Burnham PF-5 Installation and Operation Manual

0 (0)
INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
PRICE
-
$3.00
PF-5
SERIES
HYDRONIC
HEATING UNIT
FORCED DRAFT
FOR
LIGHT OIL,
GASILIGHT OIL,
OR GAS
HOT
WATER
OR
STEAM
18
SIZES:
GROSS
3,430,000
For service & repairs to the heating plant, call your heating contractor. When seeking information on the boiler, provide series and size designation shown on the rating plate.
Type
Boiler Number
Heating Contractor
Address
Form
8142501
.
No. 52009N-8194-1725f
AMERICA'S BOILER COMPANY
Firing Type System
Phone No.
Burnham Corporation
Lancaster,
PA
1
7604-3079
OUTPUT-
620,000
to
BTU/HR
SORT OUT ALL CARTONS, BUNDLES, AND SECTIONS and check against Shipping Schedule Chart below you ordered.
to
be certain that you have all the material required to assemble the Boiler
SHIPPING SCHEDULE CHART
NOTES:*Not furnished with Gordon & Piatt
VNot.required when sections are factory assembled
OPTIONAL EQUIPMENT
#548
Heater - Quantity as ordered Heater opening cover plate-Quantity as ardered Additional Controls-Type and quantity as ordered
R8
and
R10
gas or gas/oiI burners since these burners are furnished with steel mounting plates
IMPORTANT INFORMATION
PLEASE READ THIS PAGE CAREFULLY
1.
READ THIS MANUAL AND BURNER INSTALLATION MANUAL CAREFULLY BEFORE INSTALL ING, OPERATING, OR SEBVICING THIS UNIT. TO BURNHAM AND ASK FOR FORM NO.
2.
ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL PLUMBING, HEATING AND ELECTRICAL C0DE.S AND THE REGULATIONS OF THE SERVING UTILITIES.
ALL HEATING SYSTEMS SHOULD BE DESIGNED BY COMPETENT CONTRACTORS AND ONLY
3.
PERSONS KNOWLEDGEABLE IN THE LAYOUT AND INSTALLATION SYSTEMS SHOULD ATTEMPT INSTALLATION OF ANY BOILER.
4.
THE BOILER MUST BE PROPERLY VENTED IN ACCORDANCE WITH NATIONAL FUEL GAS CODE AND LOCAL CODES. SERIOUS PROPERTY DAMAGE NOT PROPERLY VENTED.
5.
READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESS-,
ORY DEVICES. THESE ACCESSORY DEVICES MUST BE INSTALLED AND USED ACCORDING TO
/
\
THE RECOMMENDATIONS OF THE MANUFACTURER.
6.
IT IS THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR TO SEE THAT ALL CONTROLS ARE CORRECTLY INSTALLED AND ARE OPERATING PROPERLY WHEN THE INSTALLATION COMPLETED.
52003
IF
YOU DO NOT HAVE A BURNER MANUAL, WRITE
(Part
#814502).
0 F HYDRONIC HEATING
COULD RESULT IF THE BOILER
IS
IS
7.
FOR OPTIMUM PERFORMANCE FROM THIS UNIT SEIRVECE AS SPE(C1FIED IN SECTION V OF THIS MANUAL.
8.
IN ALL CASES, CLEARANCES BETWEEN BOILER AND/OR SMOKE PIPE SURFACES AND COM­BUSTIBLE MATERIALS MUST COMPLY WITH NATIONAL FUEL GAS CODE ANSI DATED
ALL FLAMMABLE DEBRIS, RAGS, PAPER, WOOD SCRAPS, ETC., SHOULD BE KEPT CLEAR OF
9.
THE BOILER AT ALL TIMES. KEEP THE BOILER AREA CLEAN AND FREE OF FIRE HAZARDS.
10.
PROBE AND FLOAT TYPE LOW WATER CUTOFF DEVICES REQUIRE ANNUAL INSPBCTION AND MAINTENANCE. REFER TO SECTION V ITEM ING INSTRUCTIONS.
HIGH WATER TEMPERATURES INCREASE THE RISK OF BURNS OR SCALDING INJURY. INSTALL AUTOM-4TIC MIXING VALVE AT THE TANKLESS HEATER OUTLET TO AVOID EXCESSIVELY HOT WATER AT THE FIXWRES AS SHOWN IN FIGURE
1988
OR CURRENT EDITION AND, FOR OIL, NFPA
@
26.
211.
FOR STEP BY STEP INSPECTION AND CLEAN-
2223.1
(NFPA
54)
AN
TABLE OF CONTENTS
.
SECTION I
Ratings . Data Setting the Unit Air Supply/Venting
.SECTION TI . CAST IRON BLOCK ASSEMBLY
GENERAL INFORMATION
................................................................................................................................................
.............................................................................................................................................
....................................................................................................................................
6
7
7
..
Assembly of Sections, Manual Draw-up Assembly of Sections. Hydraulic Draw-up
Hydrostatic Test
SECTION I11 . INSTALLATION INSTRIJCTIONS
Flue Cover Plates Pressure Relief Door Firewall Plates Burner Mounting Plate Canopy
Boiler Piping
Jacket Assembly
Tankless Heater Piping Steam Trim Water Trim Burner Installation
SECTION IV . OPERATING INSTRUCTIONS
Filling System Adjusting Controls Adjusting Burner Testing Controls Initial Cleaning, Steam Boilers Initial Cleaning, Water Boilers Boiler Water Treatment pH or Alkalinity Test Warnings about Frequent Water Addition
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9
13 14
15 15 15
15
16 18 22 24 24 28 28
29
29 29 29
29-31
31 31 32 32
SECTION V . SERVICE INSTRUCTIONS
Cleaning Boiler Heating Surfaces Maintenance of Low Water Cutoff Devices Checking Burner & Controls Lubrication General Maintenance Considerations Attention to Boiler while not in Operation
.SECTION VI . REPAIR PARTS
Regional Office Directory Bare Boiler Assembly Steam/Water Trim Jacket Assembly
....................................................................................................................................................
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33
.............................................................................................
.........................................................................................................
..................................................................................................
33 34 35 35 35
35
36-38
3.
40-41
9
.
4"
TOP FLOW TAPPINGS
Fig.
1
Dimensional Information
TOP VlEW
REMOVE LEFT
SlDE PANEL
FOR CLEANING
ACCESS
4
YL
3
RETURNS
L.H.
SlDE VlEW
$2
WATER LEVEL
I
L29:
FRONT VlEW
4
8h
DIA.
'BURNER
OPENING
TAPPED HOLE FOR BREECHING PRESSURE SENSING
SECTION THRU BOILER
WITH FLUSH
JACKET
TABLE
RATINGS
-
- -
1
DATA
NET I=B=R RATING
Boiler(1)
Number
5iler
H.P.
Gross
output
-
MBh
sq.
Steam
Ft.
Bh
M
Steam
Water
620 785
1
95
16
11
1281 1446 1612
1777 1942 2108 2273 2438 2604 2769 2934 3099 3265 3430
Suffix "S" indicates steam boiler,
(1)
(2)
"G"
fix combination gas-oil fired.
I=B=R net ratings shown are based on piping and pickup allow­ances which vary from
water.
Consult manufacturer for installations having unusual piping and pickup requirements, such as intermittent system operation, exten­sive piping systems, etc.
Net ratings for water, square feet, are based on water temperature in system.
For higher water temperatures, select boiler on basis of Net Ratings, MBH.
The I=B=R burner capacity in GPH is based on oil having a heat
value of
indicates gas-fired,
1.333
140,000
BTU per gallon.
"W
"0"
to
indicates water boiler. Suf-
indicates oil-fired, "GO" indicates
1.288
for steam and
170°F
(2)
MBh
1.15
for
average
I
=
B= R
BURNER
INPUT
-
Gas
(mbh)
-
1204 1412 1619
I826 2033 2240 2448 2655 2862 3069 3276 3484 3691 3898
4105 4312
-
-
Boil
Gas
(3)
'ressure
?equired
(inches
watet
column)
790
5.2
6.4
997
6.6
6.9
6.5
6.5
5.9
5.7
6.8
6.3
6.1
6.2
6.0
5.5
6.2
6.2
6.7
7.4
-
Minimum gas pressure required at std. gas train inlet for maxi-
(3)
mum burner input based on
gas.
Boiler ratings are based on
(4)
sure at boiler flue outlet.
MAXIMUM ALLOWABLE WORKING PRESSURE
STEAM WATER OPTIONAL SPECIAL ORDER
Ratings shown above apply at altitudes up to
2000
feet on gas. For altitudes above those indicated, the ratings
should be reduced at the rate of
sea level.
Net
:irebo: 4olum1
(ft.3
8.5
11.1
13.7
16.3
18.9
21.5
24.1
26.8
29.4
32.0
34.6
37.2
39.8
42.4
45.0
47.6
50.2
52.8
-
(USA)
-
-
Water
Eonten
)
(I
-
Full br.)
58
-700 918 937
1056 1174 1293 1412 1530 1649 I768
1886 2005
2
123 2242 236
2479 2598
1000
Btu/cu. ft.
121/q%
15
PSI STEAM
50
PSI
COZ,
4%
1
1
+.lo
(CANADA)
WATER
-
70
for each
er
Weight
full
of
Water
(1,bs.)
233
1
2800 32i8
3687 4106 4574 5043 5512 5980 6399 6858 7335
7755
8223 8742 9161
9629
10098
0.60
specify gravity
water column pres-
-
15
PSI
-
50
PSI
PSI
1000
feet on oil and
1000
=B
=R
Vent
liarnetel
inehes]
feet above
SECTION
I
-
GENERAL INFORMATION
(
CONTINUED
)
@
INSPECT SHIPMENT carefully for any signs
.
damage.
4.
ALL EQUIPMENT is carefully manufactured, inspect-
ed and packed. Our responsibility ceases upon delivery of crated Boiler to the carrier in good condition.
B. ANY CLAIM'S for damage or shortage in shipment
must be filed immediately against the carrier by the consignee. No claims for variances from, or shortage in orders, will be allowed by the manufacturer unless
presented within sixty (60) days after receipt of
goods.
@
BOILER INSTALLATION - Must conform to the
authority having jurisdiction, or in the absence of such
-
:
-
1967 (Re-
Above or Top
-
6 Inches
requirements to
USA
-
Installation of oil burning equipment, AN'SIINFPA 31.
CANADA
Oil Fired Steam and Hot Water Boilers for 'Commercial and Industrial use, ,CSA Standard B140.7.2 affirmed 1991)
MINIMUM INSTALLATION CLEARANCES TO COM­BUSTIBLE MATERIAL:
-
Front
Sides
Rear
24 Inches
-
6 Inches Vent Connector Pipe - 18 Inches
-
6 Inches
of
IF BOILER
A
WATXR COWDIIIOR mIST8. A BOILER WUHDATIOR
ROW
PICOR IS WEAK
OR
UHEVEW
Fig.
OR
IF
2
VOTE:
Listed clearances comply with American National Stan­dard ANSIINFPA 31, Installation of oil ,burning equipment.
Listed clearances can not be reduced for alcove or closet installations.
For reduced clearances to combustible material, pro­tection must be provided as described in the above
31
ANSIINFPA
A. SERVICE 'CLEARANCE
er room so as to provide ease of venting and adequate clearance for maintenance, serviceability, and installa­tion of piping. Allow a minimum clearance of at front and back of boiler for burner service and ac­cess to pressure relief on each side of the unit for cleaning of flues and for tankless water heater installation. 'Refer for boiler dimensional data.
B. PROVIDE ADEQUATE FOUNDATION for the unit.
ON CARPETING. 'Boiler is suitable for installation
on combustible floors.
2. Floor construction should have adequate load bear­ing characteristics to bear the weight of the boiler filled with water (see Table 1). A boiler foundation similar to the one shown in Figure 2 is recommend­ed if the boiler room floor is weak or uneven or if a water condition exists.
standard.
-
Locate the unit in the boil-
door/flame observation port and
to
Figure
3
feet
1
TYPICAL ARRANGEMENT
FOR STUB VENT
Fig.
3
@
PROVIDE AIR SUPPLY AND VENTILATION to
accomodate proper combustion. A permanent opening or duct should be provided so that
4,000
the boiler input will not exceed area.
@
CHIMNEY OR VENT
The PF-5 is designed for forced draft firing and may be
a
used with
conventional natural draft stack or a stub
Btuhlin of free
vent (see Figure Draft controls are not normally required, although they may be used on installations where a natural draft stack is used or on multiple boiler installations with a common
stack. The boiler is provided with a breeching which should be adjusted to maintain a slightly positidt pressure in the vent connector box (up to
ing burner operation.
3).
See Table I for the proper vent size.
0.1"
W.C.) dur-
dampey-
SECTION
II
-
CAST IRON BLOCK ASSEMBLY
FOUR LEG SLING
('MIN.
34"
DIA.
REQUIRED
CABLE)
LIFTING INSTRUCTIONS
Fig.
4
@
FACTORY ASSEMBLED SECTIONS - The assem­blage should be set in the proper location as outlined in 9ection Figure
The tie-rod nuts should then be loosened until finger tight. Now proceed to part STATIC TEST".
@
sembly procedure outlined on the following pages. A. Assembly of Sections (Manual Draw-Up)
DRAULIC DRAW-UP EQUIPMENT, NEVER B'LE MORE THAN ONE SECTION AT A TIME.
(
I.
Lifting arrangement and weights are given in
4.
@
of this section "HYDRO-
FIELD ASSEMBLED SECTIONS - Follow the as-
WHEN ASSEMBLING 'SECTION'S WITHOUT HY-
ASSEM-
1.
Place the rear section in its approximate final posi­tion, as outlined in Section I and support it with a suitable prop. See Figure
2.
Open the Boiler Assembly Carton(s)
3. Clean nipples and nipple ports ,thoroughly with a degreasing solvent and apply nipple lubricant pro­vided.
5.
.
POSITIONING OF BACK SECTION
Fig.
5
4.
Drive nipples squarely into section using block of
wood and hammer, or preferably an aluminum
headed hammer, if available.
5.
A special n'ipple setting gauge is provided for the nipples. Gauge nipple in both directions to insure that it is driven to the proper depth into the nipple opening. Cut-out in gauge must rest on nipple, with legs of gauge touching finished face of section,
when nipple is properly driven. See 'Figure
NIPPLE'S MUST BE DRIVEN AS DTRECTED'TO INSURE TXHT JOINTS. M LEAKS ARE CAUSED BY TILTED OR COCKED NIPPLES.
6.
THIS IS A FORCED DRAFT FIRED BOILER
SEALANT MUST BE APPLIED WHERE SPECI­FIED FOR PROPER AND SAFE PERFORM­ANCE. THE BURNHAM CORPORATION HAS APPROVED A SECTION JOINT SEALANT LASTIC) MANUFACTURED BY DOW-CORN-
\
ING UNDER THE PRODUCT NUMBERS OF 732-RTV, 732-BLll AND 781. ALL THREE NUM­BERS ARE THE SAME MATERIAL.
0
B T NIPP'LE
6.
&
(SI-
SETTING OF NIPPLES
Fig.
6
The grooves in the ground joint along the edge of the section should be cleaned with a wire brush.
a
Then using apply
'/a"
cartridge of sealant in a caulking gun,
bead of Silastic to one side of each joint. to be mated. Touch up any missed spots before draw-up. Touch-up after draw-up has no value. See Figure
7.
SECTIONS MUST BE DRAWN-UP TIGHT WTTHIN FOUR HOURS OF TWE TIME WHEN STLASTIC I'S FIRST APPLIED. 'SILASTIC CURES IN FOUR HOURS AND WILL NOT FLOW INTO SEAL GROOVES AFTER FOUR HOURS FROM APPLICATION, REGARDLESS OF THE PRESSURE APPLI'ED.
7.
From arrangement of sections chart (see Figure
8)
select next section according to code letters on
section.
SECTIONS MUST BE ASSEMBLED IN PROPER ORDER.
Clean .nipple ports and place section on nipples in rear section. 'To facilitate assembly, it is advisable to enter the upper nipple first in its port, then enter the lower nipples in their respective ports.
Drive section in place with a heavy block of wood, striking blows as squarely as
%"
Insert the three
draw-up rods through the nipple
possible over nipples.
ports in the intermediate section extending them through the tapped holes in the rear section.
Place a 12" lg. steel channel on each end of the upper draw-up rod and an
8%" lg. steel channel on
each end of the lower draw-up rods along with nuts
and washers. These items are all located in the
9
Draw-Up Kit. See Figures
and 10.
Be sure to apply the sealant to the groove in the ground joints between adjacent sections as the boil­er operates with a positive pressure ,in the fireboxf
and products of combustion will escape between
sections unless the sections are properly sealed. The sealant should be applied before each section is phc­ed on the assemblage.
I
AVOID DAMAGE TO THE DRAW ROD THREADS WHILE DRAWING UP SECTIONS. APPLY OIL OR GREASE FREELY 'TO TIE ROD THREADS WHILE ASSEMBLING SECTIONS TO PREVENT STRIPPING OF THREADS ON ROD.
DRAW UP SECTION SLOWLY AND EVENLY,
tightening each draw-up rod a little at a time so that sections are equally spaced, starting with lower draw-up rods.
KEEP NIPPLES ALIGNED WITH NIPPLE PORTS. If necessary, tap nipples lightly with a blunt tool or rod to keep nipples from cocking while sections are being drawn up. DO NOT DRAW UP
SECTION WHEN
NIPP-LES ARE COCKED. Con­tinue tightening draw-up rods equally, periodically bumping the section with the heavy block of wood to relieve tensi'on on the draw-up rods, until sec­tions meet iron-to-iron on the ground surfaces.
CONTINUE ASSEMBLING SECTIONS IN THEIR RESPECTIVE ORDER. Be certain that
all sections are drawn up iron-to-iron at all three nipple ports.
APPLICATION
Fig.
OF
7
SEALANT
On long boiler assemblies, it may be necessary to draw-up a partial block if the entire boiler is not ready to be drawn-up tight within four hours of the first application of Silastic. If the block as­sembly time extends overnight, the partial block completed must be drawn-up tight before leaving
the boiler overnight. If a joint springs out, it must be re-drawn tight within four hours of first appli­cation of Silastic to the joint.
13.
Tie rods must be installed in lugs immediately after draw-up is complete.
a. Insert tie rods through the lugs on the front
back sections. Place regular steel nuts & flat washers on both ends of rods and tighten finger
tight.
Do not overtighten tie rods. Steel nuts should be
finger tight only to prevent section damage due to
thermal expansion.
b. Remove draw rod assembly from the sections and
remove the draw rod couplings from the tie rods.
&
i.
If
a
joint springs apart it must be re-drawn tight
within four hours of the time of application of the
silastic to that joint.
A
RRANGEMENT OF SECTION3
?he sections must be assemble according to the arronpemont listed in figure blow to insure proper operation and proper alignment of pipiG with jacket knockouts.
--
FX-FRONT SECTION WITH 4'* TOP TAPPING C-CENTER SECTION CX
CT
-
r
CENTER SECTION W/T.W.H. OPENING
--
SECTION ARRANGEMENT
CODE LETTERS
BX - BACK SECTION WITH
-
CENTER SECTION W/4"TOP TAPPING
4"
TOP TAPP ING
PULL - UP ASSEMBLY
Fig.
9
NOTE: . For boilers less tmklns water hooters replace
I
the
"CT"
~utions with p'~s* sections..
Fig.
8
CHANNEL BLOCK IN POSITION
Fig.
10
SECTION ASSEMBLEDGE
Fig.
11
14.
Excess length of tie rods must be sawed off so they will not extend beyond end sections. Rods should
project equally
the jacket. See Figure
blage. Illustration shows boiler equipped with sec­tions for built-in water heater.
B. Assembly of Sections (Hydraulic Draw-Up)
The entire assemblage may be drawn up at one time using hydraulic draw-up equipment providing the eration is completed within four hours after applica­tion of the sealant.
"Hydraulic Draw-Up Equipment" is available through Burnham by ordering part number
1.
Repeat steps 1 through 9 under "Assembly of Sec-
tions (Manual Draw-Up)
2.
Continue driving sections in place (in their respect­ive order) until all sections are in the assemblage. Ground surfaces between adjoining sections should be spaced
%"
will limit number of sections that can be drawn
up in one unit and could indicate cocked nipples.
Be sure to apply the sealant to the groove in the ground joints between adjacent sections as the boil­er operates with a positive pressure and products of combustion will escape between sections unless the secti'ons are properly sealed. The sealant should be applied before each section is placed on the assemblage.
On long boiler assemblies, it may be necessary to draw-up a partial block if the entire boiler is not ready to be drawn-up tight within four hours of the first application of Silastic. sembly time extends overnight, the partial block completed must be drawn-up tight before leaving the boiler overnight. If a joint springs out, it must be re-drawn tight within four hours of first appli­cation of Silastic to the joint.
3.
Insert the three appropriate) through the tapped holes in the rear section extending them through the tapped holes
in the front section. Be sure to screw draw-up rods
illto couplings far enough to prevent stripping threads.
4.
Place a upper draw-up rod and an each end of the lower draw-up rods. and washers on one end of the draw-up rods and
hydraulic rams, washers
on the other. See Figure
at
each end to insure proper fit of
11
for complete boiler section assem-
6196008.
."
%"
to
%"
apart.
%"
draw-up rods (and couplings if
12"
lg. steel channel on each end of the
Spacing of more than
'in the firebox
If the block as-
8%"
lg. steel channel
Install
and
draw-up
rod
12.
op-
on
nuts
the
elampe
5.
Draw-up Sections.
READ THE STATEMENTS BELOW BEFORE AT­TEMPTING TO USE HYDRAULIC EQUIPMENT.
-
RELEASE PRESSURE IN RAM PUMPS BE­FORE ATTEMPTING TO REMOVE CLAMPS.
-
DO NOT STAND IN LINE WITH DRAW-UP RODS AT EITHER END WHEN HYDRAULIC PRESSURE IS BEING APPLIED. TY MEASURE, ENDS OF DRAW-UP RODS
SHOULD BE COVERED WHILE SECTIONS
ARE BEING DRAWN IN CASE RODS SHOULD
SNAP WHILE UNDER TENSION.
-
DO NOT OPERATE RAM AGAINST DRAW-UP COUPLING.
-
DO NOT OPERATE PUMP AFTER RAM HAS REACHED 'STROKE LIMIT.
Use hydraulic rams to draw up sections by applying pressure alternately on the draw-up rods. When rams reach stroke limit, release pressure in ram pumps and then move clamps to new position.
KEEP NIPPLES ALIGNED WITH NIPPLE PORTS. If necessary, tap nipples tightly with a blunt tool or rod to keep nipples from cocking while
sections are being
SECTION WHEN NIPPLES ARE COCKED. Con­tinue tightening draw-up rods equally, periodically bumping the section with the heavy block of wood to relieve tension .on the draw-up rods, until sec­tions meet iron-to-iron on the ground surfaces.
6.
.Continue to draw-up until all sections make contact
at the ground joints.
7.
Repeat steps
tions (Manual Draw-Up)
drawn up. DO NOT DRAW UP
13
and
14
under "Assembly of Sec-
."
AS A 'SAFE-
Rods should be approximately centered in openings so that rods and couplings (when used) do njot drag on pipe thread in end section tappings.
:L
CHANNEL BLOCK
7
BLOCK
HYDRAULIC DRAW-UP
Fig.
@
HYDROSTATIC TEST - After the boiler sections
have been assembled, it is essential that the boiler be hy­drostatically tested before platework, jacket, or piping is installed. D.
Tankless Heater Installation If boiler is ordered with tankless heaters, install heat­ers with the gaskets provided. Table gives the maximum number of heater permissible per assemblage and the heater ratings.
Plug all boiler tappings and fill entirely water. To protect and safeguard the accuracy of steam or water gauge supplied, DO NOT INSTALL GAUGE
UNTIL AFTER TESTING OF BOILER.
I1
on page
with
25
cold
C. Testing pressure should be
E.
3''
--q
-
-
OF
SECTIONS
12
should not exceed EXAMINE BOILER CAREFULLY, INSIDE AND
OUTSIDE, to insure against leaks from cocked nipples or through concealed breakage caused in shipping and
handling. This precauti'on is for your protection and will simplify handling of necessary replacements and adjustment claims.
After making certain that there
boiler and remove plugs for boiler trim and other con-
nections.
DRAW UP
-3
REQ'D
PUMP AND
PUMP AND
50
pounds.
ROD CLAMP
RAM
at
least
are no leaks, drain
SET
10
pounds but
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