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INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Easco Boiler Corp 1175 Leggett Ave Bronx, NY 1047 T: 718.378.3000 F: 718.378.4560 [email protected] easco.com

Page 3 of 46

CONTENTS

PREFACE AND STATEMENTS

IMPORTANT INFORMATION

SECTION 1: GENERAL

1.1

Introduction

1.2

Specification Requirements & Approvals

SECTION 2: REQUIREMENTS

2.1

Installation & Service Qualification

2.2

Operation, Care & Continued Maintenance Qualification

2.3

Codes, Standards, Local Jurisdictions Utilities

2.4

Warranty

SECTION 3: IDENTIFICATION AND CONFIGURATION

3.1

Manufacturer’s Data Plate

3.2

ASME Name Plate

3.3

Manufacturer’s Data Report

3.4

Configurations

SECTION 4: INSTALLATION INSTRUCTIONS

4.1

Inspection of Equipment Shipment

4.2

Placement Setting of Equipment

4.3

Flue Gas Venting Requirements

4.4

Combustion and Ventilation Air Supply

4.5

Equipment Field Connections

4.6

Operating Controls and Safety Devices

4.7

Fuel Burning and Handling Equipment

4.8

Domestic Hot Water Tankless Heater

4.9

Boil-Out Instructions

4.10

Cleaning a New Steam Boiler

4.11

Cleaning a New Hot Water Boiler

SECTION 5: OPERATION INSTRUCTIONS

5.1

BoilerOperation

5.2

Feed Water Connection

5.3

FiringApparatus

5.4

Pressure and Temperature Controls

5.5

Water Level Controls

5.6

Maintenance of Low Water Cut-Off Devices

Содержание FST Series

Страница 1: ...PLW 3 Pass Series FPS 4 Pass Water backed Steel Horizontal Firetube Boilers Manufactured in Accordance to Current Approved Edition of the ASME Boiler and Pressure Vessel Code Section IV Rules for the...

Страница 2: ...ble efficient service All components of Equipment were chosen for their ability to enhance this design goal Although these components provide high degree of protection and safety during normal operati...

Страница 3: ...3 2 ASME Name Plate 12 3 3 Manufacturer s Data Report 12 3 4 Configurations 13 SECTION 4 INSTALLATION INSTRUCTIONS 14 4 1 Inspection of Equipment Shipment 14 4 2 Placement Setting of Equipment 15 4 3...

Страница 4: ...urfaces 33 6 3 General Maintenance Considerations 35 6 4 Repair Parts 36 SECTION 7 WATER TREATMENT 37 7 1 Boiler Water Treatment Considerations 37 7 2 Make pH or Alkalinity Test 37 7 3 Services of Wat...

Страница 5: ...t be maintained and operated only by competent and qualified operating and service personnel who are fully trained and thoroughly familiar with same equipment system application and ancillary support...

Страница 6: ...plicable Codes and Standards of the most current approved and or accepted Editions governing the design handling installation commissioning operation care and continued maintenance of such equipment i...

Страница 7: ...nd all combustible materials such as rags paper wood paint or other debris shall be kept clear of boiler room environs Boiler room shall be kept clean and free of fire hazards 8 Safety Precautionary N...

Страница 8: ...llons Per Minute Horsepower Inches Pound s Lowest Permissible Water Level Low Water Cut Off Maximum Allowable Work Pressure Maximum Allowable Work Temperature Master Bill Thousands of BTUH Manufacture...

Страница 9: ...ceed the minimum efficiency criteria and requirements of ASHRAE Standard 90 1 Energy Standard for Buildings Except Low Rise Residential Buildings I P Edition This Manual provides the required informat...

Страница 10: ...per and safe installation commissioning operation care and continued maintenance of the Equipment 2 2 Operation Care and Continued Maintenance Qualification Operation care and continued maintenance of...

Страница 11: ...es as published by Manufacturers of any and all component part of this Equipment must be adhered to assure the proper and safe design handling installation commissioning operation care and continued m...

Страница 12: ...5 and to the front tube sheet of a Firebox Vessel at about 90 This Stamp Plate includes information explicitly Certified By the Manufacturer regarding MAWP and MAWT heating surface area minimum relief...

Страница 13: ...width reversing chamber also completely submerged within water contained in the vessel shell a therefore narrow width firetube layout pattern an relatively extended vessel length to compensate the sm...

Страница 14: ...ure by the transportation carrier agent of this eat time of delivery regardless of any dispute which may ensue with transportation carrier agent regarding Equipment condition or shortage 4 1 5 Equipme...

Страница 15: ...Equipment shall be so located as to provide for proper venting and adequate clearances and means for general access inspection maintenance serviceability and installation of field piping and electric...

Страница 16: ...nt positive pressurization of breeching and chimney systems during normal operation Breeching and chimney systems shall be designed installed and maintained in a manner as to prevent any source of lea...

Страница 17: ...During cold start up procedures condensation will likely occur until Equipment reaches operating temperature limits If condensation persists the low temperature or pressure limit or fuel input turn d...

Страница 18: ...sure Gauge of 4 1 2 in dial 0 30 PSIG ASME accuracy ASME Safety Valve s 4 6 2 STANDARD WATER TRIM McDonnell Miller No 63 M MAWP 50 PSIG or No 150S MAWP 150 PSIG Float Type LWCO with Manual Reset or PS...

Страница 19: ...mended by its manufacturer 4 8 2 The following guidelines should be followed when piping tankless heater a FLOW REGULATION If flow through the heater is greater than it s rating the supply of adequate...

Страница 20: ...If a local water treatment company is going to be part of your boiler maintenance program they should be contacted for recommendation as to what boil out chemicals they recommend and how they will af...

Страница 21: ...the firesides and become evident at the drains provided in the smoke boxes This is normal and should not be cause for alarm 12 Operate the Boiler as though in conventional service reaching normal ope...

Страница 22: ...9 5 The Boiler must be fired at a low rate for at least one day to dry out the refractory linings Adjust the firing apparatus for a low firing rate and operate intermittently to keep combustion chambe...

Страница 23: ...r can be discharged with safety 6 When the Boiler has cooled down to 120 F or below refill it to the normal water line If water in gauge glass does not appear to be clear repeat steps 1 through 5 abov...

Страница 24: ...ing the radiation 8 Allow boiler water to reach operating temperature if possible 9 Continue to circulate the water for a few hours 10 Stop firing the Boiler 11 Drain the system in a manner and to a l...

Страница 25: ...oilers Top of lower gauge glass nut lowest visible water level must be located 3 in above the top of the highest firetube projection 5 1 2 Section IV Low Pressure Heating Boilers Top of lower gauge gl...

Страница 26: ...state local and insurance regulations 5 3 3 Adjust burner according to the burner manufacturer s specifications Refer to burner manufacturer s Installation Operation and Maintenance Manual furnished...

Страница 27: ...sed to possible contamination in the boiler water and subject to fouling It is important to physically remove the probe from the boiler tapping annually and inspect that probe for accumulation of scal...

Страница 28: ...nel to the extent necessary to insure freedom from obstructions and proper functioning of the working parts Inspect connecting lines to Boiler for accumulation of mud scale etc and clean as required E...

Страница 29: ...Boiler The use of the blow off or drain valve in a low pressure heating Boiler is for discharging rust colored water and sediment which settles to the bottom of the Boiler Quantity and frequency of b...

Страница 30: ...r size 5 9 3 The return water temperature should always be within 40 F to the supply temperature 5 9 4 Return water temperature should be continuously monitored Anytime when the return water temperatu...

Страница 31: ...e fluctuation and flow through the Boiler must be observed 5 10 1 It is important to operate your Boiler in such a manner as to prevent temperature fluctuation of more than 40 F at any time Rapid temp...

Страница 32: ...at the same time 6 1 2 Have burner and controls checked at least once a year or as may be necessitated 6 1 3 Retain your contractor or a competent serviceman to assure that the unit is properly adjust...

Страница 33: ...f relief must be investigated and corrected Excess pressure is dangerous and can cause damage to the heating system personal injury and serious property damage 6 2 5 DO NOT draw water from Boiler whil...

Страница 34: ...e to heat system to high temperature and vent again This will make less venting necessary during the winter 6 3 4 Where an expansion tank is used makes sure that neither the tank nor its drainpipe is...

Страница 35: ...718 378 4560 info easco com easco com Page 35 of 46 6 4 Repair Parts Give Boiler Series and Model Number when ordering repair parts All repair parts can be ordered through the commercial sales office...

Страница 36: ...efilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with hydroid paper which is used in the same manner...

Страница 37: ...he water is soft this makes the water acidic and corrosive The boiler metal and condense return lines will be attacked This can be general overall corrosion or localized pitting or cracking in stresse...

Страница 38: ...still recognized as one of the best inhibitors for protection of metal although it is now prohibited by most states or cities for use as water treatment due to the toxic effect of the chromate when du...

Страница 39: ...litmus paper except it gives specific readings A color chart on the side of the small hydroid dispenser gives the reading in pH Hydroid paper is inexpensive and obtainable from any chemical supply hou...

Страница 40: ...ses in load sudden pressure drop In case of serious trouble stop the burner and decrease the load on the Boiler until the true level can be determined Then alternately blow down and feed fresh water s...

Страница 41: ...plates washout plugs and water column connections should be removed and the furnace and combustion chambers thoroughly cooled and cleaned 3 All grates of internally fired Boilers should be removed 4...

Страница 42: ...rfaces Bulging Blistering Leaks Particular attention should be given to the plate or tube surface exposed to fire The inspector should observe whether any part of the Boiler has become deformed during...

Страница 43: ...essive vibration o Low Water Cut Off All automatically fired Boilers are required to be equipped with an automatic low water fuel cutoff so located as to automatically cut off the fuel supply when the...

Страница 44: ...d by the inspector a hydrostatic test shall not exceed that specified by applicable code During the test the safety safety relief valve should be removed from the Boiler as should all controls and dev...

Страница 45: ...port came with the Boiler to be repaired 8 3 Safety Every precaution must be taken to insure against injury to personnel who are working in the boiler room and particularly to those working inside the...

Страница 46: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL Easco Boiler Corp 1175 Leggett Ave Bronx NY 1047 T 718 378 3000 F 718 378 4560 info easco com easco com Page 46 of 46 NOTES...

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