Universal Boiler Works BF100W4, Operating And Maintenance Instruction Manual

Page 1: ... Maintenance Manual U I5647 P f e r BF100W4 Water ASME Section 4 Ship Date 1 24 2000 UNIVERSALBOILERWORKS INC 1207 S E SECOND STREET GALVA IL 61434 T 309 932 3088 F 309 932 2078 ubwl inw net www universalboiler com ...

Page 2: ...1207 S E SecondSt Tel 309 932 3088 Galva lllimis61434 Fax 309 932 2078 w w w u n i d t m k OPERATINGAND MAINTENANCE INFORMATION BOILER MODEL UNIVERSALORDER WlER SERIAL BURNER MODEL W O I INVOICE ...

Page 3: ...eers Code the boiler is designed fabricated tested and inspcted following the mtes of Section W for operating at less than 2500 F I Power Boil operationat greater irran2500 F orabove 160 psig and stamped accordingly The location ofthe authorized H or S stampis located on the upper header near the rear ofthe unit As a complete package the pressure vesse1 is mounted on a 4 high insdated base frame T...

Page 4: ...e Model BF hot water boiler does not include tappings for fresh water make up Treated water make up when needed should be added via the expansion tank A tight hot water system should have a minimal amount of make up and a water meter is recommended to monitor the amount of water make up The term wn rr ri covers the olectricnl or electro d mechanical devices mounted on the boiler or furnished loose...

Page 5: ... to indicate the relative water temperature at the outlet connection to the system 3 Brlief Valve s Dependiny upon the s i x of the boiler one or more water pressure relief valves are furnished These valves are shipped loose and should be piped to a safe point ofdis charge by the installing contractor The set point is genera1ly iess than the system operating pressure to relieve water pnti sure wit...

Page 6: ... Flame supervision is via a flame scan ner which monitots pilot ignition main flame ignition and flame strength during operation It is programmed to shut the burner fuel supply off in the event of an unsafe condition 3 Locared on the burncr provides purge air of the bile prior to ignition and following a safe shutdown Provides the air required for combustion 4 Folced Locatedin the Control Pmel Thi...

Page 7: ...section These items csln include Ieadflag systems indoor outdoor energy management interface systems system pump interlock etc For specific items furnished by UBW refer to the Bill of Materials and the Burner Manual foradditional infomation 2 i s important to u n the operation of j r device which will hterhcc with the boilerhumer so that all componentsoprstc as they have been selected and designed...

Page 8: ... missing within 48 kvrrrs o f receipt will twt be replaced o f charge as we will mmme thai he shipment h beet received complete The Model BF boiler is equipped with lifting lugs located on each side of the boiler base frame Please refer to figure 2 I These lugs have been located for the specific purpose of lifting the unit with the use of a spreader bar A spreader is needed to prevent damage to th...

Page 9: ...a negative pressure acuurn cxists We recommend a siiyntiy positive condition at all times As a rule of thumb we recommend that a quantity of 10 ctin per boiler horsepower airflow be available whcncver the burner i s operating The location of bailer room air supply dampers should provide cross flaw ventilation The recommended size of the openings shouId be in accordance with TabIe 2 I Make up air o...

Page 10: ... pl stthe boiIer connection so that it rests on the umer drum This will create n backaressure a id seriously affect cotnbusdon gnd lcakaee of combustible products The stack outlet should be fitted with some meansofpreventing ingress of rain as shown in Figure 2 4 2 U g l I R e t u r n The hot water supply connection to the system is located on the upper drum at the front and the system return comc...

Page 11: ...pipiiig extends greater than 17 feet use a VZ diamctcr larsur h r tach 12 feet length Avoid all 96 bcnds if possible r If discharge terminates outdoors wherc it can be subjected to freezing ensure appropriatc measures prevent the discharze pipe from fr reezingshut iEach discharge pipe should have 36 Or X Open drain at its lowest point Refk to Figure 2 5 for a recommeraded method ofsafety valve dis...

Page 12: ...er pressure in the boilers with the espansion tank connected to the boilers Also on high friction head systems the pump discharge is not imposcd an the bailers and standard Section IV boiler units can be used provided extreme static head pressure does not exist The return water enters the bottom rear drum of each unit and the hot water supply take off is from the top front drum The run out should ...

Page 13: ...o the boiler room in the event oi improper operation or by failure of a _pas regulator diaphragm The gas vents from the hiler should be ample sire and not less then w Ooequaner inch copper piping that is seen often in boiler installations should be avoided as it is easy to plug up such small vent piping leading to an unsafe operation of the g a s accessories I he gas vents shouid be tminated outsi...

Page 14: ...o pumps should be installed i n parallel If two pumps ate used or if gate valves are installed in the discharge line the pumps should be equipped with safety relief valves The uil loop rovrtl the pump to the boilers and hack to the tank should be located in a trench if possibte IF it is necessary to locate the loop over the boilers a check should bc made to insure that the pumps on the boilers cor...

Page 15: ...s should be interlacked with the boilerburner control circuit hfakc sure that all external wiring to stnd from the control p e l is properly identified and marked This i s to ensue that if burner power is disconnected oiher power sources are known and marked which may remain active within the panel even fhoughthe burner power has beendisconnected Check that the wiring diagrams for the burner and b...

Page 16: ...ting oils grease etc These must be removed prior to full operation ofthe boiler To accomplish this a boil out ofthe unit is recommended This procedure can be M e d out dong with the cleaning the system and can be accomplished during the timeperiod t o cure the fiont and rear wall rehctories The system should be cleaned including the boiler befbre full operation of the boiler is p e n m d Piping co...

Page 17: ... d l Safety Dab Sheet for proper safety equipment and protection and required precamtions Always wear eye protection and rubber gloves when handling boil out chernicltls 1 Remove upper and lower drum handhole covers and inspect dl internal surfaces Remove any debris and wash with a water hose Close bwer handholecover e sure that the relief valvds valve seatt 2 If the boilelm onlp is to be boiled o...

Page 18: ...pect the surfaces and if not clean repeat the boil out procedure k Replace the handhole covers with new gaskets and attach the relief valve s 1 If the boiler will b e placed into operation shortly after boil out fill the unit with clean treated water and fire the unit to reach at least 180 F If the unit will not be used right away prepare the unit for lay upstorage 3 If the boiler and system will ...

Page 19: ...ished continue with the boilat p d u r e Note On units below 150 horsepower the cuing time can be reduced by 50 This means that during hour 4 the firing rate may be increased proportionately throughoutthe hour Note One the curing process has begun it shouldnotbe intmpted Note Before boil or rehctory curing is undertaken the bumex should I x properly adjusted for proper fuel input and keYair ratio ...

Page 20: ...erOn OffSwitch Gas Oil Switch Combination Fuel Units Operating Limit Temperature ControI High Limit Temperature Control Low Water Cutoff Control Low Gas Pressure Switch High Qas Pressure Switch Proof or Closure Valve End Switch Controls used in the running interlock circuit are Blower ForcedDraft Fan Motor Starn Combustion Air Proving Switch With the programmer energized the following sequence occ...

Page 21: ...er wilI modulate fiom low to high fie in responseto systemdemand Asthe hating demand becomes less the damper motor will automatidly drive t o a lower firing rate and eventualtlly as demand becomes satisfied burner will return to the low fire position When the has retimed t o low fire and the demand ha been satisfied the operating limit control will open and the burner will turn offand commence a s...

Page 22: ... no adjustments B Control Purpose The controls selected for the boiler are fbr the safe and reliable operation of the boiler Tampring with improper setting or bypassing the controls could lead to seriously waf conditions and will void the wmm of the coatrot and boiler Each device has a spcific purpose in proper operation or serves as a safety device topreventequipmento r personalinjury This cbntro...

Page 23: ...current pathcompletion the control will permit burneroperation to beginorto continue C Operation and Adjustment Refer to Figure4 1 Owrating Limit Control Honeywell L4008 Series is the standard control Refer to the systtm temperature requirements for the project for desired owrating tempnture The operating rang for this control 1s 110 240 degrees with and adjustable differential from 5 _ to 30degre...

Page 24: ...er the ternprature is above Point A The gap between Points A and B represents the on off of the operating limit control n normal owration the burner will shut down whenever the tempcrarure reaches setting A The switch in the opratiny limit control wilt o p n When the tempemure drops to 8 set point minus differential the operating limit control switch closes and the burner is cycled on At this set ...

Page 25: ...H c i e n t for proper operation When initially m n g a newly installed boiler or when bringing a n idle boiler on tine with operating boilers the idle boiler mu be press equaltothe systemandelkboilers before addingittothe system We recommend that a o r n e t e r be btdled in the retun line i ko indicate return water temperature if Vat havenot a instaIled it will k U c u I t tu ascertain p r o p I...