Precision Boilers FTS Series Manuel utilisateur

Installation and

Operating Instructions

Precision Flextube Boilers

FTS Series

STEAM BOILERS

FOR YOUR SAFETY

This manual supplies information on the application, installation and operation of Model MCH Boilers.

Review all application and installation procedures completely before proceeding with the installation.

Consult the Precision Flextube Boilers’ Factory or local Factory Representative with any problems or

questions regarding this equipment. Experience has shown that improper installation causes most

operation problems.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause injury or property

damage. Read this manual thoroughly and follow the instructions herein.The MC Series Boilers shall be

installed according to the procedures detailed in this manual, or the Precision Flextube Boilers Limited

Warranty may be voided. The installation must conform to the requirements of the local jurisdiction

having authority, and to the latest edition of the National Fuel Gas Code, ANSI Z223.1. Any modifications

to the boiler or its gas / oil controls may void the warranty. If field installation requires modifications,

consult either the local Precision Flextube Boilers’ Representative or the Factory.

RETAIN THESE INSTRUCTIONS NEAR THE EQUIPMENT FOR READY REFERENCE

Installation and Operating Instructions

Precision Flextube Boilers

FTS Series HOT WATER BOILERS

TABLE OF CONTENTS

ITitle page ................................................................1

II Introduction............................................................2

III Index ...................................................................... 3

1.0 GENERAL INFORMATION

1.1 General Description ............................................ 4

1.2 Receiving Shipment ............................................ 5

1.3 Engineering Assistance .......................................5

1.4 Warranty ............................................................. 5

2.0. BOILER INSTALLATION

2.1 Receiving ............................................................. 5

2.2 Placement ...........................................................6

2.3 Piping Connections ............................................. 6

2.4 Fuel Supply Piping...............................................7

2.5 Electrical Connections.........................................8

2.6 Combustion Air Supply .......................................9

2.7 Combustion Gas Exhaust Connection ................9

2.8 Before Placing the Boiler into Operation ......... 10

2.9 Firing Rate Adjustments ................................... 10

3.0 SAFETY AND CONTROL DEVICES

3.1 Flame Supervisory System................................ 11

3.2 Flame Detection System ...................................11

3.3 Low Water Cut-Off ............................................ 11

3.4 Combination Low Water Cut-Off & Feeder...... 12

3.5 Combination Low Water Cut-Off Level Ctrl...... 12

3.6 Modulating Level Control ................................12

3.7 Pressure Control................................................12

3.8 High Pressure Limit –Auto Reset .....................12

3.9 High Pressure Limit- Manual Reset ..................12

3.10 Safety Valves ...................................................13

4.0 BOILER START-UP

4.1 Limit Circuit Cut-Out Test .................................13

4.2 Steam Temperature Operating Control ...........13

4.3 Additional Controls ...........................................13

4.4 Burner Start-Up.................................................13

4.5 Boil-Out .............................................................13

5.0 BOILER OPERATION

5.1 Curing ................................................................14

5.2 Water Chemistry ...............................................14

6.0 OPERATING INSTRUCTIONS

6.1 Temperature Controls.......................................15

6.2 High Temperature Limit –Auto Reset ..............15

6.3 High Temperature Limit –Manual Reset .........15

6.4 Forced Draft Adjustment ..................................16

7.0 MAINTENANCE

7.1 General ..............................................................16

7.2 Procedures ........................................................16

8.0 SHUTDOWN ......................................................16

9.0 EXTENDED SHUTDOWN ...................................17

1.0 GENERAL INFORMATION

PRECISION has made a commitment to product improvement and follows a continuing quest for

the highest standards of product performance. In pursuing this policy of continuous development

of products, the manufacturer reserves the right to vary any details in this manual without notice.

1.1 General Description

The Model MCS is a watertube boiler in which water is inside the tubes and combustion gases

are outside the tubes; it consists of three major components, the support structure, the

pressure vessel, and the casing. This particular boiler is designed to combine the higher

efficiencies of some firetube designs with the rapid responses typical of watertube designs.

1.1.1 Support Structure

The boiler is built on a heavy duty fabricated steel structure. This steel structure is designed to

support the movement and ‘rigors’ of shipping as well as the operating weight of the boiler.

The support structure is not designed to withstand heat generated by the boiler, and is

insulated from that heat. The support should be located above floor level on an elevated

housekeeping pad.

1.1.2 Pressure Vessel

The pressure vessel is constructed of carbon steel designed and tested to ASME code

requirements. The pressure vessel carries an ASME National Board number as registered with

the National Board, and includes the following major components:

1.1.2.1 Upper and Lower Headers

The lower header (mud drum) distributes water to the heat exchanger section of the boiler;

water then flows from the heat exchanger section to the upper header (steam drum) where the

steam separates from the water. Thus, separation is further aided by a mechanical steam

separator located in the header below the steam discharge nozzle. The headers are drilled to

exact dimensions for connection and support of the heat exchanger section. There are also

downcomers connected between the upper and lower headers at each end of the boiler. The

downcomer allows a natural circulation to recycle water flow from the upper header to the

lower header.

1.1.2.2 Heat Exchanger

The heat exchanger section is constructed of heavy gage steel tubes connected between the

top and bottom headers. These tubes are constructed in a ‘serpentine’ fashion and are

designed to require the combustion gases to take a long route to the boiler exhaust. This

additional time allows more heat exchange and effectively increases the heat exchanger

capacity. The tubes form a tangent waterwall, which surrounds the combustion chamber on

the top, bottom and side opposite the headers. Tubes are normally attached to the header

with ferrules, which are driven into the headers and head in place by bolted ‘keeper’ plates.

This arrangement allows for simple and easy tube replacement if the need occurs.

1.1.3 Boiler Casing

The boiler casing system consists of both an inner and outer casing, and contains all combustion

gases in their route to the boiler exhaust. By containing all the gases, the inner casing keeps

the boiler room free of exhaust gas. The boiler inner casing is constructed of heavy gage

reinforced steel plate and is insulated with layers of mineral wool and ceramic fiber to protect

the steel and retain the heat to effect higher boiler efficiency. The outer casing is separated

from the inner casing with fiberglass insulation which protects personnel from high heat and

allows a cooler boiler space. Access to the boiler combustion area is normally done by

removing a boiler side wall. The wall on the

header side of the boiler is designed to be easily removed.

1.2 Receiving Shipment

Some accessory items may be shipped in separate packages. Verify the receipt of all packages

listed on the packing slip. Inspect everything for damage immediately upon delivery, and advise

the carrier of any shortages or damage. File any such claims with the carrier. The carrier, not

the shipper, is responsible for shortages and damage to the shipment, whether visible or

concealed.

1.3 Engineering Assistance & Customer Service

Consult the Local Precision Flextube Representative or Factory regarding any questions or

problems which may come up involving the specification, installation or operation of Precision

Flextube Boilers equipment. An experienced engineering staff is ready to assist in assuring their

proper application and performance.

1.4 Warranty

Precision Flextube Boilers are covered by a limited warranty. A copy of the warranty will be

provided after all documents have been processed. Make all warranty claims to an authorized

Precision Boilers’ representative, or directly to the Factory. Claims must include the unit serial

number and model (per the name plate), installation date, and name of the installer. Shipping

and labor costs are not included in the warranty coverage.

2.0 BOILER INSTALLATION

2.1 Receiving

Electrical equipment can be damaged if exposed to adverse weather. The unit should be stored

inside. The electrical panel and controls must be covered with plastic throughout all

construction to avoid accumulation of dust and moisture on the controls and other

components.

Care must be taken not to damage controls or to deform the unit’s casing during removal of the

crate. When using pry bars or fork lifts, be certain to support the unit on the shipping skids or

the channel base.

2.2 Placement

2.2.1 Foundation

The boiler location should be prepared before uncrating the boiler. A concrete boiler

foundation is recommended; the foundation should be level and designed to adequately

and uniformly support the boiler operating weight. An existing concrete floor may be used only

if it is determined that it will be adequately and uniformly support the boiler operating weight.

CAUTION: DO NOT INSTALL BOILER ON COMBUSTIBLE FLOORING.

2.2.2 Clearance

See Table 1 for minimum clearances to wall, ceilings or obstructions. The clearances in the

Table 1 are intended as general recommendations only. Local codes must be adhered to and

minimum clearances established accordingly. Provisions must also be made for service,

accessibility and clearance for piping and electrical connections. Do not obstruct combustion

air and ventilation openings with piping, etc. All boilers must be installed in a large space

compared to the boiler physical size.

NOTE: Adhere to all applicable local codes regarding boiler installation and clearances. Be sure

to keep burner and controls covered at all times while work is in progress.

Table 1

BOILER CLEARANCES

Clearance

From / To

Model #

MCH-1

(9.5 –60 bhp)

Model #

MCH-2

(60 –110 bhp)

Model #

MCH-3

(120 –200 bhp)

Above Boiler

18”

Front of Boiler

42”

Back of Boiler

24”

Header Side of

Boiler

28”

Tube Side of Boiler

18”

NOTE: Standard Boilers have headers on left side.

2.3 Piping Connections

2.3.1 General

Boiler service piping should not be routed along the header side of the boiler. Maintain

clearances are shown on the dimensional drawing for servicing of the boiler tubes. See the

boiler dimensional drawing provided for minimum clearance dimensions for the gas (fuel

piping) train and burner. All piping should be designed, supported and installed to avoid any

piping weight transmitted to the boiler / burner connections.

CAUTION: THE BOILER IS NOT DESIGNED TO SUPPORT EXTERNAL PIPING LOADS.

2.3.2 Process Flow Connections

The process system feedwater and steam connections are shown on the boiler dimensional

drawing. The necessary code valves for feedwater, steam supply, and blowdown are normally

supplied with the boiler. To allow for inspection and cleaning, the drain valve can be opened

after the boiler is isolated and de-energized.

2.3.3 Safety Relief Valve(s)

A connection is provided in the top of the boiler for the relief valve(s). The relief valve

discharge piping must be, as a minimum, the same size as the safety valve discharge opening.

All safety valve discharge piping must be independently supported with no weight carried by

the valve. Over-tightening screwed joints can distort valve seats. Pipe the relief valve outlet(s)

to the floor drain (Section IV boilers) or to overhead discharge outside safely away from

personnel (Section I boilers).

2.3.4 Boiler Air Vent / Expansion Tank Connection

The boiler is provided with a 3/4” vent valve located on the top of the low water cutoff bridle.

This connection is for venting air on boiler filling operations and hydrostatic testing.

2.3.5 Drain Connection

A drain valve is installed at the boiler drain connection. Piping, the same pipe size as this valve,

should be routed to a suitable drain point. Drain piping should be terminated within two feet

from the drain valve for easy viewing.

2.4 Fuel Supply Piping

2.4.1 General

The installation must conform completely to the requirements of the authority having

jurisdiction, or in absence of such, requirements shall conform in the U.S. to the current

National Fuel Gas Code, ANSI Z223.1, or in Canada to the current Installation Code for Gas

Burning Appliances and Equipment code (CAN/CGA B139-M91), or Oil Burning Equipment code

(CSA B139-M91), and applicable regional regulations for the class; which should be followed

carefully in all cases. Consult the local gas utility company for inspection and authorization of

all gas supply piping and flue connections. The regulator vent line must be vented to outside of

the building on any boiler equipment with electric gas pilot ignition.

2.4.2 Gas Supply Connections

Gas supply connections must comply with the National Fuel Gas Code (NFPA 54). Gas pressure

must be regulated to the required pressure for the burner. (Standard (Power Flame burners

require a range of 5 –12 inches of water pressure.) Consult the local gas company for all

inspection and authorization of all gas supply piping and flue connections. Gas connections

should be made with unions or flanges so that the boiler gas train components and burner may

be easily removed for service, if necessary. A

drip leg or sediment trap must be installed in the gas supply line near the connection to the

burner gas valve train.

2.4.3 Fuel Oil Supply Piping

Fuel oil supply piping must be sized by a qualified engineer or contractor; pipe size must be

adequate to supply the required fuel flow. Oil supply connections must comply with NFPA 31.

Any additional local or state codes must also be adhered to. Oil supply lines must be sized for

the circulation rate of the burner pump. This is referred to as the suction gear capacity of the

pump. If a transfer pump is used, it must have a pumping capacity no less that the total suction

gear capacity of all burner pumps on the system. Refer to Burner Manual for the suction gear

capacity of standard oil pumps. Two-pipe oil systems are recommended in all cases, although a

one-pipe system might be acceptable on smaller boilers (under 6 gph). Two-pipe systems tend

to have fewer problems with air entrainment in the oil. Air in the oil will cause nuisance

problems and delayed ignition.

NOTE: Use pipe compound, which is resistant to the action of liquid petroleum gas. Do not use

Teflon tape.

2.4.4 Gas Piping Leak Test

After completion of the gas piping, the installation must be checked for leaks, using a soap and

water solution. Disconnect the boiler and gas train from the gas supply piping during any

pressure testing of the gas supply system.

2.4.5 Venting of Gas Train Components

The gas pressure regulator, diaphragm gas valves, vent valves, and gas pressure switches must

be vented outside the boiler room; minimum pipe or tubing size if 1/4”.

All gas train components must be independently routed. Vents routed to a common pipe can

experience pressure in the event of a leak. This pressure is a false back-pressure to other

components and can cause malfunctions. Vent piping should terminate in a downward

direction and be free of restrictions.

2.5 Electrical Connections

IMPORTANT: All electrical connections must conform to the National Electrical Code and to all

other applicable State and Local Codes. Most forced draft boilers require a 3-phase power

connection. See boiler wiring diagram and equipment list for details. The boiler must be

grounded in accordance with the American National Electrical Code, ANSI / NFPA #70 –Latest

Edition.

The boiler is supplied with burner(s) from various burner manufacturers. The burner

manufacturer’s ‘AS BUILT’ wiring diagram is provided as part of the documentation package

supplied with the boiler. Specific questions related to the burner controls and burner wiring is

referenced to that drawing. Controls are added to the boiler to allow the boiler to perform its

designed function. These controls are found on the Wiring Diagram provided; the drawing is

WD –‘Boiler Serial Number’.

Any questions not answered by the provided information may be answered by a call to the

Factory.

2.6 Combustion Air Supply

2.6.1 Combustion Air –General

Complete combustion of natural or propane gas requires approximately ten cubic feet of air (at

sea level and 70°) for each 1000 BTU of boiler input. In reality, additional air is required to

achieve complete combustion. Additional air is required for the proper operation of the

appliance draft diverter or barometric damper.

WARNING: Failure to provide an adequate air supply will result in boiler damage and hazardous

conditions in the building (fire and asphyxiation hazard as well as equipment damage). Please

note the following:

a. Positive means for supply an ample amount of outside air, allowing complete combustion of

the gas, must be provided.

b. Moveable combustion air dampers, automatic or manually adjustable, must be electrically

interlocked with the boiler to prevent boiler operation if the dampers are closed.

c. Combustion air openings must never be blocked or obstructed in any manner. The boiler

room must be at a positive or neutral pressure relative to the outdoors. Negative pressure, in

the boiler room, will result in downdraft problems and incomplete combustion due to lack of air

2.6.2 Ventilation Air

In addition to air needed for combustion, sufficient air must be supplied for ventilation,

including air required for personnel comfort and proper working conditions in the boiler room.

In colder climates, if needed for personnel comfort, provision should also be made to heat the

boiler room.

CAUTION: PROTECTION FROM COMBUSTION AIR CONTAIMINATION: Where corrosive or

flammable process fumes are present in the vicinity of the boiler room or the air stream for the

combustion air supply, it is essential that suitable means be provided for their safe disposal.

The boiler room and the combustion air supply must not be exposed to these fumes. Such

fumes include, but are not limited to, carbon monoxide, hydrogen sulfide, ammonia, chorine

and halogenated hydrocarbons.

NOTE: Halogenated hydrocarbons are particularly injurious and corrosive after exposure to

high temperatures.

2.7 Combustion Gas Exhaust Connection

2.7.1 Code Compliance

The installation must conform to the requirements of NFPA 54, the National Gas Code (ANSI

Z2223.1), Part 7, “Venting of Equipment”, or to the applicable requirements of all local building

codes. For factory-built and listed chimney systems(such as type B vent), consult the system

manufacturer’s instructions for correct installation procedures. Gas vents may be of any of the

construction types listed in this manual. No portion of a venting system may extend into or

pass through any circulating air duct or plenum.

NOTE: Additional state and local codes may apply and must be consulted.

2.7.2 Flue Gas Economizers

When applying flue gas economizers, care must be taken to assure that:

a. Proper draft must be maintained. This requires that the gas side pressure drop be

considered and that the economizer exchanger be designed so as to allow cleaning.

b. The vent system materials must be considered, regarding resistance from corrosion, which

might result from the lower flue gas temperature.

c. In general, it is recommended that the boiler manufacturer be consulted when a flue gas

economizer is to be added.

2.8 Before Placing the Boiler into Operation:

2.8.1 Hydrostatic Test of Boiler and System

After completing the boiler and burner installation, the boiler connections, fitting, attachments

and adjacent piping must be inspected for leaks by filling the unit with water. The pressure

should be gradually increased to a pressure just below the setting of the boiler safety relief

valve(s).

Remove the boiler header side panel (see dimensional drawing in this manual). Inspect the

tube to header joints to be certain that all tube fittings are sealed. Minor leaks in fittings and

attachments (although the boiler is hydrostatically tested at the Factory,) can develop from

shipping vibration or from installation procedures. It is often necessary to retighten such fitting

after the installation and after the boiler has been operated for some time. Replace the tube

access panel before proceeding to start boiler.

2.8.2 Test of Gas Piping

Reference gas system test under Section 2.4.4.

2.9 Firing Rate Adjustment –Forced Draft Boiler(s)

Refer to the burner manufacturer’s manual on the forced draft burner for start-up and

adjustment procedures. Do not attempt to start burner before all safety systems are checked

and fully operational. Insure the burner management system is properly installed and

operational. Do not attempt to start or operate if an accumulation of fuel is observed.

2.9.1 On / Off Firing Systems

2.9.1.1 Combination Gas Valves (VR850 or VR852)

The minimum input on these gas valves is NOT adjustable. The maximum input must be

properly set as outlined in the burner instructions. See the manufacturer’s instructions

on the VR850 or VR852 valves included in the Burner Manual for further information.

2.9.1.2 Dual Diaphragm Gas Valve High / Low By –Pass System

The minimum input on this control system is NOT adjustable. The maximum input must be

properly set as outlined in the burner instructions. This system consists of two V48A (120 volt

coil) or two V88A (24 volt coil) diaphragm gas valves which are piped in parallel. The minimum

input is controlled by or orifice plug installed in a coupling in the by-pass piping (low fire valve

piping) sized for approximately 1” WC manifold pressure at low fire for natural gas (2” WC if

propane gas). When the high fire gas is not activated,

gas flows only through the bypass piping. When the high fire gas valve is activated, gas will flow

through valves achieving full input.

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