Lattner Boiler Company H.E. Instruction Manual Download

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Lattner Boiler Company

Model H.E. Steam Boilers

INSTRUCTION MANUAL

2006 to 2007

Lattner Boiler Company

1411 9

St. SW

Cedar Rapids, IA 52404

T: (800) 345-1527
F: (319) 366-0770

[email protected]

www.lattnerboiler.com

Summary of Contents for H.E.

Page 1: ...ner Boiler Company Model H E Steam Boilers INSTRUCTION MANUAL 2006 to 2007 Lattner Boiler Company 1411 9th St SW Cedar Rapids IA 52404 T 800 345 1527 F 319 366 0770 E info lattner com www lattnerboiler com ...

Page 2: ...s M Before Firing the Boiler N Pressuretrols Controller Limit O Start Up of Standard Burners 7 7 7 7 8 8 8 8 9 9 10 11 11 11 12 Section II Boiler Care Page 14 A General B New Boiler Cleanout C Water Conditions D Water Treatments Chemicals E Water Softener F Foaming Bouncing Carryover G Water Treatment Summary H Blowdown I Feedwater System J Burner Adjustment K Sight Glass L External Inspections M ...

Page 3: ... Water Cut Off Probe Cleaning 22 23 23 Section IV Troubleshooting Page 24 A Normal Operation B Basic Service Tools C Before You Begin D Troubleshooting 24 24 24 25 Lattner Boiler Limited Warranty Page 26 Standard Terms Conditions Page 27 Additional Support Literature Page 28 ...

Page 4: ...tory lined furnace 5 Inner Casing Insulation A stainless steel gas barrier encases the pressure vessel and combustion chamber ensuring even gas travel and heat transfer This barrier is backed with 2 of mineral wool insulation 6 Outer Casing The outer casing is fabricated of a single 16 gauge steel jacket The jacket is painted with high temperature enamel to ensure corrosion resistance and longevit...

Page 5: ... design pressure of low pressure units 7 Steam Pressure Controls At least two controls are furnished with each boiler One for ON OFF operation controller and one for preventing burner operation if excess steam pressure is sensed limit The limit control is a manual reset control 8 Valves Standard valve piping package consists of one 1 feedwater stop valve one 1 quick open bottom blowdown valve and ...

Page 6: ...f the ASME data sheet is provided to the purchaser One copy is sent to the National Board of Pressure Vessel Inspectors The original copy is archived at Lattner 2 Boiler Piping Hydro Each Section I High Pressure Boiler S stamped is subjected to an additional hydrostatic pressure test This test includes the integral steam and water trim piping and the trim valves An ASME P 6 piping hydro certificat...

Page 7: ...t a forklift etc place the boiler on rollers or on 2 pipes and roll the boiler into place If the unit is dragged attach chains to the base frame only CAUTION DO NOT lay the boiler on its side as the jacketing will not support the weight of the boiler without sustaining damage If the entry is too narrow for the boiler and controls to pass through removal of the trim and controls can be executed One...

Page 8: ...used to close the opening between the stack and the stack thimble must be non combustible F Boiler Shipped with Controls Removed 1 Reassemble See assembly print inside boiler panel box 2 Wiring Re wiring the controls will be covered in L Electrical Connections DO NOT connect the power at this time G Steam Outlet 1 Pipe Size Size steam pipe according to system requirements 2 Outlet Size Refer to pr...

Page 9: ...r through the drain should be piped to the sewer Some codes require the water to pass through an air gap before entering the sewer 11 Aftercooler If the water must be cooled before entering the sewer required by some codes then an aftercooler must be used The aftercooler attaches to the separator drain connection and mixes cold water with the hot drain water Units may be either manual or automatic...

Page 10: ...rature sheets 5 Gas Supply Pipe The gas pipe to the boiler must be at least the same size as the gas train supplied with the boiler DO NOT reduce 6 Drip Leg Gas supply piping must be installed with a proper drip leg ahead of any gas train components 7 Gas Supply Pressure Natural Gas Supply pressure should be between 6 and 11 water column ahead of the gas pressure regulator Minimum supply pressure ...

Page 11: ... the McDonnell Miller level control Replace with a malleable iron plug supplied with the boiler 3 Condensate Return System Make sure there is make up water supply to the tank Make sure there is water in the tank 4 Turn On Turn on the pump switch Pump or solenoid valve should start immediately If not see troubleshooting section 5 Check for Leaks While the boiler is filling check for leaks in the pi...

Page 12: ...psi 6 Example Boiler with a 100 psi safety valve Set the controller at 80 psi with an 8 to 10 psi differential Set the limit switch at 90 psi Turn on the boiler burner will fire When the steam pressure reaches 80 psi the controller shuts down the burner When the pressure drops to 70 to 72 psi the burner restarts The boiler continues to cycle to maintain 80 psi If for some reason the steam pressure...

Page 13: ...etailed instructions i Cycle boiler on and off several times For warranty validation complete start up check list included with boiler and return it to Lattner Failure to return check list may void warranty 5 Check for Gas Leaks Brush a soapy water solution on each connection in the main gas and pilot gas lines Look for bubbles If there are any gas leaks shut off the main gas supply and fix any le...

Page 14: ...TE Never fill a hot empty boiler with cold water C Water Conditions 1 Oxygen Scavenging Generally boiler feedwater will contain oxygen and dissolved minerals Inside the boiler the heat will cause the oxygen to separate from the water The oxygen will then attack exposed metal surfaces This leads to corrosion and localized pitting of the metal 3 Scale Deposits As the water boils the dissolved minera...

Page 15: ...n The boiler and the boiler level controls should be blown down at least DAILY Blowdown removes a portion of the water in the boiler in order to reduce the amount of dissolved solids Blowdown will also remove some of the loose deposits that may be in the boiler 2 Blowdown Instructions The boiler may be blown down at any pressure provided the blowdown piping is piped to a safe location see Installa...

Page 16: ...the glass may crack L External Inspections 1 Maintenance External inspections are routine observations of the visible portions of the boiler By noticing the normal boiler operation many problems can be detected before they become serious 2 Piping Check the piping for leaks This includes steam pipes condensate pipes feedwater pipes blowdown pipes and all fittings on the boiler If leaks are found ti...

Page 17: ... loop systems and the water is treated the boiler may need to be inspected only once a year Many state and or city codes require annual internal boiler inspections 4 Gaskets The hand hole gaskets and the McDonnell Miller head gasket must be replaced after each internal inspection If any leaks are present around the gasket surfaces replace the gasket immediately High pressure water and steam leaks ...

Page 18: ...lass for excessive wear or leaks 2 Test the McDonnell Miller and auxiliary low water cut off for proper operation By opening the blowdown valves with the boiler firing the burners must shut off during this test If the burners do not shut off the control may require immediate servicing 3 Drain the sight glass 4 Visually inspect the boiler and water feed system for any water or steam leaks in the pi...

Page 19: ...pilot flame Notify service organization if readings are high low or fluctuating Hand Hole Plates Monthly Operator Visually check for leakage and replace gaskets as necessary Firing Rate Control Annually Service Technician Verify BTU input and gas pressure and check with combustion test analyzer Igniter or Pilot Annually Operator Make visual inspection and check flame strength with appropriate equi...

Page 20: ...ate rocks back and forth remove the high spots on the hand hole plate with a file Note Do not leave the hand hole plate installed without the gasket 11 Install the gasket on the hand hole plate Make sure the gasket is pressed firmly down on to the hand hole plate Do not use any grease lubricants or adhesives when installing handhold gaskets 12 Reinstall the hand hole plate into the boiler 13 Repla...

Page 21: ...nstalling a new sight glass 8 Slide the new glass into the upper fixture Glass should clear the lower fixture and tilt into position 9 Slide the sight glass down into the lower fixture until it stops Equalize the gap between the upper and lower fixtures by lifting the glass approximately 1 8 so it is not resting on the bottom fixture 10 Tighten the sight glass packing nuts hand tight 11 Use a wren...

Page 22: ...loat or float arm 10 Check the float for any holes Hold the float submerged in a bucket of water and look for any air bubbles coming from the float 11 Always reassemble the McDonnell Miller operating mechanism to the body with a new gasket 12 Reinstall the eight bolts to the operating mechanism Draw up the bolts evenly to prevent damage to the gasket body or operating mechanism Do not over tighten...

Page 23: ...r screws on top of the probe enclosure with a Phillips screwdriver 3 Remove the wire from the probe using a 5 16 wrench or a crescent wrench Only the wire on the probe is to be removed 4 Use a 13 16 spark plug socket and remove the probe 5 Clean the stainless steel probe and probe fitting 6 Reinsert the probe using a 13 16 spark plug socket Only tighten the probe enough to stop any steam leaks Ove...

Page 24: ...e boiler If the McDonnell Miller does not shut down the boiler the auxiliary low water cut off will shut down the boiler 10 If the boiler has optional controls refer to the wiring diagram B Basic Service Tools The following basic equipment will aid in troubleshooting Lattner boilers Not all equipment is needed for every repair 1 Schematic diagram of the boiler 2 Volt ohm meter 3 Ammeter 4 Gas pres...

Page 25: ...er 3 Operating pressure switch Honeywell Controller is not operating correctly Boiler shuts down on auxiliary low water cut off 1 Pump switch is turned OFF 2 Probe wired incorrectly 3 Probe has scale dirt or debris on it 4 Probe not seated in probe socket properly 5 Auxiliary level control relay wired incorrectly 6 Foaming problem in boiler possible chemical over treatment 7 Water in boiler is too...

Page 26: ...for which the Purchaser may be liable to other persons or damages to property The remedies set forth in this Warranty are exclusive and the liability of Lattner with respect to any contract or sale shall not exceed the cost of repair or replacement of the boiler or other equipment manufactured by Lattner The above Warranty shall not apply to any boiler or other equipment manufactured by Lattner wh...

Page 27: ...ges in transit and a minimum 15 restocking charge and only if the authorized material is in new and unused condition and returned within one year from original date of shipment The credit will be based on the original invoice price or the current price whichever is lower less the applicable restocking charge SECURITY INTEREST For the purposes of securing payment the Company may issue a lien on the...

Page 28: ...and gasket is in place make one last cleaning swipe of the mating surface in the boiler Use a rag wrapped around your finger 4 Set crab then center plate in opening and tighten nut enough to give a snug fit Then snug up with 1 4 turn of wrench SPECIAL NOTES If gasket leaks while pressure is being built up tighten only enough to stop leakage Never over compress a gasket Gaskets on the bottom of a b...

Page 29: ...is case vacuum pressure in the boiler would suck the cover plate in and allow the water to leak out of the boiler Re using gaskets after they have been in service is not recommended Topog E Bolt Gaskets when required should be used with Topog E Handhole Gaskets Topog E Gaskets are sold for use in steam water air and other selected applications only Recommendations for use of Topog E Gaskets are ba...

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Page 44: ...y internal threads To do so may cause the sealing compound to enter the valve and cause seat leakage Do not use the valve body or bonnet for installing the valve in threaded connections Use the wrench flats provided to tighten the valve to the connecting pipe and do not overtighten To do so may cause valve leakage 4 For flanged valves use new gaskets and tighten the mounting studs evenly Operation...

Page 45: ...and operating controls installed on the boiler 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 BTU hour or operating above 15 psi of steam pressure At least two controls should be connected in series...

Page 46: ...UMP OFF PUMP ON 3 4 DIFFERENTIAL 19mm PUMP OFF BURNER OFF NORMAL BOILER WATER LINE 113 16 DIFFERENTIAL 46mm BURNER CUT OFF LEVEL 3 8 9 5mm BELOW CAST LINE OPERATION Maximum Pressure 150 psi 10 5 kg cm2 Electrical Ratings Settings and Differential Pressures Values are 8 3 2mm Series 150 150S 157 and 157S 150 psi 10 5 kg cm2 Levels 150 psi 10 5 kg cm2 Levels 0 psi 0 kg cm2 150 psi 10 5 kg cm2 Approx...

Page 47: ...he Repair Procedure provided Snap switches must be replaced as an assembly CAUTION Replacement Switch Assembly Replacement Mercury Tubes 2 Wire Pump 3 Wire Burner NOTE More frequent blow down may be necessary due to dirty boiler water and or local codes BLOW DOWN PROCEDURE Blow down the control when the water in the boiler is at its normal level and the burner is on Slowly open the upper then the ...

Page 48: ...ering level Listings U L limit control recognition 353 240 and 208 volt units are not U L limit control recognized Installation 1 Install octal socket in appropriate enclosure using two 6 or 8 metal screws 1A Install rail mount socket on appropriate rail DIN mount in appropriate enclosure if applicable 2 Wire control per wiring diagram following N E C and local codes 3 Install control module in so...

Page 49: ... of power However loss of liquid will cause control to de ener gize and remain so until liquid again rises to electrode and pushbutton is depressed Dirty Electrode Detection The LED will flash every half second once the probe resistance reaches a value greater than the nominal control sensitivity rating The relay state will not change until it exceeds the nominal sensitivity by more than 25 typica...

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