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AAON BL Series, Installation, Service & Owners Information Manual

The Sharp BL Series Operating Instructions Manual is a comprehensive user guide for the BL Series products. Easily accessible for download, this manual provides detailed instructions and troubleshooting tips to ensure a smooth user experience. Get your free copy now from manualshive.com, your ultimate destination for user-friendly manuals.

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TABLE OF CONTENTS 

SECTION 

Page    

GENERAL DESCRIPTION………………………………………………………………………………………………….

Unpacking…………………………………………………………………………………………………………...

04 
04 

OWNER’S INFORMATION……………………………………………………………………….......................................
              Wiring Diagrams…………………………………………………………………….................................................

General Maintenance ……………………………………………………………………………………..…………
Boilers ……………………………………………………………………………………………………………....
Primary/Secondary Pumping………………………………………………………………………………………..
Make-up Water………………………………………………………………………………………………………
Expansion tank.……………………………………………………………………………………………………...
Pressure Relief Valve…………………………………………………………………………….………………….
Automatic Air Vent…………………………………………………………………………….…………………....
Dual Pumps………………………………………………………………………………………………………….
Pressure Gauges and Thermometers………………..……………………………………………………………….
Pipe Insulation………………………………………………………………………………………………………

04 
04 
04 
04 
05 
05 
06 
06 
06 
06 
07 
07 

INSTALLATION…………………………………………………………………………….…………………………….....

Lifting and Handling……………………………………….……………………………………………………….
Boiler Placement ……………………………………………………………………………………………………
Service Clearances…………………………………………………………………………………………………..
Water Connection…………………………………………………………………………………………………...
Gas Connection……………………………………………………………………………………………………...
Boiler Exhaust Connection………………………………………………………………………………………….
Boiler Intake Connection……………………………………………………………………………………………
Access Doors………………………………………………………………………………………………………..
Electrical…………………………………………………………………………………………………………….

07 
07 
07 
07 
07 
07 
08 
10 
10 
10 

STARTUP…………………………………………………………………………………………………………………….

Pre Startup…………………………………………………………………………………………………………..
Startup……………………………………………………………………………………………………………….

10 
10 
10 

SERVICING & MAINTENANCE……………………………………………………………………………………….......

General ……………………………………………………………………………………………………………...
Lubrication……………………………………………………………………………………………………...…...
Service Information…………………………………………………………………………………………………

11 
11 
11 
11 

APPENDIX: Piping Component Information………………………………………………………………………………..
BL START-UP FORM……………………………………………………………………………………………………….

12 
33 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for BL Series

Page 1: ...BL SERIES BOILER IN PACKAGED MECHANICAL ROOM INSTALLATION SERVICE OWNER S INFORMATION MANUAL ...

Page 2: ...uges and Thermometers Pipe Insulation 04 04 04 04 05 05 06 06 06 06 07 07 INSTALLATION Lifting and Handling Boiler Placement Service Clearances Water Connection Gas Connection Boiler Exhaust Connection Boiler Intake Connection Access Doors Electrical 07 07 07 07 07 07 08 10 10 10 STARTUP Pre Startup Startup 10 10 10 SERVICING MAINTENANCE General Lubrication Service Information 11 11 11 11 APPENDIX...

Page 3: ... the interest of product improvement AAON Inc reserves the right to change pricing specifications and or design of its products without notice obligation or liability 2007 AAON Inc all rights reserved throughout the world AAON AAONAIRE are registered trademarks of AAON Inc Tulsa OK R53480 Rev A 6 07 ...

Page 4: ... and this manual Wiring Diagrams A complete set of unit specific wiring diagrams in both ladder and point to point form are laminated in plastic and located inside the control compartment door General Maintenance When the initial startup is made and on a periodic schedule during operation it is necessary to perform routine service checks on the performance of the boiler Boilers Boilers and pumping...

Page 5: ...er The secondary pump has its own suction guide combination valve and isolation valve similar to the primary pump with the addition of an air separator to remove any air that is entrapped in the water See appendix for additional information on installation operation and maintenance of pumps Make up Water A city make up water connection is provided to replace water that is lost from the system Glyc...

Page 6: ...f Valve AAON installs the required pressure relief valve in the unit This valve is set at 125 psig The chart below shows inlet pressure versus capacity for this pressure relief valve See appendix for additional information Automatic Air Vent There is an automatic air vent installed at the high point of the system inside the pumping package compartment The air vent valve must be in the proper posit...

Page 7: ... cables at all lifting points lugs provided on the unit Do not push pull or lift the unit from anything other than its base UNIT MUST BE RIGGED AT ALL MARKED LIFTING POINTS Typical Boiler Placement The AAON BL Series is designed for outdoor applications and mounting at ground level or on a rooftop It must be placed on a level and solid foundation that has been prepared to support its weight When i...

Page 8: ... and inlet vent hood The exhaust panel with chimney cutout is removed for shipping and replaced with a shipping cover Remove the shipping cover and attach the exhaust panel shipped with the unit When the exhaust panel is securely fastened with sheet metal screws locate the exhaust piping that is also shipped along with the unit The exhaust piping that must be attached to the internal exhaust vent ...

Page 9: ...ction This creates the necessary airtight seal Align the seams on the vent lengths and orient them upward in all horizontal applications 2 Tighten the locking band with a nut driver until snug plus 1 4 turn Before proceeding recheck all joints and ensure that all male sections extend to the top of the flared female end and all clamps are tightened Stop bead on male end must be pushed directly agai...

Page 10: ...ounded in accordance with the current National Electric Code Power wiring is to the unit terminal block or main disconnect All wiring beyond this point has been done by the manufacturer and cannot be modified without effecting the unit s agency safety certification Note Startup technician must check motor amperage to ensure that the amperage listed on the motor nameplate is not exceeded STARTUP Pr...

Page 11: ...should be re lubricated at normal operating temperatures but not when running Rotate the motor shaft by hand and add only enough grease to purge the seals DO NOT OVERLUBRICATE Service If the unit will not operate correctly and a service company is required only a company with service technicians qualified and experienced in both boilers and pumping systems are permitted to service the systems to k...

Page 12: ...Reducing Valves Water Pressure Relief valves Automatic Air Vent Valves 13 14 15 Pumps Introduction Pumps Operation Pumps Dual Pump Specific Information 17 18 21 Horizontal and Vertical Expansion Tanks Suction Guides Glycol Auto Fill Unit Flo Trex Combination Valve 25 26 27 28 ...

Page 13: ...trademark of E I Dupont de Nemours Company Capacity MAINTENANCE INSTRUCTIONS To clean strainer remove the bottom plug and pull out strainer Adjustment To adjust pressure setting loosen the lock nut and turn the adjusting bolt clockwise to increase pressure counter clockwise to decrease pressure Note Use a pressure gauge downstream to adjust and verify the pressure setting Troubleshooting High Syst...

Page 14: ...sure on domestic storage tanks or tankless water heaters the pressure relief valve has no temperature relieving element Standard setting 125 psi Size 3 4 x 3 4 20mm x 20mm ASME construction and is tested listed and certified by the National Board of Boiler and Pressure Vessel Inspectors ANSI Z21 22 Relief Valves for Hot Water Supply Systems DESIGN CERTIFIED and listed by C S A ...

Page 15: ... float line of water is always lower than the valve seal Float is high temperature resistant polyethylene Suitable for use with glycol systems Can be disassembled for inspection and cleaning Operating Range Minimum working pressure 1 45psi 10 kPa Maximum working pressure 150psi 10 bars Temperature Range 33 F 240 F 5 C 116 C Performance Performance curve details the quantity of air vented by the Fl...

Page 16: ...s This is the proper operating setting which will allow air to be vented from the system It is advisable to leave the cap on to prevent impurities from entering the valve Maintenance No maintenance is normally necessary However if the FV 4M1 is disassembled for inspection or cleaning it is important that when re assembling to ensure that the spring loaded lever properly engages under the float col...

Page 17: ...pump is ready to connect to the piping Rotate the shaft periodically At least monthly to keep rotating element free and bearings fully functional For long term storage the pump must be placed in a vertical position in a dry environment Internal rusting can be prevented by removing the plugs at the top and bottom of the casing and drain or air blow out all water to prevent rust buildup or the possi...

Page 18: ...sed and the suction valve open and then gradually open the discharge valve when the motor is at operating speed The discharge valve may be cracked or open slightly at start up to help eliminate trapped air When stopping the pump Close the discharge valve and de energize the motor DO NOT run the pump against a closed discharge valve for an extended period of time A few minutes maximum Should the pu...

Page 19: ...f there are no grease fittings evident no periodic lubrication is required Check the lubrication instructions supplied with the motor for the particular frame size indicated on the motor nameplate Mechanical Seal Mechanical seals require no special attention The mechanical seal is fitted with a flush line The seal is flushed from discharge of the pump casing on split coupled pumps and is flushed v...

Page 20: ...s the system clean 8 Is the area around the pump clean Warranty Does not cover any damages to the equipment resulting from failure to observe the above precautions Noise Levels Estimated Pumping Unit Sound Power Level Decibels A Weighted at 1 m 3 ft from unit Vibration Levels Vertical In Line pumps are designed to meet vibration levels set by Hydraulic Institute Standard HI Pump Vibration 9 6 4 St...

Page 21: ...te quickly with force when unlocked 6 Close the seal flush line interconnect valve and restart pump VALVE OPERATION Refer to Valve Illustration on Page 45 3 4 6 Valve or Page 46 8 Valve Discharge Valve This valve performs the dual function of automatically sealing the discharge of the inactive pump when one pump is running and can manually be closed and locked to isolate one pump for service Autom...

Page 22: ...ecure in the horizontal position using set screw 11 This releases the suction locking arm 4 Note The locking handle 3 should only be rotated towards the pump stopped for service The suction valve is designed to prevent the locking handle 1 from rotating towards the running pump as the suction of the running pump could cause the valve to slam shut with sufficient force to injure the operator and or...

Page 23: ... position so that the center pin of the locking arm 4 is located in the recess on the locking handle 3 4 Loosen set screw 11 and raise locking arm 3 to the vertical position locking the center pin in the locking arm recess secure with set screw ...

Page 24: ...24 DUAL PUMPS cont ...

Page 25: ...k and adjust the charge pressure by adding or releasing air for each application Note If the system has been filled the tank must be isolated from the system and the tank emptied before charging This ensures all fluid has exited the diaphragm area and proper charging will occur If the pre charge adjustment is necessary oil and water free compressed air or nitrogen gas may be used Check the pre cha...

Page 26: ...The fitting is stationary and will strain the pumped fluid and stabilize the flow into the pump automatically Temporary strainer must be removed following system clean up After all debris has been removed from the system or a maximum of 24 running hours stop the pump and close the pump isolation valves Drain the Suction Guide by removing the drain plug or opening the blowdown valve if installed Re...

Page 27: ...rried out with water The flow rates from the unit are designed for make up rates It is therefore suggested that the system is back filled with due precautions taken to avoid contamination Glycol is sometimes subject to bacterial attack and can become slimy as a result AAON recommend the addition of a suitable biocide The dosage should be calculated on the amount of water glycol mixture added and n...

Page 28: ...en system valve The pressure will fall and the pump will start and maintain pressure Powered agitation Ultra model only A solenoid valve is fitted to provide powered agitation of the mixture Automatically this valve is periodically opened and the duty pump starts creating circulation through the pump and mixing tank Automatic mixing is inhibited when there is a system demand for make up A switch i...

Page 29: ...ened first in order to position the flange correctly Note Care should be taken to ensure that the gasket is not pinched or bent between flanges 5 Tighten remaining nuts evenly by following bolting instructions so that the flange faces remain parallel as shown in the figure labeled Recommended Bolt Tightening Procedure Flange bolts should be tightened to 70 ft lbs torque minimum to assure firm meta...

Page 30: ...ssure across the valve in the throttled position Step 4 Locate percentage of valve opening on the flow characteristic curve For the given valve record the percentage of maximum flow rate Step 5 Locate the differential pressure determined for the valve in the throttled position on the Flo Trex Performance Curve Determine the flow rate for the given valve size at this differential pressure Step 6 Ca...

Page 31: ...o metal backseating does not provide a drip tight seal Step 4 Clean exposed portion of valve stem being careful not to leave scratches Step 5 Remove and replace the O ring gasket Step 6 Install the valve bonnet Step 7 Tightening the valve bonnet is necessary to stop any leaks Step 8 Open valve to balance set point as recorded in Step 1 Note On valve sizes of 2 1 2 inch and 3 inch the full open pos...

Page 32: ...32 FLO TREX COMBINATION VALVE cont Flo Trex Cross Section 1 Body Main 2 Eye Bolt 3 Shaft 4 Spring 5 Spacer 6 Disc 7 Seat 8 O ring body 9 Body Suction 10 Capscrew 12 O ring 13 Bonnet 14 Sleeve ...

Page 33: ...te _______________________________ Yes No 8 Has the overcurrent protection been installed to match unit nameplate requirement _____________ Yes No 9 Have all set screws on fans been tightened _____________________________________________ Yes No 10 Does the field water piping to the unit appear to be correct per design parameters ______________ Yes No 11 Do all pumps rotate freely _________________...

Page 34: ...BL STARTUP FORM PAGE 2 of 2 BOILERS BOILER WATER IN TEMP_______________F BOILER WATER OUT TEMP_______________F BOILER AMPS BOILER 1 BOILER 3 BOILER 2 BOILER 4 NOTES ...

Page 35: ......

Page 36: ...BL SERIES BOILER INSTALLATION SERVICE OWNERS INFORMATION MANUAL AAON Inc 2425 South Yukon Tulsa Oklahoma 74107 Phone 918 583 2266 Fax 918 583 6094 R53480 Rev A 6 07 ...

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