York-Shipley 400 Series, Installation Instructions, Service And Parts Manual

Page 1: ...ES BOILERS WITH FV 20A B AUTOMATIC BURNERS l n _ Se Wiee ad Pa tU It YORK SHIPLEY INC YORK PA 1 7 0 A TOTAL ENERGY COMPAN Ill 1111 III I NI 111 1 l I I IIIII II IW Ill 1 I VINI J IIIII IIIII Y IIM ID 78 578R4 884 PRINTED IN U 5 A ...

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Page 3: ...l Oil Tank Suggested Procedure for Installing Fuel Oil Tanks Boiler Room Ventilation Service Maintenance and Starting Instructions for Burner Oil Nozzle Lubrication Procedure and Requirements for Motors Starting Instructions Parts List and Reference Drawings FV 20 A B Light Oil Full Modulation FV 20 A BLight Oil Gas Combination FV 20 A BLight Oil Spark Ignition FV 20 A Gas Fired Gas Ignition 14180...

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Page 5: ... other components If there is a possibility of flooding the boiler room it is suggested that the necessary steps be taken to install cellar drainage or sump pumps CHECK ALL COMPONENTS IMMEDIATELY UPON ARRIVAL l If unit is damaged make claim to the carrier 2 Check specifications of electrical service to make sure that they correspond with the electrical characteristics stamped on the unit 3 Check t...

Page 6: ... a rope sling around the neck of the blower to support and balance the unit during removal The sling should be attached to a suitable hoist or lift truck 6 Be careful to remove the burner unit from the boiler in a straight line to pre vent damage to the refractory 7 Replace all gaskets before replacing the burner unit Insert in a straight line line to prevent refractory damage 8 Coat all studs wit...

Page 7: ...0 thru 80 12 16 20 24 When high stacks or other conditions on such installations result in a draft condition of the boiler in excess of 0 3 w c Negative dampers and sequence draft controls are usually recommended FUEL CONNECTIONS AND SIZES REQUIRED FOR STANDARD BURNERS OIL Pipe size of fuel pump 2 oil Supply 1 4 Pipe Return 1 4 Pipe GAS TRAIN CONTROLS All standard U L gas trains for main flame inc...

Page 8: ...E PRESSURE REGULATOR 5 0 COCK FV20A BURNERS U L MOTORIZED VALVE I V 20A MOTORIZED VALVE PROOF OF CLOSURE I V 208 HIGH GAS LOW GAS PRESSURE PRESSURE SWITCH SWITCH o o i I I 0 I I SOLENOID VA LVE PRESSURE REGULATOR S O COCK FV20A BURNERS fM FV20B BURNERS U1L FM 6 PILOT GAS S O COCK r I I I I I I PRESSURE REGULATOR i cf I MAIN GAS I I I I I I PILOT GAS i ...

Page 9: ...000 Mlh MOTORIZED VALVE PlOOF Of ClOSURE OVU 5 DDD Mlh lOW GAS HIGH GAS PRESSURE SWITCH VENT PHSSUIE BUTTERfly t I VAlVE 5 0 COCK I I V AlVE MOTORIZED SWITCH VAlVE I SOlENOID PIESSUH FV20A B IR I 7 S O COCIC STIAINfl I L PIESSUIE MAIN GAS i I I I I l 0 ...

Page 10: ...ne Step 6 Divide Step 5 answer by 100 Step 17 Calculate the pressure drop available in the header per 100ft of pipe by dividing Step 4 by Step 6 Step 8 Refer to Fig I Locate the gas flow rate Step 1 on the left side of the chart and draw a hori zonta1 1i ne to the right Locate the available pressure drop per 100ft Step 7 along the bottom of the chart and draw a line vertically upward The location ...

Page 11: ...SP G 6 GAS PRESSURE REGULATOR REQUIREMENTS CFH U L STANDARD FM APPROVAL IRI APPROVAL Boiler Size Firing Press Req d Reg Size Press Req d Reg SHe Series HP Rate Inlet Outlet Model Inlet Outlet Model Std 6 5 5 0 1 1 2 RV 81 Std 7 0 5 5 1 1 2 RV 81 542 40 1675 Low 3 5 3 0 2 1 2 RV 91 Low 3 5 3 0 2 1 2 RV 91 High 11 0 6 5 l RV 60 High 12 0 7 0 1 RV 60 Std 9 0 7 0 1 1 2 RV 81 Std 10 0 8 0 1 1 2 RV 81 5...

Page 12: ... plans it is determined that the length of straight pipe in the header to the most distant boiler is 200 ft The allowance for fittings etc would then be 200 ft x 25 50 ft or a total length straight pipe distance of 200 ft 50 ft 250 ft Step 5 Divide 250ft Step 4 by 100 2 5 Step 6 The pressure drop available in the header per 100 ft of pipe is then 17 8 W C Step 3 divided by 2 5 Step 5 7 12 W C 100 ...

Page 13: ... and return lines MAXIMUM ALLOWABLE PIPE RUN To determine the maximum allowable pipe or tubing run from the pump suction connection to the bottom of the fuel oil tank for various lifts and for all size units use the chart below TOTAL ALLOWABLE LIFT FT RUN FT l 0 91 1 87 2 84 3 81 4 77 5 74 6 70 7 67 8 63 9 60 10 58 11 53 12 50 13 46 14 43 15 39 To determine Total Lift for all units add 4 ft to the...

Page 14: ... in vicinity of pipe runs 5 Install tank vent high enough to eliminate source of objectiona ble odors Term inate tonk vent within sight of tonk fill Use full sized tonk fill pipe 6 Use as few elbows and other fittings as possible straight run preferab le 7 Pitch lines up from tonk to burner or remote pump set 8 Run suction a nd return lines full sized to within 2 feet of burner pump connection 9 T...

Page 15: ...uin the spray and damage the nozzle permanently Keep your stock nozzles in indi vidual containers as supplied from the factory DON T place them loosely in your toolbox or a bag and expect them to be usable CLEANING Remove strainer locknut and disc from tip Brush parts thoroughly particularly the slots of the disc and the inside of the tip Usc a Monarch brass wire nozzle brush Soak in carbon tetrac...

Page 16: ...minutes drain off solvent Repeat this process until solvent comes out clear If carbon tetrachloride is used for flushing rinse housing with small amounts of light mineral oil d Follow through on Section 1 items f g and h 3 Motors with special characterisitcs a High speed motors 3450 RPM should be greased every six months b Motors 7 l 2 HP or greater should use at least one ounce of grease every si...

Page 17: ...C5 General Electric Co Schenectady N Y b A grease with following characteristics 1 ASTM worked consistency 270 290 with minimum change over range of operating temperatures 2 Melting point preferably above 150 C 3 Freedom from separation of oil and soap 4 Freedom from abrasive matter and acidity 3 Westinghouse Motors a Use Westinghouse 53701RY grease unless a special grease is specified on the name...

Page 18: ... equivalent D LUBRICANT FOR SLEAVE BEARINGS 1 G E Motors a SAE 10 viscosity turbine oil for motors up to 1 2 HP b SAE 20 viscosity turbine oil for motors 1 2 HP and larger 2 Westinghouse Motors a PD 2268 Westinghouse specification number b SAE 10 viscosity for motors up to 1 2 HP c SAE 20 viscosity for motors 1 2 HP and larger 3 Marathon Motors a Reoil with SAE No 10 oil for every 2000 hours of mo...

Page 19: ...sing the volume of air will produce a flame changing from yellow toward white Too much air usually produces a fire having sparklers and can be detected by a strong odor Decreasing the volume of air will produce a flame changing from white through yellow into an orange color with dark smokey tips at the end of the flames The best setting should yeild a flame between yellow and orange color with no ...

Page 20: ...nd set at point which gives best operation 5 Check for fluctuating pump pressure this may be corrected by step C 4 6 Check for oil leaks in suction line or on suction side of fuel unit check particularly at oil line filter and fuel unit end plate An air leak will generally be indicated by an intermittent hissing sound at the fuel unit or by unsteady pump pressure Air leaks MUST be eliminated 7 Inc...

Page 21: ... six months STARTING THE GAS BURNER MODEL FV 20 N Refer to the Flame Control Bulletin in your instruction package or manual GENERAL SERVICE A When adjusting the main flame a forward or rearward adjustment of the ignitor assembly can affect the flame pattern Generally the proper setting is with the ignitor funnel flush with the forward edge of the gas head When adjustments are correct a quiet blue ...

Page 22: ...excess of 100 PSI At this increased nozzle pressure the nozzle will deliver a greater quantity of fuel The variable pressure needed to change the firing rate is accom plished w ith a modulating metering oi l valve on the return line con nected to a linkage and operated by modulating motor which also controls the blower air damper The o il Aow to the nozzles is controlled by a solenoid valve in the...

Page 23: ... G P H 11 0 115 P S I Gas 3350 C F H 9 5 Oil 24 0 G P H 11 5 105 P S I NOTE The above typical readings ore for general use only Specific installation readings may vary due to various types of burner applications Burner start up and service personnel should adjust all settings for max imum efficiency operation 21 GAS MAN PRESS 2 5 w c 5 5 w c ...

Page 24: ...C PIPING ARRANGEMENT FOR LIGHT OIL FUU MODULATION WITH MECHANICAL ATOMIZATION NOTE OIL SUPPLY RETURN TO TANK 22 RETURN SOLENOID IS INSTALLED WITH DIRECTIONAL ARROW AGAINST NORMAL FLOW TO OPERATE AS CHECK VALVE ...

Page 25: ...2 Lg FV 206 698o5 Iris Shutter Assembly 7451 Pump Mounting Bracket Assembly 127597 l ulnp Sundstrand H6KA I 00 Sl 398 Nozzle Electrode Assembly 131550 Sc llller Extendon Aseembly 127525 Blower Housing Cover Assembly 132369 Trana onner LEEW 115 60 54671 Oil Line Assembly FV 20A 127731 Oil line AssOI Ibly l V 20B 138661 Modutrol Motor Mounting Bracket l l76o Ref No No Hqd Part No 16 17 18 19 20 2l 2...

Page 26: ...ine Assembly Main FV 20A 127731 Oi I Line Assembly Mai n FV 20B 138661 Oil Line Assembly Pilot FV 20A 1277 0 O J line Assembly P i lot FV 20B 138662 Air Switch Cleveland OFSH CO 68587 Air Switch Tubing FV 20A 127707 Air Switch Tubing FV 20B 138556 Pi Iot Tube Asscmb Iy 127709 Gas Train Assembly FV 20A 157902 Gas Train Assembly FV 20B 136500 2 21 12 1 3r o j t ___ __ _ __ L i i I Jl t I f l_ 4 1 f ...

Page 27: ...OO fV 20A I00463 Pump Sundstr and H6KA I 00 FV 20B S1398 Nozzle Electrode Assy FV 20A 131210 Nozzle Elec trode Assy FV 20B 131553 Blower Housing Cover Assy Transformer LEE 115 60 Oil Line Assy Hain fV 20A Oi I Line Assy Hain FV 20B Pi I ot Tube Assy FV 20A Oil Line Assy fV 208 Modutrol Motor Mtg Brdcket 132031 54671 1277 31 138661 127709 138662 I 389S3 i I r LBOARD I l _j Pe f No No Rqd Part N Wll...

Page 28: ...DfSH CO p lot Tube Ass lyFV 20A Gas Train Assembl When U ed on Stc m Pak Gas Tratn Asscmbl When Used As C y dutrol tor k rnr r dut ol Motor Mlf 6 1 1e ter 1r19 Anne Gasket Rlo er To Bl 8urncr Tube b tension t p pc Air Whirl Sub AHembly 28 29 30 13 Part No 12 S 1J 127 14 6171 J 4 916 48859 451 I 864 I 20 1 54671 68587 127707 127709 I 57902 160068 I 895 1062 5 45932 I 8 29 121537 127522 0 I 22 2 2 2...

Page 29: ...85 140387 7451 I 1554 127S2S I 2369 54671 68587 I J8S56 127709 160048 1600S9 I 389S3 I062JS 45932 I 38 29 1275 7 Ref No No Rqd Part J 20 21 22 2 24 25 26 27 28 29 0 I 32 3J 4 JS 36 7 38 I Air Wh irl Sub A t n oly Or 1 f i Cf P l r hen Used On t cdlll Pak Or if icc PI lL When Used As Cof vcrs ion Burner Burn Mtg f l mg Gctskct Screen A s fflh lt Conduit Bo Pul l L1d Metcr i n Arm Linkage Ro i Mod M...

Page 30: ...31546 Noz Z le Pipe Holder Alwernbly U 0338 Houle Adapter 131642 Air Restri ctor Plate 130787 Oil Ll ne Aoe bly 131202 Scanner Tube 127540 Scanner Holder 1275J5 R H Buss Bar 1 1216 L H Buse Bar 1 1217 J 16 Tube 1 8 PS Kale Cunn 50081 Wll 48xJ 1 4 20HC 2 x 1 2 Set Screw lleJ 5221 Soc Cup Pt 110 2L NC 2 x J 411 Mach icr l0517S Pan Hd Ph Cadmiwn Plated 1 411 J1 l 8 IPS HeJt Bu ahing 50280 16 1 1 ube ...

Page 31: ... Soc Hd 53615 Set St f CW Q 24 N 1 Ly F1ll Hd 50 11 1 C hine cr ew 3 16 Tube I 8 IPS Md l e Conn 50081 4t1 8 3 10 J 8 Tube I IPS M a le Conn 508 1 WH 48 6 II 8 Tube I IPS fema l e EI bow 55738 90 JH SOx6 12 Bli SS ea I 1217 I Gas Line Ass l f 12752 14 Nozz 1e Adapt er HJ7S FB 1 4 108623 IS d 0 I uckwasher 50173 16 17 Air Restr i c t o PI o1te 1275 3 18 SA Ma I e EI ow I 8 IPS x J 16T 514 9 19 Scan...

Page 32: ...10 1 Fl ule Detector Honeywll CS54A f 9559 1018 ll 1 Socket S 02 CCT H B Jones S26ol 12 2 l L Pipe Strap 51256 l 4 16 2NC 2 x 1 2 Lc Mach Scr 10Sl70 Pan lid Phlllipe Cad Plated l4 16 211C 2 Hex Nut Cad Plated 53677 15 16 1 ube 1 8 IPS Male C ftl 50081 W l 48x 16 2 l L x l 8 I P5 Hex IIIWI1nc 502110 17 6 110 24 1 2 x J 4 Maeh Serew 50111 Pan Hd Ph Cad Plated 18 1 4 20 1C 2 x 1 2 Set Serev 5221 Hex ...

Page 33: ...y f lamc Det ector Holder 2NC 2 x 1 2 Lg Mdch Scr Pan Hd Phill i ps Cad Pl ated 10 2 NC 2 x 8 Lg Phi II ips Mcllch ine Screw J 1611 Tube 1 8 IPS Male Conn W H 48x I 4 x I 8 IPS Hex Sushi ng 0 24 NC 2 x J 4 Mach Scr Rd Hd Phi IIi ps Cad PI a t ed I 4 20NC 2 x 1 2 Set Screw Hex Soc Cup Pt Photoc W Tubc F i reyc SCM I I 000 Y R H Suss Bar t H ftuss 8ar 3 16 Tube 1 8 IPS x 91 0 E II 9J S 20 2 0 4 kwc ...

Page 34: ...ode Ho lder 127518 4 Electrode Usf mbly 8Y484 5 Flame Rod 1 8642 6 1 L 20NC 2 x 1 2 Lg Set 5221 Screw Hex Socket Cup Point 10 24 X J 8 L Phillips 105172 Machine Sc rew Cad Plated 8 Buss Bar 1 1217 9 Nozzle Pipe Holder A ssembly 140 9 10 Nl0 24 314 Lg Fill Hd 105175 Mach Screw ll 1 4 IPS X 8 SA E Str Mal 50841 Cormec tor WH 48x6 12 l Air Restrtct or Plate 1 0787 r 1 4 n L 1 il tl ...

Page 35: ...nner Tu Jc I 4 20NC 2 1 7 Lg Set Screw Soc lid Cup Pt 4 NIO 24 x 3 8 Lg R H Mdch Scr Philli ps I Bun Botr No1zle Pipe Holder Assy 10 2L J Lg F I I Hd 1 Jc h Screw I 1 L l P S J 8 SAE Stc M ll e Conn WH 48x6 I 6 2 NC J 8 Lg Pan Hd Mach Screw Ai r Restri c tor Plate Scanner Hoi der r 1 11 L __J Part No 1 0499 I Ol 98 127 18 I St 60 127Sl O 12213 lOS 112 121798 140 9 lOII I 06 1 4171 I 078i 12 SJS 9 ...

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