 ‘modes; Intamat onal tier models) for mounting on 3 pipe tor steam trap (siphon loop). NOTE: Some models are avaiable wilh 1(4~ 19 BSP-TR Internal threads; see Table 1 ‘Algo can be surface reunted by stews through two knockout holes in case back, Electical Connections: internal screw terminals. Hole in side ‘of ease for U2 in, cond, Dimensions: See Fig, 1: see Fig. ? for mounting steam trap {eiphion loon) ‘Table 2. Approximate value of each divi {throtting) range ses L91A,5,0 PROPORTIONING PRESSURETROL® CONTROLLERS. ‘Woight: 1 f, 15 02 (0.88 kg). Finish: Gray. Replacement Parts 429178 Thermoplastic Cover. 2317608 Potenllomalar: For all LEIA magals and a few L918 sods (soe Tabi 1). 140 ohuns (noména)), ength of active winging is 7/64 In. 2.8 nu). 23176CF Poleniiomoter. For al LOtD models and most LStB models (see Table 1); 140 chime (nominaly length of active Winding s 14 in. (64 sn). Accessories: '50024585-001 Steam Trap (siphon leon 1/4 In. brass pipe with 14-18 NPY extomal threads aa both ends 14026 Steam Tiep (spon loop): 144 in, steel pipe wih 124 ~18 [NPT external threass on both ends. 333128 Knurled Adjustment Knob: With setsorew fs on rain ‘scale prossure adjusting sorow. 49748 Limit Siop Assombly: To lit satpolnt ranges: Includes 129684 Range Siop 107734 Range Stop Screw, ‘and 25486 Wrench, ion (A to B, B to G, ete.) on proportioning leplate (LO1B,D.F only) ing Range Value of Each Division ~ GS Gistommary | US. Customary Units Mobic Units Units Metre Units Do Warkgin eT WS Brora ETP [Ot 8 pat Tie ose [a pa Bawa [20 50 psi ~ fide Babe LAT pal 22 ePa [510 180 pal 97) ~ (Ons 103M Fees [O04 MPa 5 150 pal (TO) Sas o TOS MPa BF pa rooae MPa FO 6 300 pel (L910 wh TA a poten our 267 Bia | Ta pl Taro MB 0 t0 300 pal L7E,0 with 116i, poteniomaior) [6.07% 207 MPa [134 [BOBS Ba| | | | 1914.8, PROPORTIONING PRESSURETROL® CONTROLLERS somaya so |-——— sme ps} —————r} [a8 eet a laces rote An |heon AY cot sone es = capil | ero mare SHY EY vrowren] ' cor A ee | Ln aigkx [om 4 por amaance Le cus on! AS persue esos 1970 wane NDOT 18PEI MECH MTTABVE NAICS CN ALOTHER ERMA ELE Sie Wes aad aman afi unis cersrenmusie veapoe se oe 2S mrorormermsvaene soneme sean onirsp nos Ct AN ssc gure am oust sone 7208 P22 MM METER NES LOE HTH BTS ADE ATO HHH MEE ne 2S rom soca pr ro20r sr wes oe ONCE THe AEED MORES enone ats ee ae aa Te ea eee te a eee a ore Fig. 1. Mounting dimensions of the L91 Proportional Pressuretrof® Controllers, in in. (mm). ‘When Installing This Product... 1. Rea these instrucions carefully. Fallue to fotow them, ‘auld damage the product or cause a hazardous canditon. ‘Check the ratings given inthe insiructions and on the product lo make sure the products suitable for your ‘application. 3. Insaler must be a trained, experienced service technician. ‘ter intaiation s complete, chock out product opera- tion as provided in these instructions. so 2ss208 4 AX WARNING Eloctrical Shock Hazard. Can cause severe injury, death or property damage. 1 Disconnect power supply before begining instalation fo provent electrical shock and ‘equipment darnage, 2, Whan using te controller with @ compressor, instal a dampening device (such a5 8 needa valve, Feader or surge tank) to dampen pulsations that car damage the controler or reduce ts Is,sMPORTANT 1. Locate the controller where the amblent temperature ‘wil nol exceed 160° F (66° C) 2. When the contllor i used on a boiler to sure fo connect a sleam trap (shan ioop) betweon the com lroler and the boiler, afore instaling control, be sure tee siphon fooe has enough water info fil lower tsp. Use pine compound sparingly 0 avotd clogging the hole the pipe or bole fting. ‘De noi ighten the controler by hand by fokting onto Ihe ease and turning Location and Mounting When ubed with steam notes, eways mount the contrttor bee the water Sins nthe Bode. steam tap siphon oop) ‘rust alvays Be connected between the contraller andthe ‘alier (Fig. 2) 0 prevent baler scate ans corosive vepors from afacking the bellows. Before stalng controler, be Sure the Siphon loop hee enough weter nfo fi loner Bop. ‘The comtrofor can be mounted (1) beside the proseure gauge, (2) a fing on the bot provided by the manufactures, or (3) at a remote location incase of excessive vibration. Make alt pipe connections in accordance wha approved slandards. Use only a smail amount of pipe compound to seal the connection jini, Excess pipe compound may clog the ‘inal hoe in the fiting and prevent te contol from ‘operating property. “To avoid laaks and damage io the case, use a paral! jaw ‘wench on the control fiting. Do not tighten the conto¥er by hand by holding onto the case and turing it L914,8,0 PROPORTIONING PRESSURETROL® CONTROLLERS 4 pose “L sre rear AN ein rero| ‘eisiontooe etter A spose tetas A. mraeamsose te ae ees Pacaa siete datas She Pegiasraseseneaics, Fig, 2. Approximate dimensions in in. (mm) for mounting 1L84 Pressuretrol” Controller beside Pressure Gauge ort ‘Steam Trap (Siphon Loop) Mounting Beside a Pressure Gauge ‘To mount the controller beside @ pressure gauge (Fig. 2), retrove the gauge. ni paca, sta loam ¥ap (siohon Toop) wa tu ontop Using elbows and pipe nopples, mount the controler and pressure gauge onto ends ofthe to, Mounting on a Boiler {FIs not convenient to mount the conboier beside the pressure gauge, insta a steam trap (siphor loop) in the iting provided byte boler manufacturer. If tere is no fing, unt {he steam trap ala location recommended bythe bolet ‘rulacksror, Serow fe contol duoc tothe steam rap, F possible, Mounting at a Remote Location {Tthare is excosslve vibration atthe boll that may adversely atest the operation of the centre mount the controler et & remote cation. All piping from the boiler must be suitable and ‘solidly mountod. The pining smust be property pitched to drain Silcondensation back othe bole. tls causos the cortrafor to be located at an inconvenient haight (on large Bolts), ‘may be mounted at a lower level he connecting piping filed with clean water. A steam trap {siphon loop) must be ‘mounted between the remate piping and the controler,L914.8,0 PROPORTIONING PRESSURETROL® CONTROLLERS pene ek ‘mosrrareroneen Ay reissues Fig. 2.191 terminal blocks and internal schematics. WIRING ‘1 Disconnect power supply before beginning instalation to provent electic shock and equipment damage. Al wiring ‘ust comply with applicable electrical coves, ond ances, and regulations. Use NEC Claes 1 (ine voltage) wing, 2. For normal instatition, use moisture resistant No. 14 ‘wire suitable for at least 167°F (75°C) you are using ‘the contotor with 2 lame safeguard primery conical, or at east 194°F (20°C) if you are using twit a program ning contro 3 For high temperature instalatons, use rotsture-sesis- lant No, 14 wire, selected fora temperature ring above the maximum oporating temperature. A. Dieconnect the power supply before baginnlag wiring to prevent electrical shock and equipment damage. 6, All mode's have a termina: lock inside the cover (Fig. 3) and two 18 in. (22.2 msm) holes In one side for 12 In. andi, cable, oF wires, Remove th front cover by loos fring the serew atthe Bottom of tho scaloptate, a zis0—06 6 6. Refer to Fig, for typical hookup. W and B connections. ‘may po interchanged atthe motor for reverse action {coating}. Follow the burner or boiler manufacturer's wit- Ing diagrarnif provided. Also refer to the witing diagrams Inthe motor Instruction. 7. Replace tho front cover when wing i competed, vero E 4. rmcrromonret || A, snasamasee DS sowpnaipre,rsowpe osvorwcs ao 20 Sarat racic che wont & Fig. 4 Hookup of L 91 Proportioning Pressurctrol® Controller to Sories 90 Modulating Motor. Setting Inall modes, te propiening range ato ced tng range) tends above the man aon seipint ig. 5. The provortonig ranges faee on La redol tata Enters seca Por valu, erm Tbe nthe Spectcatons secon} ‘Main Seale Set Point (All models) Adjust te main scale setpoint fr the desired operating prassure by turing the main scale adjusting sctew (Fig. 7) oF Knurled adjustment xn on 10 to 200 pal (0.07 o 2.07 MPa) models, on the tap of the case, until the main scale soting Indicator Isat tne minimum pressure desir. The proportioning range extends above this value. The ecaleplate fs marked in both customary (o2/sq in. pl on. Ha) and metic (kPa, MPa, ce mira Hp) units, Use of 1.91 Proportioning Controller with Limit Controllers The LO? main scale setpoint plus the vous of te dierent {proportioning range) rust bo legs tan or equa fo the linat ‘sontrallers (L404) main scale setpoint For example, to control sysiam pressure between 70 and 80 pat seledd an LO1B, 6-550 psi operating range, adjustable ‘iferental (proportioning, tailing range} of 60.25 ps and an LAD2A, 10-150 ps, adjustable dferontal of 8 fo 16 ps. Set the LAD4A main scale seipent at 80 psi and is adlusiable ciiferential at 109s, The L4044 sebings wilthen provide boier Dressute fit control between 70 and 80 psi. AN LOTS {iferentil(propomioning range} pressure ofS pais desired ‘Therefore, an L91B main scale setpoint of between 79 and 75 pal fe required (L91 main soale setpoint plus is diferentiah [uel be lass than oF equal fe the ln contoler main scale setpoint). The LO1E seftings provide system modulation between 70 and 75 psi ot betwean 75 and 80 pel depending on the ‘exact setling of the LO1B main scale saipoint, Due te devies iolorances, the scaleplato settings are approximate and, therefore, the setings should be fineuned ‘wih the systam operating Proportioning Range (L91B,D Only) ‘Adjust he proportioning range (thvwitling range} by turing the proportcning range adjusting sorew (Fig. 6) onthe top ofthe ane unt he proporioning Tange seting indicators al tne Gesired value. The oroportioning range scales graduated from ‘Ato F witha MIN (meumum) value below A, The value of each Givisicn depends on the operating range of ine conte. Refer to Table 2 inthe Specticatione section, Typical Operation Proveure vito css te bolows to expand or contrac Linkage eter the Below nnd he potenkometer wie Causoe te wine o move across the potetereter windings. ‘Tis varios tne resatance between and Bano between and W. cueing an unbalance tine eeu connect fo ihe center See Pa 7 : ea “ egos | A @t Srommnn oven! A see i a JX mesoniainansenaronnen A, sores Ho roTe TERS PWINOHONEH. son Fig. 5. 918,B,0 operating points L9TA.B,D PROPORTIONING PRESSURETROL® CONTROLLERS: Resa Somer MeO, Reeoowsy Appemumumsmoreom Fig. 6. Setting 191 Proportioning Pressuretol® Controller ‘A proportioning contrloris used most often to regula the ‘rng rato of a bumer by controling a modulating motor (Fi. 4) ‘9 & modulating vaive. The controler potentiometer, fe eocback potentiometer in the motor (rin the vahe actuator, and a balancing relay in the motor (or actor} form an elect bridge creut. As long as the prassure ofthe consoled medium ‘somains af the setpoint ofthe console, the citeuitis balanced, that's, qual the olay contacts are open. When the cic ‘oalanced, the motar for actuator) does nol run. Ifthe pressure ofthe mecium rises, the skier inthe contrellar moves foward W, This unbalancos the orout, 30 a larger ‘current flaws through ono side ofthe balancing relay. Tho oso contacts in the retay make, causing the moter far valve acluator) io dive toward its closod position, As the motor for aciustos) runs, the wiper on the feedback potentiometer moves: Ina ditection fo balance the circuit When the ecu is again in| balance, the balancing elay contacts open and the motor (oF actuator) stops. The vaves and dampers connected to the motor or actustor vl be pertally closed, decreasing the fring Fale and reducing the pressure, Simlaty, ithe presaure ofthe controled medium fal, the ‘wiper en the controler potentiometer moves toward 5, and the ‘pen contacts inthe balancing celay make. Tho metor (or actuator} drives loward its opon poston until cuit balance is achieved. The vaives and dampers wil be opened wider and the fring sale wil inorease, thus increasing the pressure. AA small change inthe pressure ofthe controlled medium wat ‘cause a change inthe fag rate to companeale for i hus keeping the prescure conetanl, This process is called rmedulation,L91A,B.2 PROPORTIONING PRESSURETROL® CONTROLLERS CHECKOUT ‘After the contro is lnstallad, wired, and sof it should be tested with the systom in operation. Fist, alow the system to sSabilze, Than, abserve the operation of the controller wile Taising and lowering fs selgoin. Prossure shoud increase ‘when the setpoint is raised and docrease witen the setpoint is Tpwored. Use accurate pressure tasting equipment wien checking out the console. Do not rely on inexpensive gauges. “The contrafers are carefully calibrated af the factory. Make ura the modulating motor or modulating vaive actuator Teaches the lon and high-fe positions at tre proper points. the mato: or actuator cune in the proper direction whan the selpoint is adjusted, assume thatthe controler Is operating propery Iitruns in the wrong direction, coverse the B and W Tries, Observe the action ofthe motor er actuator unlit Stablizes. I the motor or valve is moving constant, wien the proportioning range (not adjustable on an LA) Incrementaliy Uni the system is stable fa Controller Seems to Operate Improperly If the contr is suspected of operating lmpraparty, it may’ be further checked by: 4, Leaving the eontolle instaied where itis, ut discon- necting all goner tothe conteolar motor or valve. 2. Leasening the cover serew below the main scalepiate and removing the cover 3, Disconneeting the wires fram the controller. 4 Connecting an ohmmeter between controller terminals & ‘and W to measure the resistance forthe potentiometer in the contoler The ohinmeter should read about 195 ohms for an {STA.B, of B. 5. Connecting the ahmmeter between contioller tonminals Wand R (Fig. 8) and raising the setpoint of the controler above the actual pressure being measured, The chmme- tr should 7oad th full value of Se potenometer moa- sured in stop (195 obme for an LETA., oF D. 6 Slowly bwering the setpoint ofthe controler white ‘observing the chmmoler reading. The rosistance should dap to zero at some setpoint boiow the actual pressure. 7. Making an approximation ofthe proporioning range by observing the chang in seipoint required for a resis- tance change itom zero to fl vale. 8, When the contaller is operating property, reconnecting the wires, replacing the cover, tightening tne cover ‘sorb, als song the controler io the dested valve, 9, Recornecting power tothe controled metar or valve sozssa-08 e Sedoun A. ggconuenennenroxoriner zon, Ay remus sscviomp A, neomson sasons, wees Fig. 7. Checking L81 Proportioning Pressuretrot” Controller AX CAUTION Equipmont Damage Hazard Failure (o follow checkout instructions can damage components or systems. ‘Ba net put the system into service unt you havo ‘satisfactory completed a applicable tests described in this Checkolt section ell tests tthe Checkout section Cf he applicable instructions, al tess forthe fame safeguard contel, and any tests required by the bumer and baler manufacturers,1914,8,D PROPORTIONING PRESSURETROL® CONTROLLERS SERVICE INFORMATION AS CAUTION Electrical Shock Hazard 4. Only quaifiod service tochnicians should attorp to ‘srvea or repalr lame safaguard controls and bumer systems, 2, Disconnect power supply before cleaning the potentiometer windings or wiper, or before replacing {he controll potentiometer, Calibration A controls ate carefully tested and calionated atthe factory Under controled conditions. I the actual operating pressure ‘does not match the setpoirl, move the main sealopate slightly Up or dow uni the ssipeini agroes withthe aciual pressure, Maintenance oop the caver of te contoller in pace at al times to protect the internal components from di, cust, and physical damage, Perform routine maintenance occasionslly by inspecting a blowing or brushing away any accumulates git and dust. To assure proper functioning ofthe controler at al tmes, perform ‘ah operational check ofthe entre system during routine ‘maintonance chacks. Be sure tohandte contrllars cerahly at tha time of rslaton, ding acc so, and dog smaintonance, Cleaning the Potentiometer Windings or Wiper ‘Secasinaiy the windings o per onthe potentiometer (9 fhe -OvD) may need leaning. Dissomest the power py ’efore removing tna cover fem the controler and belore

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