william and davis boilers series 2000 d 150hp
TRANSCRIPT
l5Dhp
Series 2000D
E1001-02
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I NSTALLATION AND OPERATING INSTRUCTIONS FOR W&D SCOTCH BOILERS
PLEASE READ BEFORE STARTING INSTALLATION OR OPERATION
580
CAPABLE &
DEPENDABLE SINCE 1921
Williams & Davis Bo ile rs 2044 I -45 South Hutchins, Texas USA 75141 Direct : +1 (800) 8 -Boiler Office: +1(972) 225-2356 Fax : + 1(972) 225-5739 Visit our website at : www.wdboiler .com
Table of Contents
I. General Information
A. Boiler language.................................................................................................... ... ....... .... .. .......................... ... 3-5
B. Boiler Sizing............ .................. ...................................................... ........ ...... ................ ..................... ...... .......... 6
C. Fuels: ................................. .................... .......... ..... ............. .................................. .. .. ......................................... . 7
1. Natural Gas ............................................................... ... ... ....... .. ...... ........................ ................. .... .......... .. ... 7
2. Propane .............................. ............ .... ................................. ...... ............. ................... ..... ..... ...... ....... ...... .. .. 8
3. Oil.............. ..................... .................... .. ............ ...... ......... ............... .. ................... ..... ... ........... ......... ........... 8
D. Water Supply and Treatment................................................... ............... ........... .................................. .. ........ . 9
E. Electrical Supply................................. ... .... .... ...... ... .... ... ..... ................... .. ...... ................... ...... ...... ...... .... ........ .. . 10
F. local Codes............ ........... ...................... ...... ...... ... ............... ... .................... ....... ...... .. ..... .... ........ .. ..... ............... . 10
II. Installation Instructions
A. Permits and Codes .. ...... ............ ...................................................................................................................... 10
B. Boiler l ocation and Supports ............ ... ................. .......... .............................................................................. 10
C. Installation Check list....... ............................ .............................................................................. ...... ............. 11
D. Operation Instruction ...... ............. ................ .... ............................. ...... ....... ............ ............................. ........... 11-12
E. Weights ........................... .................... ..... ........ ........ ............ ..... .. ..... ........... ....... .......... ..... ...................... ......... 12
F. Concrete Pads .... ...... ..... .. .................. .... ...... ..... ................ .... ....... .. ... ........ ........... ....... ......... .. ..... ... ............ ....... 12
G. Gas Supply............................................. ......... ... .................. ..................... ...... ....... .... .... ............ ..... .......... ........ 13
H. Wate r Supply..................................... .............. ............. ..... .................. ... ...... ..... ................ ... ........ ................... 14
1. Boile r Feed Piping ... ........................ ................ ........... .. ................... ..................... ...... ...... ...... ................. 14
2. City Water to Boiler ................................. ... ........................ ...................... ................. ............. .. .............. 14
3. Chemical Feed .......................... ....... .............. ..................................................... .. ................ ... ......... .. ..... 14
I. Electrical Service ReqLJirements ................................................................................................................... 15
J. Stack Re quirements... ...... ...... ...... ........ ........................... ..... ................................... ....................................... 16
K. Blo1'1down and Separator Pi ping ................. .. ..................................................... ................... ............ .......... 16
l. Boiler Room Ventilation & Combustion A1r ........................ ................................................................... . ... 17
M. Safety Valve D1scharge l mes ............................................... ....... ...... .................................. ...... ........ ...... .. 18
N. Steam Supply & Condensa te Return............................................................. ........................................... 18
0. Boiler Piping....... ..... ...... .......................... .... . ..................... .......................................... ................. ........... .... 19
P. Blow - Off Valves........ ... ... ................................. ............................... .. .................. .......................................... 19
Ill. Maintenance
A. Da ily.............................. ..... ....................... .. ................................. .......... ........................ ... ....... ......................... 20
B. Weekly ......... .. ................. ....... ............... ......... ........................... ............ .. .... ............ .. ..... ........................... ....... 20
C. 90 Day............ ... ................................................................................. .................................................. ............. 20-21
D. Yearly........ .................................. ............... ... .. ................ ..... ....... ............................... .. ....... ....... .... ....... ........... . 21
E. Replacing Hand hole & Manhole Gaskets ............ .......................... .......................... .................. .. ............. .... 22
Page I 2
)
Arch
ASME Code
Baffle
Blower
Blowdown Separator
Boiler
Boiler Tubes
Breeching
Burner
Check Valve
Compression Gauge Cock
Contractor
Donut
Daft Door
Dry Pan
Electron tic Control
Bo il er Language
The refractory at the rear of the boiler that forms the top of the turn box.
A set of rules developed by the American Society of Mechanical Engineers that governs the minimum construction specifications of boilers and pressure vessels. It has been adopted by boiler manufacturers and users as a standard for safety and quality.
A steel trough used to disperse boiler feedwater as it enters the boiler. It prevents cooler feedwater from contacting directly with hot return tubes.
A mechanical device used to force air though a boiler for combustion .
A baffled tank used to separate the steam and water and kill the pressure so that the steam may be vented and the water drained to the sewer.
A pressure vessel used to transfer heat energy to a usable medium such as water.
A passage for products of combustion and hot gases used to heat water in Fire Tube Boilers.
The metal box at the stack end of the boiler that collects the flue gases from the tubes for remova l by the stack.
A device used to properly mix air and fuel and cause the chemical reaction of combustion and the attendant release of heat energy.
A device which allows flow in only one direct1on.
A manual valve located on the water column of the boiler trim which is used to determ1ne the location of the water level without the use of the gauge glass. Two or more compression gauge cocks are used together. If steam emerges from one and water emerges from the other, then the water level is between the two compression gauge cocks. They should be opened only when there is no water glass.
Normally an electrically operated switch used to relay single phase power to an electric motor or other similar load.
A ring of refractory material located in the boi ler furnace that IS used to stabilize furnace pressure.
An air register used to control the volume of combustion a1r entering the furnace.
A steel plate located under the steam nozzle to prevent water from splashing in to the steam nozzle and being carried out mto the steam distribution system .
A safety device which controls the sequence of operation of the burner. The general sequence of opera tion of most electronic controls 1s first to establish and prove that a pilot flame is present and then to allow the main volume of fuel to flow to the burner.
Page I 3
Feed Pump
Firetube
Gas Pressure
Gas Pressure Regulator
Gauge Glass
Hand holes
Head
Ignition
Transformer
Inspection Door Plug
Jacket
Load
Magnetic
Starter
Main Gas
Valve
Manhole
fVli llboard
Non-Return Valve
Peep Sight
Pilot
Pilot Gas Valve
Refractory
A water pump used to inject water into the boiler.
A primary combustion furnace of the boiler.
The force per square inch exerted by the gaseous fuel which causes flow through the burner when the control valves are opened.
A mechanical device which can control the gas pressure by using an opposing spring pressure.
A glass tube that will withstand pressure that allows the level of water in a boiler to be visible.
Openings provided in the boiler pressure vessel that allow ordinary maintenance of the boiler pressure vessel,
including cleaning, inspection and tube removal. Handhole openings are usually a 3" x 4" oval opening.
The flat ends of the boiler pressure vessel or the tube sheets into which the return tubes are rolled and beaded .
An electrical device which makes available electrical energy in a form which can cause a spark to ignite the burner fuel.
A refractory access opening in the rear door of the boiler which allows access to the combustion area for inspection without opening the rear door.
A metal covering placed over the boiler insulation for appearance and protection of the insulation .
The output required of the boiler.
An electrically operated sw itch that relavs three-phase power 10 an electnc motor or other similar load.
An electrically opera ted valve which controls the flow of the main volume of gas to the burner
An opening in the boiler pressure vessel to allow ordinary maintenance and inspection of the boiler pressure
vessel.
A board made of ceramic fiber material which is used to line the front breaching.
A main steam shut-off valve provided with a built-in check valve.
An observation port prov1decl in the burner fron t and the rear door of the boiler for v1sual check of burner flame.
A small gas flame Llsed to ignite the main volume of fuel. Also known as the pilot gas burner assembly.
An electrically operated valve used to control the flow of gaseous fuel to the pilot burner.
A material which will withstand high temperatures. Boiler refractories usually should withstand temperatures in
excess of 2,6oo· F.
Page I 4
) I
. I
Scanner
Shell
Stack
Transformer
Tri-Cock
Heatmizer
Turn-Box
Vertical Check Valve
Water Column
Water Treatment
W &D
An electronic device used to convert ultra-violet, visible, or infra-red light into an electronic signal that can
be used by an appropriate electronic control to prove the existence of a flame within a boiler furnace.
The cylindrical outer portion of the boiler pressure vessel into which all of the external openings are welded.
The ven t used to remove the combustion gases from the boiler furnace to the outside atmosphere.
An electrical device used to change one alternating current vo ltage in to another alternating curren t voltage.
A manual valve located on the water column of the boiler trim which is used to determine the location of the
water level withou t the use of the gauge glass. Two or more tri-cocks are used together. If steam emerges from
one alone and water emerges from the other, then the water level is between the two tri-cocks. They should be
used only when there is not water glass.
Bent metal straps engineered to break up smooth flow through the return tubes, thus making the flow turbulent,
thereby allowing more hot gases to come in contact with the retu rn tube surfaces and causing an increase in heat
transfer to the boiler water.
The area at the rear of the boiler that allows the combustion gases from the firetube to flow to the return tubes.
A device which allows flow in only one direction, and may be installed in piping running vertically.
A Vertical tubular member connected at its top and bottom to the steam and water space respectively of a boiler,
to which the water gauge, compression gauge cocks, high and low level alarms and fuel cutoff may be connected.
The method used to render the available raw water useful and safe for boiler operation. The Object of water
treatment is to remove impurities which would form harmful scale deposits, or excess oxygen which would
cormde metal Sllliaces with in the boiler.
A sign of quality and service-initials and trademark of Williams & Davis Boilers. The appearance of "W&D" on a boiler or related equipment signifies the highest obtainable standard of craftsmanship accrued for over 70 years of boiler manufacturing and service.
Page I 5
Boiler Sizing
Boilers are sized according to the amount of useful heat they make available. Heat is measured in BTU's (British Thermal Units)
One BTU is defined as the amount of heat required to raise the temperature of one pound of water one degree Fahrenhei t .
Below are some of the relations required in boiler sizing:
One boiler horsepower equals:
a. 33,475 BTU per hour output.
b. 34.5 pounds steam per hour output.
c. 9.81 Kilowatts input
One mechanical horsepower equals:
a. 33,000 foot-pounds per minute
b. 2,546 BTU per hour
One electrical horsepower equals:
a. One mechanical horsepower
b. .746 Kilowatts
One Kilowatt equals:
a. 1,000 watts
b. 1.34 mechanical horsepower
c. 3,415 BTU per hour
d. 44, 236.5 foot-pounds per minute
To determine the size required, add up the requirements of each individual piece of equipment and then add at least 10%
to the total requirement.
Machine Boi ler
Ad Justa-Form Body & Bosom Press Collar & Cuff Press Handy Ironer, 54" Ironing Board Sleever Spotting Board
Horsepower'
2.00 1.00 1.00 1.20 .25 .SO .33
Laundry & Dry Cleaners
1V1acn1ne
Yoke Press 2-roll, 120" Ironer 3-head Puff Iron 30" X 42" 40" Press
Boiler Horsepower
.so 3. 80 .25 2.50 1.00
52" Press 1.50 Water ga l
100 degree rise in one hour 2.50 ' Approximate figures. Manufacturer's Data be used when available
Feed Mil l
1 boiler HP per 1" ot roll Yz boiler HP per one horsepower of Pellet M ill
Page I 6
Fuel
Natllral Gas
Domestic and Commercial distribution pressure - 4 oz. Industrial distribution pressure ranges up to 30psi and occasionally higher.
Natural gas is metered by the gas company primarily to determine the volume of gas that 1s consumed for the purpose of charging their customers. The meter may also be used to determine the volume of gas required by individual pieces of equipment used by a customer. It is important, therefore, for the customer to understand how to read a meter.
The most common type of meter has a series of dials that rotate in opposite directions and record the volume of gas used in
multiples of ten. One dial measures each cubic foot. The next dial measures each 10 cubic feet and so on until the last dial usually
records each 100,000 cubic feet on small domestic meters.
100,000 10
The read1ng in Figure 1, above, would be 416,712 cubic feet. As gas is used, the read1ng becomes larger To obta'n the volume
of gas consu med over a period of time, the reading taken at the beginning of the period is subtracted from the reading taken
at the end of the period.
To establish the volume of gas being used by a particular piece of equipment, f irst turn off all other equipment. Make sure
the equipment bemg tested is set for max1mum input. M onitor the 10 cubic foot dial for one minute and count the cubic feet
consumed by the equipm ent. To obtain the BTU input each hour, multiply first by 60 min/hour and then by 1,000 BTUift.]
When pressures above 4 oz. are present through the meter, a correction factor must be applied to the volume read at the
meter The exact correct1on factors can be obtained from the gas service company. An approximation can be made. however,
using the following formula.
Correction Factor =
The correction factor is then applied to the volume read .
EXAMPLE·
Pressure at meter =30 psi Volume r ead at meter =90 cubic feet per minute
(]Jressure at meter· in psi) + 15
15
Correction Factor = 30 +
15 + ~ = 3.0 15 15
Corrected cubic feet per minute =90 x3.0 = 270 cubic feet per minute. BTU per hour =270 x 60 x 1000 = 16,200,000 BTU hour.
Page I 7
Propane
Propane is manufactured gas that is supplied in a liquid form in pressurized storage tanks. As the pressure is relieved by
demand, the liquid boils to a gas and can be used in a way similar to natural gas. Propane is heavier than Natural gas. Its
specific gravity is 1.53, as compared to 0.61 for Natural gas. The heating va lue of propane is 2500 BTU/ff' as compared to
1000 BTU/fP for Natural gas
Propane is normally used where distribution lines for Natural gas are not available. It is also used as a stand-by fuel for
some dual fuel burner systems.
Propane, when used in the quantity required to fire most boilers, requires vaporizat ion. Vaporization is ach ieved by a device very similar to a hot water heater. Propane liquid is piped through the vaporizer and is heated and boiled to insure
that dry vapor only is used at the burner head.
If vapor from the storage tank alone is used, two things occur. First, when the flow rate becomes high, liquid propa ne will be carried through the piping to the burner along with the vapor. The liquid will vaporize as it passes through the burner
orifices and will result in more propane being burned than design calls for. Second, propane contains impu rities. These impurities consist of a small percentage of heavier compounds left after refining and of oil introduced during each pumping
and handling required to distribute and store propane. These Impurities are left in the tank as the propane vapor is removed for use. The result is that the tank must be blown down and cleaned periodically.
Vaporization allows the use of propane liquid from the bottom of the storage tank. A vaporizer of adequate size will add
enough heat to the liquid propane to deliver dry gas from the pressure regulator at the vaporizer. By taking liquid from the
bottom of the storage tank the heav1er substances are used in acceptable quantities, and no accumulation occurs in the
storage tank.
Pounds per gallon Cubic feet gas per gallon liquid Cubic feet per pound BTU per gallon BTU per cubic pound BTU per cubic foot Dew point
Oil
Properti es of Propane
4.24
36.20 8.50 91,800 21,600 2,530 -45° F
Vapor Pressure @ o· F @ 10° F @ 1oo· F Specific Gravity gas Specific Gravity liquid Gallons per hour per boiler horsepower Cubic feet per hour per boiler horsepower Gallons storage pe r boiler horsepower
28 psi 122 psi 190 psi
1.53 0.511
0.5 18.0 25.0
Oil for use <lS boiler fuel comes in severa l grades. The two most common!\ encountered are N0.2 and N0.6 oi .. N0.2 oil is a
light, refined oil that requires no preheat or other special handling. N0.6 oil is a heavy oil with a high viscosity. N0.6 oil
requires preheating and special handling.
Properties of Fuel Oil No. No. 1 No.2 No.4 No. 5 No preheat No. 5 Preheat No.6
BTU/gal. 136,000 139,000 145,000 148,000 149,000 152,000
BTU/lb. 19,000 19,500 19,200 19,000 18,950 18,80(1
Lb./Ga. 6.9 7.1 7.6 7.8 7.9 8.1
cfm air gal. 22.43 22.90 24.00 24.76 24.96 25.74
Page I 8
I
WATER SUPPLY & TREATMENT
All fresh water available from natural sources in the entire world today will require varying degrees of treatment prior to use in a
boiler. The impurities in fresh water are many, and each requires special attention. Solids in the form of minerals, chemicals, and
organic material are all found in so-called fresh water and all have a different effect on the internal surfaces of a boiler.
WATER TREATMENT
The trea tment of feedwater and the conditioning of boiler water are beyond the control of this Company. This Company does not
assume the r·esponsibility for water treatment and does not make specific recommendations for control purpose.
The successful operation of boilers depends upon a rigid control of feedwater and operating variables to assure freedom from scale
formation and corrosion of water and steam-contacted surfaces of the boiler.
This control is very important in lower pressure boilers and becomes increasingly magnified at intermediate and higher pressure
operation.
Scale formation in borler·s is prevented by providing a good make-up water to the feedwater system and by avoiding condensate
contamination.
Corrosion oi metal surfaces in contact with water and steam constrtutes the major marntenance expense to the power industry. The
condensate and feedwater must be free of dissolved corrosive gases and the pH of the water must be properly adjusted to prevent
the attack of meta l surfaces.
The oxygen content in the feedwater must be reduced to low levels by effective deaeration in the condenser and in deaerating
heaters. Care must be taken to prevent the introduction of air into heater drips which may be added directly to the feedwater
system without deaeration. Minimum forced boiler outage time has been realized where the oxygen content has been reduced and
held belo'.'' 0.01 PPM. It is important to maintain a chemical reducing environment in the boiler and chemicals such as sulfite and
hydrazine have. been used effectively to achieve this.
The pH of the feedwater must be controlled to prevent the dissolution of the iron and copper alloys in the pre-boiler system. These
form corrosive products when introduced rnto the boiler and will contribute to the corrosion of boiler steam generating surfaces.
Oxides of iron and copper may permit the diffusron of boiler water to the heated surfaces of the unit and cause locally htgh
concentrations the heated sL.rfaces of the unit and cause locally htgh concentrauons of boiler water salines that result in the attack
of the tube metal.
The pick-up metals from pre-boiler surfaces can be minimized by the addition of volatile alkaline chemicals that raise the pH of the
feedwater. Ammonia and various amines, added to maintain a pH range of 8.8 - 9.2 have produced the best results.
Close control of solids in the boiler water must be established. The presence of oil, grease, high alkalinity, or other foam-inducing
solids cannot be tolerated.
Boiler feed water treatment by a competent company will result in the prevention of scale and deposi ts, removal of dissolved gases
(free oxygen), protection against corrosion, elimination of carry-over of water with steam prevention of caustic embrittlement,
reduction of boiler down-time, production of the best boiler efficiency and reduction of fuel and maintenance costs.
Page I 9
Electrica l Supply
Several voltages are encountered in boiler work. The most common are 24, 110 220 single phase; 220 three phase and 440
three phase. In some parts of the country 550 volt, three phase, is being used . 24 volts is normally used for thermostatic and
other open-type controls where human contact is most likely. 24 volts is usually obtained from a step-down transformer from
110 volts. 110 volts is normally used for the operating controls. 110 volts is normally obtained f rom one line of a 220 volt
single phase source, but is also availabiP. dimc:tly frnrn a 220 volt, three phase, source. When the primary source is 440 vo!t,
three phase; or 550 volt, three phase, a step-down transformer from the higher voltage to 110 volts is required. 60 Hertz is
the standard in the United States, while 50 hertz is found in numerous foreign countries.
Loca l Codes
Boiler Codes vary from state to state and from city to city within a state. It is impossible, therefore, to anticipate the exact
requirements in a particular location. Normally a new installation would require a building inspection, electrical inspection.
The exact requirements for a particular location can be obtained from the city hall, if it is an urban location, or from the State
government, if it is a rural location.
Insta llat ion Instructions
PERMITS and CODES
Permits for installation should be obtained before work is started. Local installa tion codes should be followed to prevent delays in installation or possible added expense for rework.
BOILER lOCATION and SUPPORT
The location for the boiler should be determined well in advance of the equipment arrival in order to allow adequate time to provide adequate utilities for the boiler location. Every boiler location requires:
1. Fuel 7. Stearn Distribu tion 2. Water 8. Condensate Return 3. Fresh Air 9. Boiler Support 4. Stack 10. Clearance for maintenance 5. Electrical Power 11. Clearance for tube replacement 6. Floor Dr<Jinage.
RECOGNIZING THE POTENTIAL EXISTS TO CONTAMINATE YOUR POTABLE WATER SUPPLY SYSTEM(S) FROM BOILER INSTALLATIONS, IT IS RECOMMENDED THAT PROVISIONS TO PREVENT CONTAMINATION FROM YOUR BOILER INSTALLATION BE CONSIDERED.
Page I 10
Insta ll ation Check List
Pre-1 nsta llation 1. Boiler Location
2. Clearance for installation and maintenance
3. Support Pad
4. Stack outlet through roof
5. City water to boiler room
6. Natural Gas Supply
a. Meter Size
b. Meter Pressure
c. Pipe size to boiler room
d. Pressure available at boiler room
7. Propane Gas Supply
a. Storage Capacity
b. Vaporizer Capacity
c. Pipe Size to boiler room
d. Pressure available at boiler room
Installation
1. Boiler Level 5. Fuel Supply
2. Clearance for maintenance and local code compliance 6. Blow-down
3. Stack 7. Electrical
4. M ake-LIP City water 8. Steam Supply
a. To return tank 9. Condensate Return
b. To boiler 10. Ventilation
Operating Instructions
READ BEFORE STARTING BOILER:
A. Boiler/Burner Inspection Check Before Start-up:
1. Check for completed installation. (See Pre-Installation Check List.)
2. Turn off all electrical switches and disconnects.
3. If necessary, bleed air from gas supply line. Do not depend on odor to detect gas presence. Purge
through gas pilot line
4. Close all gas supply va lve.
5. Close steam supply valve.
6. Close al l blow-down valves .
7. Check boiler refractories for shipping damage.
8. Check t ightness of piping connections on boiler t rim.
9. Check for loose or broken electrical connect ions.
10. Note any damage ca used during install ation and correction and correct before start-up.
11. Remove shipping bolts from rear of skids. (Size 100 and Larger)
Page 111
B. Boiler/Burner Preparation before Start-Up:
Size
10 15 20
25 30
40
so
1. Open valves at top and bottom of the water column gauge glass.
2. Open city water valve to condensate return tank and check function
3. Open pump suction line valve .
4. Open pump discharge line valve.
5. Remove W' shipping plug from McDonnell-Miller water level control and replace with W' pipe
plug.
6. Check supply voltage.
7. Turn on main power disconnect and check pump rotation.
8. Fill boiler with water to normal operating level. Use ei t her city water make-up or pump. Turn
pump off, if return tank goes dry.
9. The following list of data is pertinent to the boiler/burner start-up and should be carefully studied
BEFORE commencing start-up:
a. Boiler/ Burner Manu<JI
b. Boiler/Burner Material List
c. Boiler/ Burner Wiring Diagram
d. Boiler/ Burner Flame Safeguard Bulletin
Flooded Weights of W&D Boi lers
Scotch Marine
Wt. (lbs.) Size Wt . (l bs.) Size
2225 60 11980 250 2850 80 16100 I 300 3875 100 18940 I 350 4775 125 21300 i 400 6265 150 25400 500
7015 175 29320 I 600
10030 200 31370 I 700
Concrete Pads
J Wt. (lbs.)
1 37460
I 44600 51500 57000
73000
79650
86300
The boiler support shou ld be a concrete pad with enough steel reinforcement to support the weight of the boiler and the
amount of water required to operate the boiler.
Size L w Thiel< Size L w Thick : Size I L w Thick
10 5' 6" X 3' 0" 4" 60 10' 6" X 5' 0" 5" I 250 17' 0" X 7' 6" 6"
15 7' 0" X 3' 0" 4" 80 11' 6" X 5' 6" 5" 300 19' 0" X 8' 6" 6"
20 7' 0" X 3' 6" 4" 100 13' 0" X 5' 6" 5" 350 19' 0" X 9' 0" 1 6"
25 8' 0" X 3' 6" 4" 125 10' 6" X 5' 0" 5" 400 19' 0" X 9' 0" 6"
30 7' 6" X 4' 0" 4" 150 13' 0" X 6' 6" 6" 500 22' 6" X 9' 0" 6"
40 8' 6" X 4' 0" 4" 175 14' 0" X 6' 6" 6" 600 23' 0" X 9' 6" 6"
50 9' 0" X 5' 0" 5" 200 16' 0" X 7' 6" 6" 700 24' 0" X 9' 6" 6"
Page I 12
Size
10 15 20 25 30 40 so 60 80
100
I Boiler i Size
' 10 I
-15 : 20 I 25 30 I 40 I
so l 60 80 I
100 125 I 150 I
I 175 I 200 250
! 300 350 i 400 500 1 600
Gas Supply
Gas Pressures Required (Natural Gas)
CFH Gas Min. Max. Size CFH Gas Min. Max.
450 4 oz. 8 oz. 125 5250 5 psig 30 psig 680 4 oz. 8 oz. 150 6300 5 psig 30 psig 900 4 oz. 1 psig 175 7350 5 psig 30 psig
1150 4 oz. 1 psig 200 8400 2 psig 30 psig 1350 4 oz. 1 psig 250 10500 2 psig 30 psig
1680 4 oz. 1 psig 300 12600 3 psig 30 psig 2100 4 oz. 1 psig 350 14700 3 psig 30 psig
2520 4 oz. 1 psig 400 16800 5 psig 30 psig
3360 8 oz. 1 psig 500 21000 10 psig 30 psig
4200 8 oz. 1 psig 600 25200 10 psig 30 psig
If the gas pressure available for your equipment does not fall within the limits given in this chart, notify the gas service
company. If the gas company service cannot provide the prescribed pressure, the equipment will require modification for
proper operation.
If the gas meter servicing the boiler also services other equipment, the requirements of the other equipment will have to
be added to the capacity shown in the chart for your equipment in order to establish the capacity required from the gas
meter .
GAS SUPPLY PIPE SIZES FROM METER TO BOILER
Distance fro m M eter Min. Gas 30' 50' 100' ! 200' 300' 400' 500' Pressure 1" 1-1/4" 1·1/4'' 1·1/2" 1-1/4'' 2" 2" 4 oz.
1·1/4" 1·1/4" 1·1/2" 2" 2" 2" 2" 4 oz. 1·1/4" 1·1/2" 2" I 2" 2'' 2" 2-1/2" 4 oz. 1-1/2" 2" 2''
' 2" 2·1/2" 2-1/2'' 2-1/2" 4 oz.
1·1/2" 2" 2" 2·1/2" 2·1/2" 2-1/2" 2·1/2" 4 oz. 2" 2" 2" 2-1/2" 2-1/2" 3" 3" 4 oz. 2" 2" 2-1/2" L 2·1/2" 3" 3" 3'' 4 oz. 2" 2" 2-1/2" 3" 3" 3" 3" 4 oz. 2" 2" 2·1/2" 3" 3" 3" 3" 8 oz. 2'1 2" 2·1/2" 3" 3" 3" 3" 8 oz. 2" 2·1/2" 2·1/2'' I 3" 3" 4" 4" 5 psig 2" 2" 2-1/2' 2-1/2'' , ..
::> 3" 3" 5 psig 2·1/2" 2·1/2" 2·1/2" I 3" 3" 3" 3" 5 ps1g 2·1/2'' 2-1/2" 2·1/2" 3" 3" 3" 4'' 2 psig 2-1/2" 2·1/2" 3" 3" 3'' 4" 4 2 ps1g
3'' 3" I 3" 3'' 4" 4" 4' 3 psig 3" 3" 3" 4" 4" 4" 4' 3 ps1g 3' 3" 3" 3" 3" 3" 4' 5 psig 3" 3" 3" 3" 4" 4" 4" 10 psig 3" 3" ...i. 3" 4" 4'' 4" 4" 10 psig
Add 5' to length for every elbow or equivalent fitt ing between meter and boiler.
PIPING Always apply pipe dope to the male th reads of the pipe, and NEVER to the female threads of the fitting. No galvanized pipe or fittings should be used on gas or steam.
Page I 13
I
I
I
I
Drip Leg Insta llation : GAS
SUPPLY
I I BURNER
---- DRIP LEG SHOULD BE SAi>IE SIZE AS 11-ICOt·liNG GAS LII'IE AND AT LEAST or LONG
:coRRECT:
WATER SUPPLY
GAS - --h-+--------1 SUPPLY
----DRIP LEG
FIGURE 2
All check valves and shut all valves must be steam service rated.
RETURI·I Ti\NK
CHEMICAL FEED
M anual:
FRO~·I BOILER -Joo FEED PU~IP
CITY \VATER
II'•
CHEI•I:CAL !'.
CHEt•IICAL FEED TANK
TO DRAII •!
FIGURE 4
)
BURNER
Boiler Size
10
15 20
25 30
40
I 50 60
I 80
100
125 150
175
200
250 300
350
400 500
600
700
Chemiwl Feed, continued Automatic:
CHEMICAL STORAGE TANK
FROM BOI LER FEED PUMP
CHEMICAL FEED PUM P
FIGURE 5
ELECTRICAL SUPPLY
Every boiler requires 110V, 60HZ power supply for boiler control.
FUSED ELECTRICAL SERVICE APPROXIMATE REQU IREM ENTS
AMPS
Boiler Burner Motor Boiler Feed System
110-1<P 220-3<1> 440-3<1> 110-1<1> 220-1<P 220-3<1> 440-3<P 110-1<1>
10 15 10 15
10 ! 15 10 15 10 I
15 10 15
10 15 15 15 15 15 10 15 15 15 15 15
30 20 25 15 15 15
30 I 30 15 15 15
30 I 40 20 15 --20 15 30 15 20 1 15 45 25
20 15 45 25 20 15 70 35
20 15 70 35
30 15 90 45
30 15 90 45 30 15 90 45
45 25 125 60
45 25 125 60 90 45 175 80
125 60 175 80
125 60 175 80
Page 115
BOI LER
Oil Pump
I 220-3<1> 440-3<1> I I
I I
I
I
10 15
' 10 15 10 15
10 I 15
I 10 I 15
10 15
10 15
10 15 I 10 15
10 15
10 15 10 15
10 15
10 15
STACI<
Stack diameter should be the same as the outlet diameter of the boiler being installed.
STACI< DIAMETERS
Boiler Size Stack Size Boiler Size Stack Size Boiler Size
10
15
20
25 30
40
so
8"
8"
10" 10"
10"
12" 12"
FIGURE 6
60
80 100 125
150
175
200
12" 250
16" 300 16" 350 18" 400
20" 500
20" 600
20" 800
'•:'l EAT HER CAP - r-1Ait-JTAIN CLEARANCE ABOVE STACK OF 2i 3
SKIRT
ROOF
.l.
STACK DIAMETER
SLEEVE - DIAMETER TO BE T\'i!CE THE STACKDIAfl.lETER
1+--- B•X LEf;. STAC~.
BLOWDOWN The boiler blowdown lines should be piped together into a blowdown separator as shown below.
VVHEN REQ'D BY LOCAL -~ CITY WATER
Schedule 80 pipe recommended. Do Not reduce Blow-Down Line !
VENT
BLO\'iDO'•;'/N SEPARATOR
\'lATER COLUJI.l ~·l /' BLO\'VOO\·'IN VALVE
FIG URE 7
Page I 16
BLOVIOOWN VALVES
Stack Size
20"
24"
24" 24" 24"
24'' 24"
I
I
BOILER ROOM VENTILATION & COMBUSTION AIR
0 Most boile r and combustion controls operate erratica lly above an ambient temperature of 125 F. Adequate vent ilation should be provided at the upper area of the boiler room wall or roof to allow the escape of hot air from the boiler room. Forced vent il ation is acceptable with the precaution t hat the powered exhaust does not starve the boiler of combustion air. An opening must be provided in th e lower area of the boil er room wall to allow t he influx of fresh air needed for ventil ation and combustion.
r- ~ OR
.f ROOF UPPER '.'!ALL
,. J I // EXHAU">T VFr-JT
ROOF EXHAUST VE~IT
* OUTSIDE \·'iALL D +-RELIEF SLIDE IN """,/'
* Required, if stack is over 10' high.
I ,.. /'_, I =~K
Before slack is installed, a 4" x 8" opening with a slide cover is t o be placed in the stack.
1 !~!TAKE AIR VENT ,. BOILER
0
~
'----- DO NOT DEPEND ON t.N OPEt·l DOOR OR '.'.:INDO\'/ FOR COI•1BUSTION AIR
The amount of sl ide opening for correct
burner operation wil l have to be set with
proper combust ion met ering equipment .
Intake grills should be located Ol" outside walls' when possible in order to eliminate possible interference from exhaust equipment located in adjacent buildings. If powered exhaust eqL•ipment is employed, allow at least one square mch for each 3 cfrn of rated capacity of exhaust equipment in addi tion to the area required for combustion air.
Boiler Size Grille Area
10 128 in·
15 128 in1
20 128 in1
25 128 in2
30 128 in2
40 256 in'
so 256 in2
60 256 in2
80 512 in'
100 512 in2
M INIMUM INTA I<E GRILLE SIZES
f or Combust ion Air On ly
Grill e Dim. Boiler Size Grille Area
8" X 16" I 125 512 in1
8" X 16" I 150 640 111:'
8" X 16" 175 640 in~
8" X 16" 200 960 in2
8" X 16" 250 960 in2
8" X 32" 300 1344 in2
8" X 32" 350 1344 in2
8" X 32" 400 1536 in2
16" X 32" 500 2048 in 2
16" X 32" 600 2304in2
Grille Dim.
16'' X 32"
16" X 40"
16" X 40"
24" X 40"
24" X 40"
24" X 56"
24" X 56"
24" X 64"
32" X 64"
32" X 72"
* Based on .015 in W.C. drop across grill e with approx 400 fpm Velocity t hru grill e.
Page 117
SAFETY VALVE DISCHARGE LIN ES
Discharge lines from the safety relief valve should be supported so as to remove any strain on the relief valve. Safety relief valves will not support the weight of a steel discharge line. Do not reduce the outlet size of the relief valve. If long runs of pipe are required to the discharge line outside the boiler room, larger pipe must be used. If the discharge line is to be verti ca l, a drip panel should be employed to prevent water f rom standing in the discharge line. Since a column of water has weight, it will cause a pressure against the relief valve, thus making the relief valve discharge at a higher pressure.
SAFETY RELIEF VALVES
The primary purpose of safety valves is to prevent excessive pressu re in the boil er. Safety relief valve(s) furnished by W&D are sized to comply with the latest applicable Code (ASME, National Board, USCG, ABS, etc.) requirements for which the boiler was designed.
Safety valves are normally located on the shell and are factory ·set" and ·sealed" by the valve manufacturer. The warranty is IMMEDIATELY VOIDED if the seals are broken . Therefore, DO NOT ALLOW anyone to attempt to adjust or reset the relieving pressure. There should be no obstructions at the safety valve inle ts or outlets.
Safety valve relieving pressures conform with the maximum allowable working pressure stamped on the boiler shell (150 PSIG), as the safety valve's purpose is to protect the boiler, not the distribution system nor connected equipment. When boilers having different design pressures are connected into a common header, special code regulations become effective.
Safery valve discharge capacities are stamped on the valve label by the valve manufacturer for the -, relieving pressur·e at which the safety valve has been set. Changes in the relieving pressure w ill resul t in a change in the valve capacity and in many instances; safety valves reset to a lower pressure may not be adequate to meet minim um code requirements. Therefore safety valve substitutions should not be made w ithout first communicating with W&D.
A pipe wrench MUST NOT BE USED to install a sa fety valve. This type wrench squeezes the valve body and often causes the valve(s) to weep. Warranty replacement WILL NOT BE MADE for such damage. Always use an adJustable end w rench tor safety valve installations.
Safety valve discharge piping shall have an internal area equal to or greater than the aggregate internal area of the valve outlets piped 1nto them The weight of the discharge piping MUST BE INDEPENDENTLY SUPPORTED and must NOT rest on the safety v<Jive body.
Safety valve bodies are eq uipped with a drain tapp1ng which shall not be plugged. but should have discharge pip ing run to a point where the accumulated condensate will not drain onto the boiler.
STEAM SUPPLY and CONDENSATE RETURN
The main steam valve may be either a gate va lve or a steam-rated globe valve. Each piece of equipment should be provided with a steam shut-off valve and a condensate trap. A condensate trap is not necessary, if the steam is used directly during a process. The end point of each main stea m supply line and each branch supply line shOLild be trapped to maintain dry steam to the equipment and to prevent water hammering in supply pipes. The valves used in the condensate return lines must also be steam service rated valves. Steam and condensate lines should always be insulated, because the losses by radiation must be replaced by additional input.
Page I 18
TYPICAL LOAD PIPING
BLOW-OFF VALVES
One (1) slow opening valve and one (1) quick opening va lve may be used, or the valve assembly may consist of two (2) slow opening valves. A slow opening valve requires at least five full turns to completely open. A quick opening valve is usually lever actuated.
All valves shall be temperature/pressure rated and shall be equivalent to the IVl.A.D.P. stamped on the boiler. Blow-off piping between the boiler and the second valve, whether screwed or welded, should be at least Sch.BO
and all fittings shall be steel.
Blow-off valves & piping are subject to water hammer shock and ext remes can be momentarily induced by rmproper operation of the valves. ALWAYS OPERATE TH E LEVER OPERATED VALVE VERY SLOWLY.
The data on blowdowns should be recorded . The frequency and du ratron are best determined from a chemical analysis of the boiler water. Since the water treatment system varies for each plant, a competent authority on water conditioning should be engaged to prescribe suitable feedwater treatment from analysis of the wa ter supply and to furnish the necessary instructions for blowing down . If thi s is not practical, the boiler should be blown down at least once every 24 hours, however, W&D recommends blowdown once at least every 8 hours, or more often if the feeclwater is of inferior quality or the amount of make-up is large.
The use of the boiler bottom blow-off va lves should be restricted to periods of moderate steaming rates and
preferably very low combustion rate. The bottom blow should always be used to free a boiler of sediment when
the boiler is being cutoff.
Page I 19
MAINTENANCE
DAILY:
1. Slowdown boiler at least twice every 8 hour period in use. On high pressure boilers, it is recommended the
boiler be blown-down at 15-25 PSIG if possible. Blow clown as follows:
a. Open the f irst va lve from t he boi ler
b. Open the second valve from the boiler
c. Allow boiler to blow down until the pump turns on and the burn er cuts off.
d. Close the second valve f rom boiler.
e. Wa it for pump to turn off, then repeat steps b, c and d at least three t imes.
f. Close the va lve from boi ler .
_, ·.,.'11\TER ( ')LUI\lN BL0\'!00'. IN v'ALVE
T O E'LO·.'iOQ', '/~1
SEPARATOR ~ .c VALVE = :? -- (. VALJ'3. = :
F IGURE lo
2. Slowdown water gauge glass to keep free of scale obstructions. See item 5 weekly.
3. Slowdown the water column and level control, and check that the pump starts and the low water cut-off operates in the proper sequence, at least twice every 8 hour period.
WEEI<LY:
1. Check flame safety system for proper operation 2 Check ignition w ires and replace if brittle or cracked 3. Clean scanner tube with a soft cloth and detergent. Wipe completely dry. t\. Visually check burner condition and flame appearance 5. On 80 HP and larger, gauge glass valves should be closed and reopened to maintain freedom of the ball
check mechanism. The ball check mechanism is to prevent steam and water from spraying from the water column in case of gauge glass blow-out.
90 DAY:
1. Avoid excessive "popping" of the safety/re lief valve as even one opening can provide a means for leakage. Safety/relief valves should be operated only often enough to assure that they are in good working order.
2. Blow-out steam gauge and pressure switch line slowly at 15 to 20 psig. 3. Remove all hand hole and man hole plates for internal Inspection of scale and corrosion conditions,
scrape clean internal seating surface and plate surface. Wash the boiler thoroughly, especiall y the rear
tube sheet and top of furnace. Install only new gaskets. Replace leaking gaskets
Page I 20
immediately to prevent wire drawing of the seating surface. 4. Remove plugs on feed line and water column connections and clean out fittings into boiler shell . 5. Inspect tubes for cleanliness and leaks. 6. Repack leaky va lve stems. 7. Replace water gauge glass as necessary for good visibi lity of water level. 8. Clean pump suction strainer.
9. Clean lint and dust from blower wheel blades. 10. Check and clean airway to pilot. This may be done easily by pushing a hacksaw blade or similar piece of
material through the opening several t imes. l ow pressure air may be used.
YEARLY:
1. Call inspector for annual inspection. 2. Remove water level control float and clean float bowl. 3. Remove secondary low water cut-off probe and check for corrosion. 4. Clean Steam Dry Pan on Vertical Tubeless Boiler. Clean Ooiler Feed Filling, be sure to install "Top" as
stamped on nipple.
STEAM DRY PIPE FOR VERTICAL TUBELESS BOIL
BOILER FEED FITTING
I I
•
STEM•l OUT
ERS ~
j - -4
. ~ \ ~
I ....._____.. [ I l}) ..,- ,. co Qi
Page I 21
~ REt·lO VE FOR CLEANING
.... I"'
-!II
1111
f . _I
------..
TC F OF BOILER
-- --4(- \'!AT ER
RE[I.lOVE NIPPLE FOR CLEANING
1.
2.
3.
4.
REPLACING HANDHOLE & MANHOLE GASI<ETS
Match-mark the plate(s), the hole and the top edge so the plate can be reinsta lled in the same posit ion in the same opening.
Remove old gasket and thoroughly clean the surface on the inside of the boiler, and on the plate, using a scraper, wi re brush, or grinder, if necessary. Extreme care should be taken not to undercut the gasket surfaces.
Carefully center the gasket on the plate. DO NOT use any grease, lubncant nor adhe~ive. Center the plate in the opening so the gasket-bearing surface is even all around.
After plate is in boiler and gasket is in place, set crab and tighten nut only enough to provide a snug fit. Make it hand-tight, then snug with wrench about 1/4 turn. DO NOT COMPRESS excessively.
5. If gasket leaks while pressure is being built up, tighten only enough to stop lea kage. Never tighten more than necessary to prevent leakage. Excessive tigh tening may shorten life of gasket.
GASI<ET INSTALLATION ILLUSTRATION
CORRECT
C. ~lRRECT >-RESSURE 0~1 G.l.SKCT
: rNCORRECT. NE"·/ER 0 1EF.- COt·lPRESS
.::.:.s~=- .:.s sHo·: r.
Leakage of boiler manhole/handhole gaskets is not only an unsightly nu1sance, but can develop into a serious maintenance problem unless promptly corrected. Even small or intermittent leaks cause a general deterioration of adjacent boi ler and manhole/handhole plate surfaces. As the corrosion progresses the metal parts will be wire-drawn.
If the plate &/or boiler surface has been corroded by leak(s) they may be too irregc~lar to f1t, or there may be insufficient gasket su rface area left to make a tight jomt. If so, repairs must be made. The boiler surface may be built up by a certified welder and ground flush. It is generally more economical to install a new handhole plate rather than attempt to repa1r the old one.
Gasket leaks are sometimes caused by excessive use of boiler compounds. Such leaks are identified by a crusty formation of "beards· around the plate. The concentration of water trea tm ent chemical should be checked and if too high, the boiler should be drained, washed & refilled. and enough water added to bring it within the recommended range. All gaskets should be replaced with special attention given to cleaning surfaces.
When boilers have been cleaned, new gaskets should be insta lled before the boiler is placed back in service.
Page I 22
I I I
DO's & DON'Ts:
1. l.ALWAYS promptly and permanently stop the gasket leak. 2. Always replace manhole & handhole plates in the same opening, and in the same position. Match-mark the plate,
the opening and the top edge before removing. 3. Always use new gaskets. Do not try to reuse an old gasket even in the same opening. 4. Frequently check manhole plate bolts for t ightness. 5. Do NOT use a long-handled wrench, nor try to tighten a bol t when boiler is under full steam pressure. A joint rupture
can resul t in serious sca lding. 6. Do not allow boiler insulation to cover any hand hole openings.
COMMON CAUSES OF GASI<ET LEAKAGE:
1. Use of old gaskets that have lost their flexibility.
2. Improper positioning of gasket on the plate &/or location of the plate in t he opening.
3. l oose bolts.
4. Rough, wire-drawn, scaled or pitted surfaces of the plate &/or boiler surface.
S. Excessive use of boiler compounds resulting in high caustic concentrations of boiler water .
6. Use of handhole or manhole crabs as lugs for jacks or levers, or for attachment of hooks or slings for pulling or lifting.
Page I 23
~ ~·
"•JEF- f~ - ,. "LC ':'i ·:.-
VENT
0
STEAr·1~ OUTLET ;f-.,
,---, SAFETY RELIEF VALVES
n .... ,, ·-·-. :J v'U- ,
I;!
CITY ' 6' ·,·'lAT ER--- .. ;. 0·\-n' ·~ rFEED '- - ;..t __ ;--u._.~;
, . . . , . FRO~· I PUI\IP ' l . ;A,' ) : DISCHARGE ------.... r · -~,A--it- ../ ~" - ~ ~ •:~ ;;o --- .. ......, ._ ...... ..:J. .... ,.. ;,..,.4 ~
S\'iiNG CHECK .J ( SPR.IN~ CHECK VALVE VALVE
( ) BLO\'i-OFF
. DO NOT REDUCE T HIS PIPE SIZE
SCOTCH M ARINE BO ILER WITHOUT BOILER FEED SYSTEM DOTTED PIPING & FITTINGS SUPPLI ED BY CUSTOM ER
/ CIT) \';AT ER FEED STEt.i' , ( UTLET --, ~ S» FEn REL:EF 'AL .'ES
RETIJR/'1 . .
f__.. INLETS ------.... ' . · ·- r ..: ·.; : ';R. ~ - -! .
,-10--------<::-------c,.:.l.'...... .., .::! :
0 BL0'.-'1-0FF DO NOT REDUCE THIS PIPE SIZE
SCOTCH MARINE BOILER WITH MODEL 11 B" BOILER FEED
SYSTEM DOTIED PIPING & FITIINGS SUPPLIED BY CUSTOMER
Page I 24
I I I
\ :) I tAIVI I A-stt Total Heat Above 32 • F
I Gauge Pressure Temp. "F
Vo lume In 1 Lb. Latent Total
Lb./Sq . ln. Cu. Ft./lb. Water Heat 1 Lb. Steam
0 221.0 26.80 180.1 970 .3 1150.4 1 215.5 25 .13 183.6 968.1 1151.7
2 218.7 23.72 186.8 966.0 1152.8 3 221.7 22.47 189.8 964.1 1153.9 4 224.5 21.35 192.7 962.3 115.0
5 227 .3 20.34 195.5 960.5 1156.1 6 229.9 19.42 198.2 958.8 1157.0 7 232.4 18.58 200.7 957.2 1157.9
8 234.9 17.81 203.2 955.6 1158.8 9 237.2 17.11 205.6 954.1 1159.7 10 239.5 16.46 207.9 952.5 1160.4
11 241.7 15.86 210.1 951.1 1161.2 12 243.8 15.31 212.2 949.7 1161.9 13 245.9 14.79 214.3 948.3 1162.6 14 247.9 14.31 216.4 946.9 1163.3 15 249.8 13.86 218.3 945.6 1163.9 16 251.7 13.43 220.3 944.3 1164.6 17 253.6 13.03 222.2 943.0 1165.2
18 ! 255.4 12.66 224.0 941.8 1165.8 19 257.1 12.31 225.7 940.6 1166.3 20 258.8 11.98 227.5 939.5 1167.0 21 260.5 11.67 229.2 938 .3 1167.5
22 262.2 11.37 230.9 937. 2 1168.1 23 263 .8 11.08 232.5 936.1 1168.6 24 265.4 10.82 234.1 935.0 1169.1 25 I 266.9 10.56 235.6 934.0 1169.6
30 274.1 9.45 234.0 928.9 1171.9 35 I 280.7 8.45 249.8 924.2 1174.0 40 286.8 7.82 256.0 919.8 1175.8 45 292.4 7.20 261.8 915.7 1177.5
50 297 .7 6.68 267 .2 911.8 1179.0 55 302.7 6.23 272 .4 908.1 1180.5 60 307.3 5.83 277 .2 904.6 1181.8
65 311.8 5.49 281.8 901.3 1183.1 70 316.4 5.18 286.2 898.0 1184.2 75 320.1 4.91 290.4 894.8 1185.2
80 323.9 4.66 294.4 891 .9 1186.3
85 327.6 4.44 298.2 899.0 1187.2 90 331.2 4.24 301.9 886.1 1188.0 95 334.6 4.06 305.5 883.3 1188.8
100 337.9 3.89 308.9 880.7 1189.6 105 341.1 3.74 312.3 878.1 1190.4 110 344.2 3.59 315.5 875.5 1191.0
115 347.2 3.46 318.7 873.0 1191.7 ) 120 350.1 3.34 321.7 870.7 1192.4
125 352.9 3.23 324.7 868.3 1193.0
Page I 25
STEAM TABLE
Volume Total Heat Above 32°F
Gauge Pressure Temp: F In 1 Lb. Latent Total
Lb./Sq. ln . Cu. Ft./lb. Water Heat 1 Lb. Steam
130 355.6 3.12 327.6 865 .9 1193.5
135 358.3 3.02 330.4 863.7 1194.1
140 360.9 2.93 333.1 861.5 1194.6
145 363.4 2.84 335.8 859 .3 1195 .1
150 365.9 2.76 338.4 857 .2 1195 .6
155 368.3 2.68 340.9 885 .0 1195.9
160 370.6 2.61 343.4 853.0 1196.4
165 372.9 2.54 343.9 850.9 1196.8
170 375.2 2.47 348.3 848.9 1197.2
175 377.4 2.41 350.7 846 .9 1197.6
180 379.5 2.35 353.0 845.0 1198.0
185 381.6 2.30 355.2 843.1 1198.3
190 383.7 2.24 357.4 841.2 1198.6
195 358.8 2.19 359.6 839 .2 1198.8
200 387.8 2.14 361.8 837.5 1199.3
BOILER FEED SYSTEMS BLOW-DOWN SEPARATORS
Page I 26
)
Honeywell
L404F,T,V Pres.sureTrol® Controllers
~ OIF... \ J
!.1 MAI N •t ' ll . ",l • · -l tJ ., .. ~ ..
: J I ' ,, PSI t..J- r f f ., .. , ,~·' . ;-:, ~~~
t lrlUHtnot
APPLICATION
L404F PressureTrol® Controllers provide operating control with automatic limit protection for pressure systems of up to 2070 kPa, or 300 psi.
L404T,V PressureTrol® Controllers are for use on oil burner systems for pressures up to 1035 kPa or 150 psi.
PRODUCT DATA
FEATURES
• Models available in a series of control ranges, and pressure scales in kPa and psi.
• All models automatically reset and have an adjustable differential.
• Models have snap switch to open or close a circuit on a pressure rise.
• Case has a clear plastic cover so setpoints can be observed.
• 1/4 inch- 18 NPT connection for pipe on diaphragm assembly.
• Ground screw terminal.
L404F:
• Controllers may be used with steam, air, or noncombustible gases, or fluids noncorrosive to the pressure sensing element.
L404T:
• High pressure limits, break a circuit on oil pressure rise above setpoint.
L404V:
• Low pressure limits, makes a circuit on oil pressure rise above setpoint.
Contents Appl ication . ... ... . .. . . .. .. ... . ..... . . . . . . ... .. . .. . . . . .. . .. . . ..... . . .. . . . . . . . . . .... 1 Features ........ ........ ........ ....... ...... .. .......... .. ............ ............ 1 Specifica tions ....... ... .. .. .. .... ... .. ... .. .. ...... .. ........ .. . . .. . . . .. . .. .. ... 2 Ordering Information .... ........ .... .. ............ ... .. .. ... . .. .. .. .. .. .. .. . 2 Installation .... . ... ....... ............. ............ .......... ..... .... .... ......... 3 Settings and Adjustments .............. ........ ... .. ...................... 6 Checkout ........... ...... ........... ....... ..... .. .. ... ........ ............. ...... 7
71-2429-4
L404F, T, V PRESSURETROL ®CONTROLLERS
SPECIFICATIONS Model: L404F,T,V PressureTrol® Controllers. See Table 1.
Table 1. Models with kPa-psi.
Operating Ranges Subtractive Differentiala Maximum Diaphragm
pressure
Model Number kPa psi kPa psi kPa psi
L404F1060 15to 100 2 to 15 15 to 40 2 to 6 170 25
L404F1078 35 to 350 5 to 50 40 to 100 6to 14 590 85
L404F1094 140 to 2070 20 to 300 140 to 345 20 to 50 2410 350b
L404F1102 70 to 1035 10 to 150 70 to 150 10 to 22 1550 225
L404F1 219c 15 to 100 2 to 15 15 to 40 2 to 6 170 25
L404F1243c 35 to 350 5 to 50 40 to 100 6 to 14 590 85
L404F1227c 70to 1035 10 to 150 70 to 150 10 to 22 1550 225
L404F1 235c 140 to 2070 20 to 300 140 to 345 20 to 50 2410 350b
L404F1300c 415 to 1240 60 to 180 40 fixed 6.0 Fixed 1550 225
L404F1326 0 to 100 0 to 15 15 to 40 2 to 6 170 25
L404F1334 0 to 350 0 to 50 40 to 100 6 to 14 590 85
L404F1342 35 to 1000 5 to 145 70 to 150 10 to 22 1550 225
L404F1359 70 to 2000 10 to 290 140 to 345 20 to 50 2410 350b
L404F1367 7 to 55 1 to 8 5 to 14 0.75 to 2 170 25
L404F1375d 35 to 350 5 to 50 40 to 100 6 to 14 590 85
L404F1383d 70 to 1035 10 to 150 70 to 150 10 to 22 1550 225
L404F1391 d 140 to 2070 20 to 300 140 to 345 20 to 50 2410 350b
L404F1409d 15 to 100 2 to 15 15 to 40 2 to 6 170 25
L404T1055 35to 350 5 to 50 40 to 100 6 to 14 590 85
L404T1063 70 to 1035 10 to 150 70 to 150 10 to 22 1550 225
L404V1087d 70 to 1035 10 to 150 70 to 150 10 to 22 1550 225
L404V1095d 35 to 350 5 to 50 40 to 100 6 to 14 590 85
a Nominal at midscale operating range.
b Brass bellows instead of stainless steel diaphragm. c Models with 1/4-1 9 BSPT thread instead of 1/4-1 8 NPT thread.
d Make-on-rise models with terminal B omitted for miswir·ing compl iance.
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the TRADELINE® Catalog or price sheets for complete ordering number.
If you have additional questions, need furiher information, or would like to comment on our products or services, please write or phone :
1. Your local Honeywell Automation and Control Products Sales Office (check wh ite pages of your phone directory). 2. Honeywell Customer Care
1885 Douglas Drive North Minneapolis, Minnesota 55422-4386
In Canada-Honeywell Limited/Honeywell Limitee, 35 Dynamic Drive, Toronto, Ontario M1V 4Z9. International Sales and Service Offices in all principal cities of the world . Manufacturing in Australia, Canada, Finland , France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United f<ingdom, U.S.A.
71-2429-4 2
L404F, T, V PRESSURETROL ® CONTROLLERS
Table 2. Conversion Table.
Operating Range Conversions
kg/cm2 kPa psi
0.1 to 1.05 15 to 100 2 to 15
0.4 to 3.5 35 to 350 5 to 50
0.7 to 10.0 70 to 1035 10 to 150
1.5 to 20.0 140 to 2070 20 to 300
Table 3. Switch Ratings (Amperes).
Switch State 120 Vac 240 Vac
Full Load 8.0 5.1
Locked Rotor 48.0 30.6
Pressure Sensing Element: Stainless steel diaphragm (140 to 2070 kPa models) has brass bellows.
Maximum Ambient Temperature: 66•c (150.F). Also, refer to note under Mounting.
Adjustment Means: Screws on top of control case. Scales are marked in psi or kPa.
Mounting Means: 1/4 inch-18 NPT connection on diaphragm assembly; or surface mounts using holes in back of case.
Dimensions: See Fig. 1.
... 1---- 3·1/4 (83)=&=-- -+-'.
t--- 2·3/4 (70)--~
-= =~ I I I I I I I I I
HOLE FOR t II
1-DI~IENSION
3·3/4 "A" (95) (SEE TAB)
Subtractive Differential Conversions
kg/cm2 kPa psi
0.15to0.4 15 to 40 2 to 6
0.4 to 1.0 40 to 100 6 to 14
0.7to 1.6 70 to 150 10 to 22
1.5 to 3.5 150 to 300 20 to 50
Switching Action: Snap switch breaks R-B (closes R-W) on pressure rise. Make-on-rise devices omit terminal B.
Grounding Means: Ground screw terminal marked with a circled ground symbol.
Accessories: 50024585-001 Brass Steam Trap. 14026 Steel Steam Trap. 11 8023 Steel Steam Trap for BSPT Models. 33312B Knurled Knob-fits on top of adjusting screws. 129564 Range Stop-range stop screw, Part No. 107194, and
wrench, Part No. 23466, to limit setpoint range.
Approvals: Underwriters Laboratories Inc. Listed: file no. MP466, vol. 10,
guide no. MBPR. Canadian Standard Association certified: file no. LR1620,
guide no. 400E-O.
3/ 16 X 11132 (5 X9)
KNOCKOUT
f-"'1---- 4-1/2 (115) ___ _,,_
,__ ____ 4-11/32 (111)----
MAIN SCALE ADJUST~IENT
SCREW
3·7/81 (99) 1 1/2 1NCH ~1-3/16 ~ PSI DIMENSION 0
I CONDUIT (30) I RANGE 'A
2TO 15 123 5TO 50 126
10 TO 150 126 20 TO 300 146 ,::±:)
PLASTIC
==~-======== === ===-:-'
CLEAR
COVER ----' ------'---
--1 1-1 16 (27)~
& 1/4-18 NPT
I I
r-2- 1/8(54)~
REAR VIEW l--1-1/2 (38)---.j & 15 TO 100 kPa (2 TO 15 PSI) SCALE ~IODELS ONLY M19635D
Flg.1. L404F,T,V approximate dimensions in inches (millimeters in parentheses).
INSTALLATION
When Installing This Product ... 1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous condition.
3
2. Check on the ratings given in the instructions and marked on the product to make sure the product is suitable for your application.
3. Installer must be a trained, experienced service technician.
4. After installation is complete, check out the product operation as provided in these instructions.
71-2429--4
L404F, T. V PRESSURETROL ® CONTROLLERS
IMPORTANT When making pipe connections, use pipe dope sparingly to seal the joints; any excess dope may clog the small hole in the fitting and prevent the controller from operating properly
Location and Mounting (L404F) Locate the L404F where the ambient temperature will not exceed 66· c (150. F). The L404F can be mounted near the pressure gauge, at a remote location, in a fitting provided by the boiler manufacturer, or in a special mounting on low water cutoffs. The L404F should always be mounted above the water line in steam boiler applications.
NOTE: For accurate operation, supplemental heat should be added to installations where temperatures fall below -29•c (-2o· F).
A steam trap must be connected between the L404F and the boiler (see Fig. 2) to prevent boiler scale and corrosive vapors from attacking the elbows or diaphragm.
4-1/2 TO 5-112 (114.3 TO 139.7)
BOILER
STEM\ TRAP .&. (SIPHON LOOP)
.&. 1/4 IN PIPE WITH 1/4 · 18 NPT EXTERNAL THREADS ON BOTH ENDS AND 2-1/4 IN. DIA~IETER LOOP.
Fig. 2. Steam trap mounting.
Pressure Gauge Mounting
M2JS85
To mount beside a pressure gauge, remove the gauge, and install in its place the steam trap with a tee on top. Mount the PressureTrol® unit and pressure gauge on the side of the tee by means of nipples and elbows (see Fig. 2).
71 -2429-4 4
Remote Mounting Excessive vibration at the boiler may affect the operation of the L404F. In these cases, the L404F should be remotely located, subject to the following:
1. All piping must be suitable and properly pitched to drain all condensation back to the boiler.
2. The remote mounting must be solid. 3. A steam trap must be used at one end of the piping.
Boiler Mounting If it is not convenient to mount the L404F adjacent to the pressure gauge, install a steam trap at the location recommended by the boiler manufacturer, then screw the device directly to the steam trap.
Location and Mounting (L404T,V)
Location
NOTE: For most accurate operation, supplemental heat should be added to installations where the temperature falls below -2o•F (-29.C).These controllers can be mounted at any location in the oil supply line, depending on the application. Typical locations are shown in Fig. 3. The low oil pressure controller should be located upstream from the safety shutoff valve(s). In a downstream location, there would be zero pressure when the burner is not running and the safety shutoff valve(s) is (are) closed. This could prevent startup or require manual reset every time the burner is started. The high oil pressure controller should be located as near to the burner as possible.
Mounting Mount the oil pressure controller directly on the main pipe. Insert a tee in the pipe line, and connect a pipe nipple of appropriate size to the tee (see Fig. 4). Screw the hexagonal fitting (1/4-18 NPT internal thread) of the pressure control ler to the pipe nipple. To avoid leaks and damage to the case, use a parallel jaw wrench on the hexagonal fitting close to the pipe nipple. Do not tighten the pressure controller by hand by holding the case.
Make all pipe connections in accordance with approved standards. Use only a smal l amount of pipe compound to seal the connection joints. Excess pipe compound may clog the orifice in the pipe fitting and prevent the controller from operating properl y.
MAIN OIL + LINE
L404F, T, V PRESSURETROL ® CONTROLLERS
HIGH OIL PRESSURE CONTROLLER
1.117861
Fig. 3. Typical locations of pressure controllers in an oil burner system.
OIL PRESSURE CONTROLLER (AT RIGHT ANGLES TO THE MAIN PIPE LINE) ~
Fig. 4. Mounting an oil pressure controller directly on the main pipe.
Using with Preheated Oil When used with preheated oil, a siphon loop must always be connected between the controller and the main pipe (see Fig. 5) to provide thermal buffering.
~ OIL PRESSURE
~ CONTROLLER
-t -4-112
TO 5· 112
(114 TO 140)
_t SIPHON LOOP & TEE
PREHEATED OIL SUPPLY LINE
& 114 1NCH PIPE WITH 114·18 NPT EXTERNAL THREADS ON BOTH ENDS AND 2-114 IN. (57 MM) DIA~IETER LOOP. 1.123856
Fig. 5. Mounting of a s iphon loop, w ith approximate dimensions in in. (mm).
5
\!Ill D I ~I f'! .. .. , .. ,'-"
A wARNING Electrical Shock Hazard. Can cause severe injury, death or property damage. Disconnect the power supply before beginning wiring. More than one power supply disconnect may be required.
All wiring must comply with applicable codes and ordinances. All models have terminals (on the MicroSwitch® snap-acting switch) inside the cover and knockouts for conduit and cable. Refer to manufacturer installation and wiring instructions, if available, and to typical hookups shown in Fig. 6 to 10.
24 VOLT POWER SUPPLY
!1 PROVIDE DISCONNECT ~.lEANS AND OVERLOAD PROTECTiON AS REQUIRED
& AS SHOWN, SWITCH OPENS ON PRESSURE RISE. REVERSE ACTING (MAKE ON PRESSURE RISE) UNITS ARE WIRED TO R.W TER~IINALS AND TERMINAL B IS O~IITIED.
1.119637A
Fig. 6. L404F in low voltage re lay c ircuit.
71-2429-4
L404F, T, V PRESSURETROL ® CONTROLLERS
LINE VOLTAGE THERMOSTAT L404F PRESSURETROL
L1 L2 (HOT)
POWER A SUPPLY ill
!1 PROVIDE DISCONNECT ~ lEANS AND OVERLOAD PROTECTION AS REQUIRED.
& AS SHOWN, SWITCH OPENS ON PRESSURE RISE. REVERSE ACTING (MAKE ON PRESSURE RISE) UNITS ARE WIRED TO R-W TERMINALS AND TERMINAL B IS OMITIED.
M19638A
Fig. 7. L404F in a typical 2-wire control circuit.
L404T L404V
R
w B (OMITTED)
BREAKS ON PRESSURE MAKES ON PRESSURE RISE TO SET POINT RISE TO SET POINT
M1601B
Fig. 8. L404T,V terminal blocks and internal schematics.
FLAME SAFEGUARD CONTROL
1.~9789
Fig . 9. Hookup of an oil pressure controller used on a single burner system with an integral oil pump.
71-2429-4 6
FLAME SAFEGUARD CONTROL
1.19790
Fig. 10. Hookup of an oil pressure controller used on a single burner or multi burner system with an external oil
pump.
SETTINGS AND ADJUSTMENTS
When the pressure at the control rises above the L404 setpoint, a circuit opens between the R-B terminals. During a pressure fall, R-B will close at the setpoint pressure minus the switch differential.
For example, if a controller is set to differential B (see Fig.11) with a controller setpoint of A, R-B will open when the pressure rises to A . Then during a pressure fall, the R-B terminals will close when the pressure drops to C (A minus differential B).
For make on rise applications, the switch is wired to R-W terminals. The R-W circuit will close on pressure rise to the setpoint. R-W will open again on a pressure drop past the switch differential.
A
SWITCH ACTION ON PRESSURE R ISE
R-W B R-W
.:..._-'v-:'F-'ti-B-:·R ~AKES \(R-W BREAKS)
B·R W
SWITCH ACTION ON PRESSURE FALL
§} iNDICATES C .. OSED SWITCH CONTACTS. M 19639B
Fig. 11. Operation of switch on pressure rise and fall.
Setpoint Adjustment Turn the pressure adjusting screw on the top of the controller (Fig. 12) to adjust the setpoint. Turn the differential adjusting screw to the desired pressure difference between switch opening and switch closing.
NOTE: When the main scale setting is at the lower end of the operating range, the differential range will be less than the differential setting by approximately 20 percent.
PRESSURE ADJUSTING SCREW
~lAIN SCALE PRESSURE INDICATOR--HI-c-r!-~t·u
1.119&40A
Fig . 12. view of L404 PressureTrol® Controller.
Scale plate Adjustment The L404F,T,V has been carefully calibrated during manufacture and should not require recalibration.
7
L404F, T, V PRESSURETROL ® CONTROLLERS
However, if recalibration is necessary, remove the cover and loosen the setscrews which hold the scaleplate. Adjust the plate up or down, as required, to bring the device into calibration . Tighten the setscrews securely and replace the cover.
CHECKOUT
After the controller has been installed, wired and adjusted, it should be tested with the system in operation. First, allow the system to stabilize. Then, observe the operation of the controller while raising and lowering its setpoint. Pressure should increase when the setpoint is raised and decrease when the setpoint is lowered.
Also, check the make and break points of the controller. If they do not agree with a separate, accurately calibrated pressure gauge, a slight adjustment of the scaleplate(s) may be necessary.
Use accurate pressure testing equipment when checking out the controller. Do not rely on inexpensive gauges. The controllers are carefully calibrated at the factory.
71-2429-4
L404F, T, V PRESSURETROL ® CONTROLLERS
Automation and Control Solutions
Honeywell International Inc.
1985 Douglas Drive North
Golden Valley, MN 55422
customer.honeywell .com
® U.S. Registered Trademark © 2007 Honeywell International Inc. 71-2429-4 M.S. Rev. 04-07
Honeywell Limited-Honeywell Limitee
35 Dynamic Drive
Toronto, Ontario M1V 4Z9
Printed in U.S.A.
Honeywell
Honeywell
L4079A,B,W PressureTrol® Limit Control
APPLICATION
The L4079A,B, and W PressureTrol® Limit Controls are high pressure limit switches which break electrical circuits when pressure rises to a preset value.
The L4079A and 8 can be used with steam, air, noncombustible gases, and flu ids noncorrosive to the sensing element.
L4079W 1s for use on oil burner systems.
PRODUCT DATA
FEATURES
• L4079A has two ganged spst switches; breaks two circuits (may be both sides of the power supply) simultaneously.
• L4079B has one spst switch.
• L4079W is the same as L4079B, but with seals for oi l applications.
• MICRO SWITCH® snap-acting switches are visible through transparent cover.
• Switches open automatically, but must be reset manually.
• Trip-free reset mechanisms do not permit the limiting ro le of the PressureTrol® Cont ro l to be defeated by jamming the reset lever.
• Control does not need leveling.
• The L4079 is unaffected by moderate vibration.
Contents
Application . .. . . . .... . ... . .......... .. . ... .. ............ ... ......... ... ... .. ....... 1 Features ............ .................... .. .. ... ............. .......... ...... .. ..... 1 Specifications . . . . .. .... . ... .. ...... ... ... ... .... .. ... ... . . .. . . . .. .... . .. .. . . . . . . 2 Ordering Information ... .... ......... ..... ... ... ....... .. ....... .. ........... 2 Installation ... ......... .. ........... ... ...... ... ....... ........... .. ............... 3 Wiring .... ...... ..................... .. ................... .. ...... ...... ... .. ... ..... 3 Checkout ....... ................. .... .... ............. ........ .... ......... .. ...... 4
60-2156-03
L4079A,B, W PRESSURETROL ® LIMIT CONTROL
SPECIFICATIONS
Models: Pressure and Electrical Specifications: See Table 1.
Table 1. Pressure and Electrical Ratings.
Maximum Ratings in Amperes Diaphragm
Range Pressure 120 Vac 240 Vac
Locked Locked Model Number psi kPa psi kPa Fu ll Load Rotor Full Load Rotor
L4079Aa and 2 to 15 15 to 100
L40788b 5to 50 35 to 350
10 to 150 70 to 1035
L407981 066b 20 to 300 140 to 2070
L4079W1 ooob 10 to 150 70 to 1035
a Ratings apply to each of two separate circuits. b One circuit only.
Switching Action :
25
85
225
350
225
L4079A- Snap-switch. Breaks two circuits automatically on pressure rise. Each circuit must be manually reset.
170
590
1550
2410
"1550
L4079B,W- Snap-switch. Breaks one circuit automatically on pressure rise. Circuit must be manually reset.
Adjustment means: External adjustment screw. Scale is calibrated in psi and kPa.
Maximum Ambient Temperature: 150•F (66•C).
Mounting Means : Pipe fitting-1 /4-18 NPT. Connection on diaphragm assembly.
These devices may be either boiler mounted directly to a boiler fi tting. or may be surface mounted . such as on a wall . by using the knockouts in the case.
Approvals: Underwriters Laboratories Inc. (UL) Listed: File No. MP466,
Guide No. MBPR. Canadian Standards Assocuation (CSA): File No. LR95329.
Certificate No. 1720340
Accessories : 50024585-001 Brass Steam Trap. 14026 Steel Steam Trap. 333128 Knurled adjustment knob.
ORDERING INFORMATION
9.8 58.8 4.9 29.4
9.8 58.8 4.9 29.'1
9.8 58.8 4.9 29.4
9.8 58.8 4.9 29.4
9.8 58.8 4.9 29.4
Dimensions: See Fig. 1.
--4-112 COVER)-l
- 4-3/S(CASE) -
.-1-15/16 1-15!16j
-- 3/16 1
~<22-135
Fig. 1. L4079A ,B,W PressureTrol® Limit Control dimens ions in inches.
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the TRADELINE® Catalog or price sheets for complete ordering number.
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Honeywell Automation and Control Products Sales Office (check white pages of you r phone directory). 2. Honeywell Customer Care
1885 Douglas Drive North Minneapolis, Minnesota 55422-4386
In Canada-Honeywell Limited/Honeywell Limitee, 35 Dynamic Drive, Toronto, Ontario M1V 4Z9. International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland , France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United l<ingdom, U.S.A.
60-2156- 03 2
INSTALLATION
When Installing This Product. .. 1. Read these instructions carefully. Failure to follow them
could damage the product or cause a hazardous condition.
2. Check on the ratings given in the instructions and marked on the product to make sure the product is suitable for your application.
3. Installer must be a trained, experienced service technician.
4. After installation is complete, check out the product operation as provided in these instructions.
Location PressureTrol® Limit Controllers must be mounted above the water line in steam boilers. They can be mounted alongside the pressure gauge, at a remote location, in a fi tting provided by the boiler manufacturer, or in special mountings on low-water cutoffs.
Mounting See Fig . 1 for mounting dimensions.
A steam trap must always be connected between the PressureTrol® unit and the boiler. The steam trap prevents boiler scale and corrosive vapors from attacking the diaph ragm.
Pressure Gauge Mounting: To mount the limit control beside a pressure gauge. remove the gauge and install in its P.lace a steam trap with a tee on top. Mount the PressureTrol® unit and pressure gauge on the side of the tee by means of nipples and elbows.
Remote Mounting: If excessive vibration seems likely to affect the operation of the control , it may be located remotely. as long as all piping is suitable and properly pitched to drain all condensation back to the boiler.
Boi ler Mounting: If it is not conven1ent to mount the control adjacent to the pressure gauge. mstall a steam trap at a location on the boiler recommended by the boiler manufacturer and screw t11e unit directly to the steam trap.
WIRING
A wARNING Electrical Shock Hazard. Can ca use severe injury, death or property damage. Disconnect the power supply before beginning wiring. More than one power supply disconnect may be required.
All wiring must comply with local codes and ordinances. See Fig. 2 for internal schematics and wiring.
3
L4079A,B, W PRESSURE7ROL ® LIMIT CONTROL
Ll (HOT) L2
1 l
LINE VOLTAGE THERMOSTAT
L4079A
~~~p~~ ~~L4079B, w I TO ~ RISE
THERMOSTAT ~~-.. ,..} (HOT)
TO POWER--- ------ ---SUPPLY
TO I.IOTOR
~ PROVIDE DISCONNECT I1IEANS AND OVERLOAD PROTECTION AS REQUIRED 1.122.:35
Fig. 2. Schematics and wiring. L4079A breaks both s ides of power supply; L4079B,W breaks hot side only.
Setting To set the control. turn the pressure adjusting screw (see Fig. 3) until the pressure setting indicator on the front of the case is in line with the requi red control pressure setpoint. The indicator setting is the point at which the switch breaks contact.
PRESSURE ~ ADJUSTING SCREW ~ '\
~ ~
PRESSURE SETT 1~!G
INDICATOR
SCALEPLATE
~IANUAL RESET BUTTONS
1.122<37
Fig . 3. Cont ro ls and indicato rs on L4079A. L4079B,W is the same except for having only one reset button.
60-2156-03
L4079A,B, W PRESSURETROL ® LIMIT CONTROL
Manual Resetting When the circuits have broken automatically, they must be manually reset. After the pressure returns to normal, manually reset by depressing the manual reset button(s) firmly and releasing. The circuit is not complete until the reset button is released. The trip-free manual reset mechanism prevents the limit controller from operating as an automatic controller (selfresetting) even if the manual reset button has been tied down.
Automation and Control Solutions
CHECKOUT
After the control has been installed and wired, test as follows:
Note the boiler pressure by checking the boiler pressure gauge (boilerJ ressure should be near the middle of the PressureTrol " pressure scale to perform this test properly).
Rotate the PressureTrol® pressure adjusting screw (see Fig. 3) until the pressure setting indicator on the front of the case corresponds to the boiler pressure gauge reading.
The limit control should break the r.ontrol cirr.u it(s) whP.n the boiler pressure gauge reading equals or slightly exceeds the PressureTrol® pressure setting.
If the limit control is operating properly, manually reset it and adjust the pressure adjusting screw until the pressure setting indicator is in line with the required limit setpoint.
Honeywell International Inc.
1985 Douglas Drive North
Golden Valley, MN 55422
customer.honeywell.com
Honeywell Limited-Honeywell Limitee
35 Dynamic Drive
® U.S. Registered Trademark © 2007 Honeywell International Inc. 60-2156- 03 M.S. Rev. 05-07
Toronto, Ontario M1V 4Z9
® Printed in U.S.A. on recycled paper containing at least 10% post·consumer paper fibers.
Honeywell
Honeywell
L91A,B,D Proportioning Pressuretrol® Controllers
APPLICATION
L91 Proportioning Pressuretrol® Controllers are Series 90 Modulating Pressure Controllers that provide direct control of modulating motors or valves used on automatic burners or steam heating systems.
PRODUCT DATA
FEATURES
• Models available for pressure systems up to 300 psi (2068 kPa).
o May be used w ith steam, air, noncombustible gases, or other fluids noncorros ive to brass or phos-bronze (300 psi model) bellows.
• When used with steam boilers, a steam trap (siphon loop) is recommended.
• Wiper on controller potentiometer moves in response to pressure c hanges.
• L91 D has two potentiometers for unison control o f two motors.
• L91 B, D models have adjustable proportioning (throttling) range to allow selection of desi red pressure control range.
• Adjustments made with screws on case top.
• Large, eas ily -read scale plates in both U.S. customary (oz/sq. in., ps i, or in. Hg) and metric (kPa, MPa, or mm Hg) units.
o Steel case with clea r plastic cover to observe pressure settings and potentiometer action.
• Fitting with 1/4-18 NPT threads allows rapid installation.
• Surface mount with screws through knockout holes in case back.
Contents
Application ............. ................................. .. ........................ ·1 Features ................................ .. .............. ................ ........... 1 Specifications ... .... .. .... .... ........... ....... ..................... ........... 2 Ordering Information .. ............. ...... .. .... .... .. ....... ... ... .. ........ 2 Wiring .. ... ... ... .............. ...................................................... 6 Checkout ..................... .. .. ....... .... ............ ..... .. ..... ...... .... ... . 8 Service Information ......... .. ................ .. ... .. .................. ...... 9
60-2152-06
L91A,B,O PROPORTIONING PRESSURETROL ® CONTROLLERS
SPECIFICATIONS
Table 1 Models Available Maximum Surge
Operating Rangesa Proportioning (Throttling) Range at Midscale Pressure
U.S. u.s. Customary Potentiometer Customary
Model Units Metric Units Part No.b Adjustable Units Metric Units psi kPa
L91A 0 to 15 psi 0 to 103 kPa 23176CB No 0.5 psi 3.4 kPa 25 172
5 to 150 psi 0.03 to 1.03 MPa 23176CB No 5 psi 0.03 MPa 225 1551
1 0 to 300 psib 0.07 to 2.07 MPa 23176CB No 12 psi 0.08 MPa 350 2413
L918 0 to 16 oz/sq in. 0 to 7 kPa 23176CF Yes 2 to 38 oz/sq in. 0.9 to 16.4 kPa 6 41
0 to 4 psi 0 to 28 kPa 23176CF Yes 5 to 38 oz/sq in. 2.2 to 16.4 kPa 6 41
0 to 15 psi 0 to 103 kPa 23176CF Yes 1.5 to 12 psi 10 to 83 kPa 25 172
2 to 50 psi 14 to 345 kPa 23176CF Yes 5 to 32 psi 34 to 221 kPa 85 586
Sto 150 psic 0.03 to 1.03 MPa 23176CB Yes 5 to 23 psi 35 to 160 kPa 225 1551
1 0 to 300 psic 0.07 to 2.07 MPa 23176CB Yes 12 to 48 psi 85 to 330 kPa 350 2413
10 to 300 psi 0.07 to 2.07 MPa 23176CF Yes 30 to 110 psi 0.21 to 0.76 MPa 350 2413
L910 0 to 15 psi 0 to 103 kPa 23176CF Yes 1.5 to 12 psi 10 to 83 kPa 25 172
5 to 150 psic 0.03 to 1.03 MPa 23176CF Yes 13to 52 psi 0.09 to 0.36 MPa 225 1551
1 0 to 300 psic 0.07 to 2.07 MPa 23176CF Yes 30 to 110 psi 0.21 to 0.76 MPa 350 2413
a Scaleplates are marked in both customary (oz/sq in. psi, or in . Hg) and metric (kPa, MPa, or mm Hg) units. b Length of active winding is 7/64 in. (2.8 mm) for part no. 23176CB, and 1/4 in. (6.4 mm) for part no. 231 76CF. c Model available with 1/4 in. BSP-TR internal threads (British Standard Pipe Threads) for mounting.
Models (Table 1 ): L91A: Single potentiometer; nonadjustable proportioning
range. L91 B: Single potentiometer: adjustable proportioning range. L91 D: Two potentiometers allow unison control of motors;
adjustable proportioning range.
Electrica l Rating: 24 Vac .
Potentiometer Action : Wiper moves toward W on pressure rise, toward B on pressure fa ll. Potentiometer is field replaceable.
Poten tiometer Resistance : 140 ohms (nom1nal ) for L91 A. B. and D models.
ORDERING INFORMATION
Pressure Sensing Element: Brass bellows, 10-300 psi models phos-bronze bellows.
Minimum Ambient Temperature: 32• F (0° C)
Maximum Ambient Temperature: 150° F (66° C)
Adjustment Means: Screws on controller case top; knurled knob for main scale setting on 10 to 300 psi (0.07 to 2.07 MPa) models.
Setpoint: At low pressure end of proportioning (throttling) range.
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the TRADE LINE® Catalog or price sheets for complete ordering number.
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone:
1. Your local Honeywell Automation and Control Products Sales Office (check white pages of your phone directory). 2. Honeywell Customer Care
1885 Douglas Drive North Minneapolis, Minnesota 55422-4386
In Canada- Honeywell Limited/Honeywell Limitee, 35 Dynamic Drive, Toronto, Ontario M1V 4Z9. International Sales and Service Offices in all principal cities of t11e world. Manufacturing in Australia , Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
60·2152-06 2
Main Sca leplate : Marked in both U.S. customary (oz/sq . in, psi, or in. Hg) and metric (kPa, MPa, or mm Hg) units.
Proportioning Range Scaleplate (L91 8,D only): Graduated from A to F with a MIN (minimum) value below A. (See Table 2 for the value of each division.)
Mounting Means: Fitting on bellows has 1/4- 18 NPT threads (external on 0 to 16 oz/sq. in., 0 to 4 psi, and 0 to 15 psi models; internal on all other models) for mounting on a pipe or steam trap (siphon loop).
NOTE: Some models are available with 1/4- 19 BSP-TR internal threads; see Table 1.
Also can be surface mounted by screws through two knockout holes in case back.
Electrical Connections: Internal screw terminals. Hole in side of case for 1/2 in. conduit.
Dimensions: See Fig. 1; see Fig. 2 for mounting steam trap (siphon loop).
L91A,B,D PROPORTIONING PRESSURETROL ® CONTROLLERS
Weight: 1 lb, 15 oz (0.88 kg).
Finish: Gray.
Replacement Parts: 129178 Thermoplastic Cover. 23176CB Potentiometer: For all L91 A models and a few L91 B
models (see Table 1 ); 140 ohms (nominal); length of active winding is 7/64 in. (2.8 mm). ·
23176CF Potentiometer: For all L91D models and most L91 B models (see Table 1 ); 140 ohms (nominal); length of active winding is 1/4 in. (6.4 mm).
Accessories: 50024585-001 Steam Trap (~iphon loop). 1/4 in. brass pipe
with 1/4 -18 NPT external threads on both ends. 14026 Steam Trap (siphon loop): 1/4 in. steel pipe with 1/4 -1 8
NPT external threads on both ends. 333128 l<nurled Adjustment Knob: With setscrew; fits on main
scale pressure adjusting screw. 4074BWJ Limit Stop Assembly: To limit setpoint ranges;
includes 129564 Range Stop 107194 Range Stop Screw, and 23466 Wrench.
Table 2. Approximate value of each division (A to 8, 8 to C, etc.) on proportioning (throttlin~) ran~e scaleplate (L91 8 D F only)
Operating Range Value of Each Division
U.S. Customary U.S. Customary Units Metric Units Units Metric Units
0 to 10 oz/sq in . 0 to 7 kPa 6.2 oz/ sq in. 2.7 kPa
0 to 15 psi 0 to 103 kPa 1.8 psi 12.4 kPa
2 to 50 psi 14 to 345 kPa 4.7 psi 32.4 kPa
5 to 150 psi (L91B) 0.03 to 1.03 MPa 7.8 psi 0.054 MPa
5 to 150 psi (L91 D) 0.03 to 1.03 MPa 6.7 psi 0.046 MPa
10 to 300 psi (L91 B with 7/64 in. potentiometer) 0.07 to 2.07 MPa 16.4 psi 0.113 MPa
10 to 300 psi (L91 B,D with 1/4 in. potentiometer) 0.07 to 2.07 MPa 13.8 psi 0.095 MPa
3 60-2152- 06
L91A,B,D PROPORTIONING PRESSURETROL ® CONTROLLERS
L91A,B,D - 4-112 (114.3) (COVER,__..
- 4-11132 (110.3) (CASE)-- 2-314 (69.9)-
- 3-5711>4 (98.8)---·
3-13/32 (86.5)---· .... - 1-3116 (30.2)
& -- 1·1116 (27.0) &l & ~- -·-- ~~- 1:1''-( -' t (
I
1-3132 (27.8)
t
I I
\ I
t I 3-2ll32 ' - ( (S-1.5)
ALL OTHER ~IOOELS
10 TO 300 PSI
O T0 15P51
t 1·1l'16 ® (460)
~rr===t====:i=_~-~, ~_L I 1 I I I
I I t I _,_ /
I
3-7/8 98.4)
2-564 (52.8)
~ 1-- 7/8 ! + I (22.2)(2)
~ I 13116 - (20.1)
+
lf_ - 1-1116 -(27.0\
- Dl~l A (SEE Ti\:lULATION TA8LEj - D!~I B SEE _.,.. ( TABULATION
TABLE) /1 EXTERNAL THREADS ON 0 TO 16 OZIIN' AND 0 TO 15 PSI ~'.ODELS: INTERNAL THREADS o·~ ALL OTHER MODELS SOo!E MODELS ARE ALSO AVA!lABcE WITH 1/4-19 BSP·TR INTERNAL THREADS: SEE TABcE I
&. PROPORTIONING RANGE JI.DJUSTING SCREW ON L91B.D MODELS ONLY.
L0, 33312B KNURLED ADJUSTMENT SCRBV KNOB, 718 IN. (22 2 M\1) DIA\ !ETER.. KNOB IS INCLUDED WITH 10 TO 300 PSI (0.07 TO .07 MPaJ l.lODELS: OPTIONAL ACCESSORY FOR OTHER fi.OOELS.
FOR 10 TO JCoj PSI (0.07 TO 2.07 r.:Pa) hlODELS D::.l C 1\lCLUDES THE KNURLED AD.USTiv.ENT KNOB.
T.>.SU.ATIC\ OF D" IENSIONS ;-.. & h''D C .. ... OPERATI\lG RANGE DIM A D:"I S 01.\I C
CUSTO.\IARY UNITS " IETRIC UMTS 1~: ~.11\1 1~. ~~~.1 IN ~1\1
0 TO 16 OZ/IN. 0 TO 7 kPa 4. 718 123.8 2. 7 16 61.9 7 . 1132 178.6
C TO 15 PSI 0 TO 103 kPa ~. 7 16 61" 1 . 7i32 3i .O 6 -7/8 1746
2 TO 50 PSI 14 TO 345 kPa 1 • 518 ·11 . ..> 13 16 2oo 5. 3'·1 146.1
5 TO 150 PSI 0.03 TO 1.03 ~.!Pa 1. 518 •11.3 , 16 20.6 5. 3'4 146 1
1 1u3C'. PSI 1 07 lo 2.C7 ~:Pa 1-1-t .It 58 15.::: 6-11~ 15 1.0&
DI~IC TABULA
(SEE JION E) TABL
'.\S52J A
Fig. 1. Mounting dimensions of the L91 Proportional Pressuretrol® Controllers, in in. (mm).
When Installing This Product.. . A wARNING 1.
2.
3.
4.
Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition. Checl< the ratings given in the instructions and on the product to make sure the product is suitable for your application. Installer must be a trained, experienced service technician. After installation is complete, check out product operation as provided in these instructions.
60-2152-06 4
Electrical Shock Hazard. Can cause severe injury, death or property damage. 1. Disconnect power supply before beginning
installation to prevent electrical shock and equipment damage.
2. When using the controller with a compressor, install a dampening device (such as a needle valve, header, or surge tank) to dampen pulsations that can damage the controller or reduce its life.
IMPORTANT 1. Locate the controller where the ambient temperature
will not exceed 150° F (66° C). 2. When the controller is used on a boile1; be sure to
connect a steam trap (siphon loop) between the controller and the boiler.
3. Before installing controller. be sure the siphon loop has enough water in it to fill/ower trap.
4. Use pipe compound sparingly to avoid clogging the hole in the pipe or bellows fitting.
5. Do not tighten the controller by hand by holding onto the case and turning it.
Location and Mounting When used with steam boilers, always mount the controller above the water line in the boiler. A steam trap (siphon loop) must always be connected between the controller and the boiler (Fig. 2) to prevent boiler scale and corrosive vapors from attacking the bellows. Before installing controller, be sure the siphon loop has enough water in it to fill lower trap.
The controller can be mounted (1) beside the pressure gauge, (2) in a fitting on the boiler provided by the manufacturer, or (3) at a remote location in case of excessive vibration.
Make all pipe connections in accordance with approved standards. Use only a small amount of pipe compound to seal the connection joints. Excess pipe compound may clog the small hole in the fitting and prevent the controller from operating properly.
To avoid leaks and damage to the case. use a parallel jaw wrench on the controller fitting. Do not tighten the controller by hand by holding onto the case and turning it.
5
L91A,B,D PROPORTIONING PRESSURETROL ® CONTROLLERS
L91 PRESSURETROL CONTROLLER
[
PRESSURE GAUGE
~ ~
.& STEAM TRAP IS A 1/4 IN. PIPE WITH 114 • 18 NPT EXTERNAL TRHEADS ON BOTH ENDS.
& FITTING ON BELLOWS HAS 1/4·18 NPT EXTERNAL THREADS ON 0 TO 16 OZ/SO. IN. AND 0 TO 15 PSI f~ODELS: INTERNAL THREADS ON ALL OTHER MODELS. SOME MODELS ARE ALSO AVAILABLE WITH 114·19 BSP-TR INTERNAL THREADS: SEE TABLE 1
Fig. 2. Approximate dimensions in in. (mrn) for mounting L91 Pressuretrol® Controller beside Pressure Gauge on
Steam Trap (Siphon Loop).
Mounting Beside a Pressure Gauge To mount the controller beside a pressure gauge (Fig. 2), remove the gauge. In its place, install a steam trap (siphon loop) with a tee on top. Using elbows and pipe nipples, mount the controller and pressure gauge on the ends of the tee.
Mounting on a Boiler If it is not convenient to mount the controller beside the pressure gauge. install a steam trap (siphon loop) in the fi tting provided by the boiler manufacturer. If there is no fitting. mount the steam trap at a location recommended by the boiler manufacturer. Screw the controller directly to the steam trap. if possible.
Mounting at a Remote Location If there is excessive vibration at the boiler that may adversely affect the operation of the controller, mount the controller at a remote location. All piping from the boiler must be suitable and solidly mounted. The piping must be properly pitched to drain all condensation back to the boiler. If this causes the controller to be located at an inconvenient height (on large boilers), it may be mounted at a lower level if the connecting piping is filled with clean water. A steam trap (siphon loop) must be mounted between the remote piping and the controller.
60-2152- 06
L91A,B,D PROPORTIONING PRESSURETROL ® CONTROLLERS
ACTION ON PRESSURE FALL
W B
ACTION ON PRESSURE FALL
W B
REAR POTENTIO~IETER
ACTION ON PRESSURE FALL
B
FRONT POTENTIOMETER
& TER~IINALS ARE LABELED
L910
M8522J.
Fig. 3. L91 term inal blocks and internal schematics.
WIRING
1. Discon nect power supply before beginning installation to prevent electric shock and equipment damage. All wiring must comply with applicable electrical codes, ordinances, and regulations. Use NEC Class 1 (line voltage) w1nng.
2. For normal installation, use moisture-resistant No. 14 wire suitable for at least 167"F (75°C) if you are using the controller with a flame safeguard primary control. or at_least 194 oF (90°C) if you are using it with a programmulg control.
3. For high temperature installations, use moisture-resistant No. ·14 wire, selected for a temperature rating above the maximum operating temperature.
4. Disconnect the power supply before beginning wiring to prevent electrical shock and equipment damage.
5. All models have a terminal block inside the cover (Fig. 3) and two 7/8 in. (22.2 mm) holes in one side for 1/2 in. conduit, cable, or wires. Remove the front cover by loosening the screw at the bottom of the scaleplate.
60-2152- 06 6
6. Refer to Fig. 4 for typical hookup. Wand B connections may be interchanged at the motor for reverse action (cooling). Follow the burner or boiler manufacturer's wir!ng diagram i_f provided. Also refer to the wiring diagrams rn the motor Instructions.
7. Replace the front cover when wiring is completed.
L91 PROPORTIONING CONTROLLER
SERIES 90 MODULATING MOTOR
CLOSED M9484
(LOW FIRE) ~·19494
orEN (HIGH FIRE)
TRANSFORM ER
WIPER MOVES TOWARD WEND OF POTENTIOMETER ON PRESSURE RISE AND TOWARD B END ON , PRESSURE FALL. (HOT) L 1 L2
TERMINALS ARE LABELED
POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. i\!8520A
Fig. 4. Hookup of L91 Proportioning Pressuretrol® Controller to Series 90 Modulating Motor.
Setting In all models. the proportioning range (also called throttling range) extends above the main scale setpoint (Fig. 5). The proportioning range is fixed on L91 A models. but is adjustable on L9 1 B,D models. (For values, refer to Table 1 in the Specifications section .)
Main Scale Set Point (All models) Adjust the main scale setpoint for the desired operating pressure by turning the main scale adjusting screw (Fig. 7) or knurled adjustment knob on 10 to 300 psi (0.07 to 2.07 MPa) mo?els. on the top of the case. until the main scale setting md1cator 1s at the minimum pressure desired. The proporiioning range extends above this value. The scaleplate IS marked 111 both customary (oz/sq in .. psi. or in. Hg) and metnc (kPa. MPa, or mm Hg) uni ts.
Use of L91 Proportioning Controller with Limit Controllers The L91 main sca le setpoint plus the value of the differential (proportioning range) must be less than or equal to the limit controller's (L404) main scale setpoint.
For example, to control system pressure between 70 and 80 psi: sele_ct an L91 B, 5-150 psi operating range, adjustable d1fferent1al (proportioning, throttling range) of 5 to 23 psi and an L404A, 10-150 psi, adjustable differential of 8 to 16 psi. Set the L404A main scale setpoint at 80 psi and its adjustable differential at 10 psi. The L404A settings will then provide boiler pressure limit control between 70 and 80 psi. An L91 B differential (proportioning range) pressure of 5 psi is desired. Therefore, an L91 B main scale setpoint of between 70 and 75 psi is required (L91 main scale setpoint plus its differential must be less than or equal to the limit controller main scale set
point). The L91 8 settings provide system modulation between 70 and 75 psi or between 75 and 80 psi, depending on the exact setting of the L91 8 main scale setpoint.
Due to device tolerances, the scaleplate settings are approximate and, therefore, the settings should be fine-tuned with the system operating.
Proportioning Range (L91 B,D Only) Adjust the proportioning range (throttling range) by turning the proportioning range adjusting screw (Fig. 6) on the top of the case until the proportioning range setting indicator is at the desired value. The proportioning range scale is graduated from A to F vvith a MIN (minimum) value below A. Tile value of e3ch division depends on the operating range of the controller. Refer to Table 2 in the Specifications section.
Typical Operation Pressure variations cause the bellows to expand or contract. Linkage between the bellows and the potentiometer wiper causes the wiper to move across the potentiometer windings. This varies the resistance between R and 8 , and between R and W, causing an unbalance in the circuit connected to the controller. See Fig 7.
t PRESSURE RISE
I
MAIN SCALE SETPOINT
~
~-----------,--• I I I
PROPORTIONING : RANGE 1
/1 0--: I
(WIPER) 1 I I I I I _.:.... _____ --..
/1 FIXED ON L91A. AD" USTAo "E 0:-J L91i3.D
LOW-FIRE !CLOSED)
H IGH-FIRE (OPEN)
& L9 1 D HAS n'JO POTENTIOMETERS OPERATING It\ UNISIO.\
Fig. 5. L91A,B,D operating points.
7
L91A,B,D PROPORTIONING PRESSURETROL ® CONTROLLERS
PROPORTIONING RANGE ADJUSTING SCREW (L91 B.D ONLY)
MAIN SCALEPLATE
& KNURLED ADJUSTMENT KNOB ON tO TO 300 PSI [0.07 TO 2.07 MPa) ,,\ODELS.
INAL BLOCK
:.:6525A
Fig. 6. Setting L91 Proportioning Pressuretrol® Controller.
A proportioning controller is used most often to regulate the firing rate of a burner by controlling a modulating motor (Fig. 4) or a modulating valve. The controller potentiometer, the feedback potentiometer in the motor (or in the valve actuator), and a balancing relay in the motor (or actuator) form an electric bridge circuit. As long as the pressure of the controlled medium remains at the setpoint of the controller. the circuit is balanced; that is, equal the relay contacts are open. When the ci rcuit is balanced, the motor (or actuator) does not run.
If the pressure of the medium rises, the wiper in the controller moves toward W. This unbalances the circuit, so a larger current flows through one side of the balancing relay. The close contacts in the relay make, causing the motor (or valve actuator) to drive toward its closed position . As the motor (or actuator) runs, the wiper on the feedback potentiometer moves in a direction to balance the circuit. When the circuit is again in balance, the balancing relay contacts open and the motor (or actuator) stops. The valves and dampers connected to the motor or actuator will be partially closed , decreasing the firing rate and reducing the pressure.
Similarly, if the pressure of the controlled medium falls. the wiper on the controller potentiometer moves toward 8 , and the open contacts in the balancing relay make. The motor (or actuator) drives toward its open position until circuit balance is achieved. The valves and dampers will be opened wider and the firing rate will increase, thus increasing the pressure.
A small change in the pressure of the controlled medium will cause a change in the firing rate to compensate for it, thus keeping the pressure constant. This process is called modulation.
60·2152-06
L91A,B,O PROPORTIONING PRESSURETROL ®CONTROLLERS
CHECKOUT
After the controller is installed, wired, and set, it should be tested with the system in operation. First, allow the system to stabilize. Then, observe the operation of the controller while ra ising and lowering its setpoint. Pressure should increase when the setpoint is raised and decrease when the setpoint is lowered . Use accurate pressure testing equipment when checking out the controller. Do not rely on inexpensive gauges. The controllers are carefu lly calibrated at the factory.
Make sure the modulating motor or modulating valve actuator reaches the low- and high-fire positions at the proper points. If the motor or actuator runs in the proper direction when the setpoint is adjusted, assume that the controller is operating properly. If it runs in the wrong direction, reverse the B and W wires. Observe the action of the motor or actuator unti l it stabilizes. If the motor or valve is moving constantly, widen the proportioning range (not adjustable on an L91A) incrementally until the system is stable.
If a Controller Seems to Operate Improperly If the controller is suspected of operating improperly, it may be further checked by:
1. Leaving the controller installed where it is, but disconnecting all power to the controller motor or valve.
2. Loosening the cover screw below the main scaleplate and removing the cover.
3. Disconnecting the wires from the controller. 4. Connecting an ohmmeter between controller terminals B
and W to measure the resistance for the potentiometer in the controller. The ohmmeter should read about 135 ohms for an L91A,B, or D.
5. Connecting the ohmmeter between controller terminals Wand R (Fig. 8) and raising the setpoint of the controller above the actual pressure being measured. The ohmmeter should read the full value of the potentiometer measured in step 4 (135 ohms for an L91 A,B, or D).
6. Slowly lowering the setpoint of the controller while observing the ohmmeter reading. The resistance should drop to zero at some setpoint below the actual pressure.
7. Making an approximation of the proportioning range by observing the change in setpoint required for a resistance change from zero to full value.
MAIN SCALE SETIING INDICATOR
00
MAIN SCALE \;·~~LISTING SCREW
\&
INPUT OUTPUT
I I I I I I I I I I
I I I I I I I I I 1 I\
1 '~ \ ' .... ___ _ ..
INCREASES TO !:.. 135 OH~.IS ill
PROPOTIONING RANGE ADJUSTING SCREW (L91B,D ONLY)
SETPOINT INCREASE
ffi r<NURLED /1DJUSTMENT KNOB ON 10 TO 300 PSI [O.Q7 TO 2 07 MPA[ MODELS
&. TERMINALS ARE LABELED
&. 135 OHI.IS ON L91A.S OR D ,0.,~3 546A
Fig. 7. Checking L91 Proportioning Pressuretrol® Contro ller.
8. When the controller is operating properly. reconnecting the wires. replacing the cover, tightening the cover screw, and resetting the controller to the desired value.
9. Reconnecting power to the controlled motor or valve. & cAUTION
60-2152- 06 8
Equipment Damage Hazard . Failure to follow checkout instructions can damage components or systems. Do not put the system into service unti l you have satisfactorily completed all applicable tests described in this Checkout section, all tests in the Checkout section of the applicable instructions, all tests for the flame safeguard control, and any tests required by the burner and boiler manufactu rers.
SERVICE INFORMATION
it. CAUTION Electrical Shock Hazard 1. Only qualified service technicians should attempt to
service or repair flame safeguard controls and burner systems.
2. Disconnect power supply before cleaning the potentiometer windings or wiper, or before replacing the controller potentiometer.
Calibration All controllers are carefully tested and calibrated at the factory under controlled conditions. If the actual operating pressure does not match the setpoint, move the main scaleplate slightly up or down until the setpoint agrees with the actual pressure.
Maintenance Keep the cover of the controller in place at all times to protect the internal components from dirt, dust, and physical damage. Perform routine maintenance occasionally by inspecting and blowing or brushing away any accumulated dirt and dust. To assure proper functioning of the controller at a ll times, perf orm an operational check of the entire system during routine maintenance checks. Be sure to handle controllers carefully at the time o f installation, during actual use, and during maintenance.
Cleaning the Potentiometer Windings or Wiper Occasiona lly, the windings or wiper on the potentiometer (two on the L91 D) may need cleaning. Disconnect the power supply before removing the cover from the controller and before cleaning the potentiometer.
IMPORTANT 1. Use an electncal contact cleaner that does not con
tain solvents. 2. Use extreme care to avoid bencling the wiper arm.
changing the wiper tension and damaging the potentiometer windings.
3. Do not use an abrasion or bumishmg tool to clean the potentiOmeter windmgs or w1per.
4. Do not use hard paper. such as a business card. or abrasive materials (sandpaper. eme1y boards, file. etc.) to clean the windings or wiper
Solvent-type electrical contact cleaners can deteriorate plastic components and wire insulation and leave an oily residue that accumulates particulate matter (dust, etc.). The residue can break down to form various carbonaceous substances that cause early potentiometer failure.
Use of abrasive materials results in wearing of the potentiometer windings and accumulation of particulate matter that changes the resistance between the windings and the wiper.
9
L91A,B,D PROPORTIONING PRESSURETROL ® CONTROLLERS
Replacing the Controller Potentiometer (Fig. 8- 10)
IMPORTANT: 1. Replace the controller potentiometer only when nec
essaly to obtain proper operation. 2. When replacing the potentiomete1; be ve1y careful not
to bend or damage the wiper arm, and not to change the wiper tension. Any damage or change in tension will decrease the life of the new potentiometer.
1. Disconnect all power to the controller. 2. Loosen the cover screw below the main sr::a leplr~ te Fmd
remove the cover. 3. Mark the wires to the external device (motor or valve
actuator) and disconnect them from the terminal block. 4. Remove the screw holdin'g the terminal block bracket to
the top of the case (Fig. 8). Put this screw in a safe place because it will be needed later.
5. While carefu l not to damage the potentiometer wiper or any of the internal wiring, lift out the terminal block and bracket.
6. Before removing any potentiometer wires, carefully note and record (sketch) the position (off-center) of the active winding on the potentiometer and the location and connections of all wiring terminals. The new potentiometer must be inserted and connected the same.
Example: In Fig. 9, the active winding is on the left half of the potentiometer; the wire from the left end of the winding is connected to the (W) terminal on the terminal block, and the wire from the right end of the winding is connected to the (B) terminal on the terminal block.
7. Loosen the (W) and (B) screws on the terminal block, and remove the two wires to the active winding of the potentiometer. Leave the wire to the wiper arm intact.
8. Carefu lly unscrew the bolt that holds the potentiometer to the bracket. Make sure the potentiometer wires do not entangle with the wiper and bend it.
9. Carefully slide the old potentiometer off the bolt. 10. Carefully slide the bolt through the new potentiometer.
Make sure that: a. The off-center position of the winding on the new
potentiometer is the same as the old potentiometer. (Consult sketch in step 6.)
b. The wiper will con tact bare wires. (Rotate the potentiometer on the bolts so the surface of the winding where the brown enamel was removed is toward you.)
11. Screw the bolt into the potentiometer bracket. Make sure the wiper is contacting bare wires (step 1 O.b); then tighten the bolt.
12. Connect the two potentiometer wires to the (W) and (B) terminals on the terminal block and tighten the screws. Make sure these wires are connected to the same terminals as in the old potentiometer. (Consult sketch in step 6.)
13. Carefully fi t the hole in the bottom of the terminal block bracket over the screw protruding upward from the bottom of the case (Fig. 1 0). Insert the screw (removed in step 4) through the hole in the top of the case (Fig. 8) and into the top of the bracket, and tighten it.
14. Reconnect the wires from the external device (motor or actuator) to the terminal block.
15. Replace the cover and tighten the cover screw. 16. Reconnect power to the controller.
60-2152-06
L91A,B,D PROPORTIONING PRESSURETROL ® CONTROLLERS
TERMINAL BLOCK BRACKET
Fig. 8. Removing terminal b lock bracket.
POTENTIOMETER WIRES
I
BARE WIRES (ENMIEL RH.IOVED) .&.
POTENTim iETER
TERMINAL BLOCK
!A
.&. THE POTENTIOMETER IN AN L91A IS MOUNTED AT A•15 DEGREE AN GeE INSTEAD OF HORIZONT1\cLY M l L9 1D HAS TWO POTENTIOMETERS
TER~IIN 1\LS ARE LABELED
Fig. 9. Replacing potentiometer in L91.
60-2152-06 10
TERMINAL BLOCK BRACKET
TER,.IINAL BLOCK
FIT HOLE IN BOTTOI.I OF BRACKET OVER SCREW PROTRUDING UPWARD FROM BOTTO~ I OF CASE
M854SA
Fig . 10. Replacing terminal b lock bracket.
L91A,B,D PROPORTIONING PRESSURETROL ® CONTROLLERS
11 60-2152- 06
L91A,B,D PROPORTIONING PRESSURETROL ® CONTROLLERS
Automati on and Control Solutions
Honeywell International Inc. Honeywell Limited-Honeywell Limitee
1 985 Douglas Drive North 35 Dynamic Drive
Golden Valley, MN 55422 Toronto, Ontario M1V 4Z9
customer.honeywell.com
® U.S. Registered Trademark © 2007 Honeywell International Inc. 60-2152- 06 M.S. Rev. 05-07 *
Printed in U.S.A. on recycled paper containing at least 10% post-consumer paper fibers.
Honeywell
J
Sensors Warrick® Series 160M Controls
Installation and Operation Bulletin . ', - .· i.
Form 164 Sheet PIN 100226-1
Rev. D
This bulletin should be used by experienced personnel as a g~Jide to the installation of series 160M controls. Selection or
insiallation of equipment should always be accompanied by cqmpetent technical assistance. We encourage you to contact
Gems Sensors Inc. or its representative if further information i's required. J
Specifications
C~iiti'O~ Qs~dgr...; - Sc}i :1-·St:4!o -cornpons~ts -ei1;_' .. 1osed li-i clear· Lexan p:ug-ii1 sty Ia :lot.iSing. i-iousing
carries no NEMA rating
Contact Design: 2 SPOT (2 form C): Two Normally Open (N.O.) and two Normally Closed (N.C.),
non-powered contacts
Contact Ratings: 5 A@ 120, 240 VAG resistive, 1/8 H.P.@ 120 or 240 VAG
Contact Life: Mechanical: 5 million oper::ttions - Electrical: 100,000 operations minimum at
rated load
Supply Voltage 24, 120, or 240 VAG Models - Factory Set. Plus 10%, minus 15%, 50/60 Hz
Supply Current: 120, 240, 24 VAG, Relay enc~rgized 4.4 VA
Secondary 12 VAG RMS Voltage on probes. 1.5 milli-amp Current
Circuit: Models operate from 0 to 1.000,000 OHM maximum
Sensitivity: specific resistance - Factory set
-40° To 150°F Ambient
Temperature: All connections #6-32 screw type with pressure clamps
Terminals : Standard, 0.5 seconds on rising level.
Time Delays: Additional time delays on risfng and/or falling level available as option.
U.L. Listing, Industrial Motor Control (508). 240 and 208 volt units are not U.L.
Listings: limit control recognized.
Installation
1. Install octal socket in appropriate enclosure using two #6 or #8 metal screws.
a) Install rail mount socket on appropriate rail (DIN mount) 1n appropriate enclosure, if applicable.
2. Wire control per wiring diagram, following N.E.C. and local codes.
3. Install control module in socket.
Sensitivities vs Maximum Probe Wire Distance*
Dimensions
· 2-3/ll in J
Sensitivity Sensitivity Di stance
_j,..,.,-.. _______ ] 2-5/16 in
Character (K Ohms) (Ft.) A or K 4.7 10,000 B or L 10 5,700 CorM 26 2,200 0 or N 50 1,075 E or P 100 570 For R 470 270 G or S 1,000 38
* Based on type MTW or THHN wire, #14 or #16 Awg
.!: .!: ~ .!: ~ "? .!: <D ~ N ~
c0 0 -~ c--i ~ . .....
11164 india
Use copper (60/70° C) wire only. Torque to 20 inch pounds.
Wiring Diagram AC Supply
+ +
Reference Probe r ------ ----, Low Probe
I r - HighProbe- - - 1 I I I ~-----, 1 I
. 1 I 1 j_ 1 I · 1 I 1 V I I . I I 1 I I
I I 1 I I
;,: I : II 7~ I __ ~ L _j _I_: If metallic, tank may be used
instead of reference probe.
i I
For Differential Service Note: For Single Level Service , use "H" and "G" Connections
QQera'tion Direct Mode - Sing le Level Servi ce: When the liquid rises to the electrode on terminal 3, the control energizes, changing state of the load contacts. (LED w ill be lit) The control remains energized until the liquid leve l recedes below electrode on terminal 3. The control then de-energizes , (LED will not be lit) returning load to original state. Inverse Mode- Single Leve l Service: Control energizes with power, changing state of u-,e load contacts. (LED will be lit) When the liquid rises to the electrode on terminal 3, the control de-energizes, returning the load contacts to shelf state. (LED will not be lit) The control remains de-energ ized until liquid level recedes below the electrode connected to terminal 3. The control then energizes.
Direct Mode - Different ial Service: When the liquid rises to the electrode on terminal 3, the control energizes, changing state of the load contacts. (LED wi ll be lit) The control remains energized until the liquid level recedes below electrode on terminal 4. The control then de-energizes, (LED wil l not be lit) returning the load contacts to orig inal state. Inverse Mode- Differential Service: Control energizes with power, (LED wi ii be iii) chanying state of the load contacts. When the liquid rises to the electrode on terminal 3, the control de-energizes, re tu rning load contacts to shelf state. (LED w ill not be li t) The control remains de-energized until the liquid level recedes below the electrode on terminal 4. The control then energ izes.
QP-t ional Time Delays: With time delay on increasing level, the liquid must be in contact with the short electrode for the full duration of the time delay before control will ope rate. With delay on decreasing level, the liquid must be below long electrode for the fu ll durat1on of the time delay before control will ope rate. In single level service. terminals 3 and 4 must be jumpered together to achieve time delays on both increasing and decreasing levels or just decreasing level.
160M X-X-X-X-XX-XX
II I L_ Time Delay: (decreasing level) 1-20 sec.
11 1--~------- T im c -Dc !o.y:-(increosing level} 1 -20 sec.
'------ Enclosure : 0-none, 1-NEMA 1, 4-NEMA 4, 7-NEMA 7, 12-NEMA '12 Socket Style: A- 11 Pin Octal, B - 11 Pin DIN Mount , M- None, Module Only Supply Vo ltage: 1- 120 VAG, 2- 240 VAG, 3- 24 VAG, 8- 208/240 VAG*
'---------- Mode/Sens itivity: Direct A- 4. 7K, B- 1 OK, C- 26K, D- 50K, E- 1 001<, F- 4 ?OK, G- 1M Inverse K- 4.7K, L-10K, M- 26K, N- 50K, P- 100K, R- 470K, S- 1M
* 187 Vmin to 255 Vmax VAG
Gems Sensors Inc. One Cowles Road Plainville, CT 06062-1198 Tel: 860-793-4579 Fax: 860-793-4580
Features • 0-ring seats available for exceptional leak
free performance, reduced maintenance cost, multiple cycles with tight shutoff, improved seating integrity.
• Wide hex on valve nozzle provides wrenching service clearance fur ea::;y installation.
• Dual control rings offer easy adjustability for precise opening with minimum preopen or simmer and exact blowdown control.
• Pivot between disc and spring corrects misalignment and compensates for spring side thrust.
• Grooved piston model disc reduces sliding area and friction
• Each l<.unkle valve is tested and inspected ior pressure setting and leakage.
Model Descriptions Model 6010: Side outlet. Full nozzle design with bronze/brass trim. Available with 0-ring seats. For exceptional leak-free performance.
Model 6021: Same as model 6010 with Teflon® (PFA) disc rnsert For exceptronal leak-free performance (use on steam only).
Model 6030: Same as model 6010 except Starnless Steel (SS) trim (nozzle and d isc). Available with 0 -ring seats for exceptional leak-free performance.
Model 6182: Top outlet. Full nozzle design with bronze/brass trim. 0-ring seat available for exceptional leak-free performance.
Model 6121: Same as model 6182 with Teflon® (PFA) disc insert. For exceptional non-leak perior(llance (use on steam only).
Model 6130: Same as model 6 182 except SS trim (nozzle and disc) 0 -r ng seat available for exceptional leak-free performance.
Model 6186: Top outlet. Full nozzle design :!i!h bronze/brass trim -so osrg r· o.3 barg] maximum set pressL.re Replaces lvlodel 86 (original equipment only)
Model 6283: Over-sized side outlet. Full nozzle design bronze/brass trim
Model 6221 : Same as model 6283 with Teflon® (PFA) disc rnsert. For exceptional leak-free performance (use on steam only).
Model 6230: Same as model 6283 except SS trim (nozzle and disc).
Model 6933: Same as model6010 except certified for ASME code Section IV. Low pressure steam heating boilers set at 15 psig [ 1.0 barg] only.
Model 6934: Same as model 6021 except certified for ASME code Section IV. Low pressure steam heating boilers set at 15 psig [1.0 barg] only.
tqca FlowControt
ASME Section I and VIII, Steam, "V" and "UV," ASME Section VIII, Air/Gas "UV" National Board Certified. Models 6933, 6934, and 6935 are ASME Section IV, "Steam" "HV" National Board Certified. PED Certified for Non-Hazardous Gas.
Model 6935: Same as mooel 6030 excep: certified for ASME cooe Sect on IIJ Lo·.\ pressure steam heat 'lg barters set a: · 5 psg [ 1.0 barg] only.
Applications • Steam Boilers and Generators.
• Air/Gas Compressors - reciprocating or rotary · portable or stationary, intercoolers and aftercoolers.
• Pressure Vessels -containing steam, air or non-hazardous gas. Including tanks, receivers, sterilizers and autoclaves.
• Pressure Reducing Stations - protection of the discharge or low pressure side of system.
Model 6010
@J@c@C E
Pressure and Temperature Limits Models 6010, 6021, 6182, 6283, 6221 Stearn Service 3 to 250 psig [0.2 to 17.2 barg~ -60° to 406°F [-5 1- to 208°C]
Air/Gas Service 3 to 300 psig [0.2 to 20.7 barg~ -60° to 406°F [-51 o to 208°C]
Models 6030, 6130, 6230 Steam and Air/Gas Service 3 to 300 psig [0.2 to 20.7 barg] -60° to 425°F [-51 o to 21 8°C]
~~ h' 1. Resilient seats determine temperature range
(see page 11 ).
Kunkle is either a trademark or registered trademark of Tyco International Services AG or its affiliates in the United States and/or other countries. All other brand names, product names, or trademarks belong to their respective holders.
Series6000
Parts and Material s
13
12
11
10
9
8
7
6
5
4
3
2
Models 6010, 6030, 6283, 6230,6933,6935
Models 6121, 6221, 6934 Teflon® Seat Configuration
Models 6010, 6030, 6283, 6230,6933,6935
Optional Soft Seat
Models 6182,6121,6130,6186 Top Outlet Configurat ion
23
24
No. Part Name
1 Nozzle
2 Body Set Screw
3 Warn Ring Set Screw
4 Disc
5 Wire and Seal
6 Guide Set Screw
7 Retainer Nut2
8 Stem
9 Body
10 Lever
11 Jam Nut
12 Lift Nut
13 Cap
14 Lever Pin
15 Cap Set Screw
16 Compression Screw
17 Spring
18 Spring Step
19 Stem Retainer
20 Guide
2 1 Warn Ring 7
22 Seat
23 Seat Retainer
24 Warn Ring SpringB
lv'odels 6021 . 6121. 6221 and 6934 Teflon~. op tional 0 -ring seat available for all others except models 6933 and 6935.
2. Sect,on v only.
3. ~.lodels 6030. 6' 30, 6230 and 6935 are SS SA351-CF8.
4 :v1odels 6030. 6130, 6230 and 6935 are SS SA479-304 (0 through H Orif•ce rr SS SA479-31 6 (J Orifice).
Materials
BRS B283-C48500 or 8RZ S8623
ss 18-8
ss 18-8
821 C485004 SS Wire and Lead Seal
ss 18-8
Brass B16
SS, A582 TY416
BRZ 8 584-C84400
STL A109 or JIS SPCC Equivalent/ZN Plated Yellow
Brass 81 6
STL A 108-1018/ZN Plated
Aluminum, Anodized
STL A 108-12L 14
ss 18-8
BRS B 16
ASTM A-313 TY 63 1
BRS B 16
BRS B16
BRS B16 forD and E Orifice BRZ 8 584-C84400 for F through J Orifice
8RS 816
Note 1
8RS 8 165
STL
5. Models 6030. 6130 and 6230 are SS SA479-304.
6. Variation 02 (vibration dampening) only.
7 Sofl seat "D and "E" orifice require spec1al .varn r;ng (notch on O.D. of fins).
Model Orifice Connections Numbert ANSI Standard
Inlet in [mm]
60"'0C# 0 1/2 (12.7]
60"00#2 0 3/4 (19.0]
61'"DC# 0 1/2 (12.7)
60"'ED# E 3/4 [ 19.0)
60'"EE#2 E 1 [25.4]
61""ED# E 3/4 (19.0)
62''ED# E 3/4 [19.0)
60' 'FE# F [25.4]
60"FF#2 F 11/4 [31.8)
61"'FE# F [25.4]
62""FE# F [25.4]
60"GFII G 11/4 [31.8] 60"'GG#2 G 1'/2 [38.0]
61 "GF# G 11/4 [31.8]
62''GF# G 1'/" [31.8]
60"HG# H 11/2 [38.0]
60"1-11-1#2 H 2 [51.0]
6 1"' !-IG# H 11/2 (38.0)
62"'HG# H 11/2 [38.0]
60' 'JH# J 2 [51.0]
60" JJ#2 J 2'/2 [64.0 ]
6 1'"JH# J 2 [51.0] 62"JH# J 2 rs· .oJ
Dimensions are for reference only.
l 1. Rep lace asterisks with desired model number
Replace # with desired seat material
2 lv.ooel 6030 ava1lable onl~ ' /? x .J; (12 7 x 19 rrrr] 3'" x 1 [19 v 25.4 m"l: 1 x 1'/4 [25 4x31 .8 r'1m] 1' :x 1' [31 8 x 38mm]. 11 2x 2 [38x s· mmj ana ?. x 2'/? [51 x 64 mm].
3 Moo IS 6933 6934 and 6935 na•te same d1mcns1ons as model 60 • ~
.: ~· fo• BSP [5~].
5. 7Jie for BSP [1 92.5;
Outlet in [mm]
3f4 [19.0]
3/4 [1 9.0]
[25.4]
[25.41
11/4 (31 .75]
11/4 (31.8]
11/4 (31 .8]
11/2 [38.0]
11/2 [38.0]
11/2 [38.0)
2 [51.0]
2 (51.0]
2 (51.0j
2 '/2 [64.0]
2 1/2 (64.0]
2' 2 (64.0]
3 (76.01
Valve Dimensions Approximate in [mm] Weight
A B c lb [kg]
21/s [54] 15/s (41] 6 1/2 [165] 11/2 [0.7]
21/s [54] 15/s [41] 61/2 [ 165] 13/4 [0.8)
61/2 [ 165] 11/4 [0.6]
23/s [60) 13/4 [44] 71/2 [1 91] 21/2 [1.1 1 21/24 [64] 13/4 [44] 75Ja5 [194] 23/4 [1.2]
71/2 (191) 21/4 [1 .0)
27/s [73) 13/4 (44] 71/2 [191] 23/4 [1.2]
25/s (67] 2 [51 ] 81/2 [216) 31/2 (1.6)
27/s (73] 2 [51] 83/4 (222) 33/a (1.7]
81/2 [222] 3 1/4 [1.5) 27/s (73) 2 (51 ] 81/2 [222] 33/4 [ 1.7)
31/s [79] 23/s [60] 95/s [244] 51/2 [2.5)
33/s [86] 23/s [60] 10 [254] 53/4 (2.6)
95/s [244] 5 [2.3] 33/s [86] 21/" [57] 95/s [244] 53/4 [2.6]
35/s [92] 23/4 [Yo: 105/s [270] 73/4 [3.5]
41/s [ 105] 23/a [70; 111/s [283] 8 [3.6]
105/s [270] 71/4 (3.3] 3-/8 [98] 3 (76] 105/s [270] 8 [3.6 ]
4 1/< [ 108] 33/s [86] 135/s [346] 15 1/2 (7.0 ]
4 '/2 (11 4] 33/a [86: 14 [356] 153/" (7.2]
135/s (346] 15 [6.8 ] 45/s [11 7] 33!2 [86: 135/E (345] • 5'/2 (7.0]
Capacities
Set Pressure Orifice Area, in2 (psi g) D E F G H J
(0.121) (0.216) (0.338) (0.554) (0.863) (1 .41 4)
3 28 50 78 127 198 325 4 32 57 89 146 228 374 6 39 70 109 178 278 456 8 45 80 125 205 319 523
10 50 89 139 228 355 582 15 64 114 178 292 454 744 20 73 131 205 336 524 858 25 83 148 232 381 593 972 30 93 166 259 425 663 1086 35 104 185 289 474 739 1211 40 114 204 319 523 815 1336 45 125 223 349 572 892 1461 50 136 242 379 621 968 1586 55 146 261 409 671 1045 1711 60 157 281 439 720 1121 1837 65 168 300 469 769 1197 1962 70 179 319 499 818 1274 2087 75 189 338 529 867 1350 2212 80 200 357 559 916 1426 2337 85 211 376 589 965 1503 2462 90 221 395 619 1014 1579 2588 95 232 414 648 1063 1656 2713
100 243 434 678 1112 1732 2838 105 254 453 708 11 61 1808 2963 11 0 264 472 738 1210 1885 3088 115 275 491 768 1259 1961 3213 120 286 510 798 1308 2038 3339 125 296 529 828 1357 2114 3464 130 307 548 858 1406 21 90 3589 135 318 567 888 1455 2267 3714 140 329 586 918 1504 2343 3839 145 339 606 948 1553 2420 3964 150 350 625 978 i602 2496 4090 160 371 663 1037 1700 2649 4340 170 393 70' '097 1798 2802 4590 180 414 739 1157 1897 2954 4841 190 436 778 1217 ' 995 3107 5091 200 457 816 1277 2093 3260 5341 210 478 854 1337 2191 34 13 5592 220 500 892 1396 2289 3566 5842 230 521 931 1456 2387 3718 6092 240 543 969 151 6 2485 3871 6343 250 564 1007 1576 2583 4024 6593 260 586 1045 1636 2681 4177 6843 270 607 1084 1696 2779 4329 7094
(Thlr:] 280 628 1122 1756 2877 4482 7344
1. No code stamp or "NB" on nameplate below 290 650 1160 1815 2975 4635 7594 15 psig set. 300 671 1198 1875 3074 4788 7845
Series 6000 ''
Capacities
Set Pressure Orifice Area, cm2 [barg] D E F G H J
[0.781] [1.394] [2.180] [3.574] [5.567] [9.123)
0.2 45 81 126 207 322 528
0.3 55 98 154 252 393 644 0.4 63 113 177 290 452 740
0.6 77 138 215 353 549 900 1.0 104 180 281 461 71 8 1177
1.5 123 220 345 565 880 1443 2.0 146 261 408 669 1042 1708
2.5 171 305 477 782 1218 1996 3.0 196 350 547 896 1396 2288
3.5 221 394 616 101 1 1574 2579 4.0 246 439 686 1125 1752 2871
4.5 271 483 756 1239 1930 3163 5.0 296 528 826 1353 2108 3455
5.5 321 572 895 1468 2286 3746 6.0 346 617 965 1582 2464 4038
6.5 371 662 1035 1696 2642 4330 7.0 396 706 1104 1811 2820 4622
7.5 421 751 11 74 1925 2998 4913 8.0 446 795 1244 2039 3176 5205
8.5 471 840 1313 2153 3354 5497 9.0 496 884 1383 2268 3532 5788
9.5 521 929 1453 2382 3710 6080 10.0 545 974 1523 2496 3888 6372
10.5 570 1018 1592 2611 4066 6664 11 .0 595 1063 1662 2725 4244 6955
11.5 620 1107 1732 2839 4422 7247 12.0 645 1152 1801 2953 4600 7539
12.5 670 11 97 1871 3068 4778 7831 13.0 695 1241 1941 31 82 4956 8122
13.5 720 1286 20 11 3296 5134 8414 14.0 745 1330 2080 3411 5312 8706
14.5 770 1375 2150 3525 5490 8997 15.0 795 1419 2220 3639 5668 9289
16.0 845 1509 2359 3868 6024 9873 17.0 895 1598 2499 4096 638' 10456
18.0 945 1687 2638 4325 6737 11040 I~W:t 19.0 995 1776 2777 4553 7093 11623
i. No code s1amp or "NB" on nameplate below 20.0 1045 1865 2917 4782 7449 12207 1.0 barg set.
1. No code stamp or "NB" on nameplate below 15 psig set.
Capacities
Set Pressure (psi g)
3
4
6
8 10
15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
100 105 110
115 120 125 130 135 140 145 150 160 170 180 190 200 21 0
220 230 240 250 260 270 280 290 300
-------- Orifice Area , in2 --------D
(0.121)
87 100 121 137 i52 179 206 234 261 291 321 351 381 411 442 472 502 532 562 592 622 652 682 712 742 773
803 833 863 893 923 953 983
1043 1' 04
1164 1224 1284 1344
1404 1465 1525 1585 1645 1705 1766 1826 1886
E (0.216)
155 178 215 245 27i 319 368 417 466 520 573 627 681 734 788
842 896 949
1003 1057 1110 1164 1218 1272 1325 1379 1433 1487 1540 1594 1648 1701 1755 1863 ' 970 2077
2185 2292 2400
2507 2615 2722 2829 2937 3044 3152 3259 3367
F G (0.338) (0.554)
243 279 337 384 424 500 576 653 729 813 897 981
1065 1149 1233 1317 1401 1486 1570 1654 1738
1822 1906 1990 2074 2158 2242 2326 24 10
2494 2578 2662 2746 2915 3083 3251 3419
3587 3755 3923 4091 4259 4428 4596 4764 4932 5100 5268
398 457 552 629 695 819 944
1070 1195 1333 1470 1608 1746 1884 2022 2159 2297 2435 2573 2710 2848 2986 3124 3262 3399 3537 3675 3813 3950 4088 4226 4364 45C2 4777 5053 5328 5604 5879 6155
6430 6706 6981 7257 7533 7808 8084 8359 8635
H (0.863)
621 711 860 980
1083 1276 1471 1666 1861 2076 2291 2505 2720 2934 3149 3364 3578 3793 4008 4222 4437 4651 4866 5081 5295 5510 5725
5939 6154 6368 6583 6798 7012 7442 7871
8300 8729 9159 9588
10017 10446 10876 11305 11734 12163 12592 13022 13451
J (1 .414)
1017 1166 1409 1606 1775 2091 2410 2730 3050 3401 3753 4105 4456 4808 5160 5511 5863 6215 6566 6918 7270 7621 7973 8325 8676 9028 9380 9731
10083 10434 10786 11138 1'489 12193 12896 13599 14303 15006 15709
16413 17116
17819 18523 19226 19929 20632 21336 22039
Series6000
Capacities
Set Pressure Orifice Area, cm2 [barg] D E F G H J
[0 .781] [1.394] [2.1 80] [3.574] [5.567] [9.1 23]
0.2 39 69 108 177 276 453
0.3 47 84 131 215 335 549 0.4 54 96 150 246 383 628
0.6 65 115 181 296 461 756 1.0 81 144 226 370 576 944
1.5 98 175 273 448 698 1144 2.0 116 207 324 530 826 1354
2.5 135 242 378 620 966 1582
3.0 155 277 433 711 1107 1814
3.5 175 312 489 801 1248 2045 4.0 195 348 544 892 1389 2276
4.5 215 383 599 982 1530 2508 5.0 234 419 654 1073 1671 2739
5.5 254 454 710 1164 1812 2970 6.0 274 489 765 1254 1954 3201
6.5 294 525 820 1345 2095 3433 7.0 314 560 876 1435 2236 3664
7.5 333 595 931 1526 2377 3895 8.0 353 631 986 1617 2518 41 27
8.5 373 666 1041 1707 2659 4358 9.0 393 701 i097 1798 2800 4589
9.5 413 737 1152 1888 2942 4820
10.0 432 772 1207 1979 3083 5052
10.5 452 807 1262 2070 3224 5283 11.0 472 843 1318 2160 3365 5514
11 .5 492 878 1373 2251 3506 5746 12.0 512 913 1428 2341 3647 5977
12.5 531 949 1483 2432 3788 6208 13.0 551 984 1539 2523 3929 6439
13.5 571 1019 1594 2613 4071 667 1
14.0 591 1055 1649 2704 4212 6902
14.5 611 1090 1705 2795 4353 7133 15 0 630 1125 1760 2885 4494 7365
16.0 670 1196 1870 3066 4776 7827
17.0 710 1267 198" 3248 5059 8290
18.0 749 1337 2091 3429 5341 8752 lligtt~ =:1 19.0 789 1408 2202 3610 5623 9215
i. No code stamp or "NB" on nameplate belov1 20.0 829 1479 2313 3791 5905 9678 1 1 barg set
er1es
Capacities
Set Pressure Orifice Area, in2 (psi g) D E F G H J
(0.121) (0.216) (0.338) (0.554) (0.863) (1.414)
15 173 309 484 793 1236 2025 20 201 358 560 918 1431 2344 25 228 407 637 1044 1626 2664 30 255 456 713 1169 1821 2983 35 283 504 789 1294 2015 3302 40 310 553 866 1419 2210 3622 45 337 602 942 1544 2405 3941 50 365 651 1018 1669 2600 4260 55 392 700 1095 1794 2795 4580 60 419 748 1171 1919 2990 4899 65 447 797 1247 2045 3185 5219 70 474 847 1325 2172 3384 5544 75 503 897 1404 2301 3585 5873 80 531 947 1483 2430 3785 6202 85 559 998 1561 2559 3986 6531 90 587 1048 1640 2688 4187 6860 95 615 "098 1718 2817 4388 7189
100 643 1148 1797 2946 4588 7518 105 671 1199 1876 3074 4789 7847 110 700 1249 1954 3203 4990 8176 115 728 1299 2033 3332 5191 8505 120 756 1349 2112 3461 5392 8834 125 784 1400 2190 3590 5592 9163 130 812 1450 2269 3719 5793 9492 135 840 1500 2348 3848 5994 9821 140 869 1550 2426 3977 6195 10150 145 897 1601 2505 4105 6395 10479 150 925 1651 2583 4234 6596 10808 160 98. 1751 2741 4492 6998 11 466 170 1037 1852 2898 4750 7399 12123 180 1094 1952 3055 5008 7801 12781 190 1150 2053 3212 5265 8202 13439 200 1 206 2153 3370 5523 8604 "4097 210 1263 2254 3527 5781 9005 14755 220 "319 2354 368C: 6039 9407 15413 230 1375 2455 3842 6297 9808 16071 240 1432 2555 3999 6554 10210 16729 250 1488 2656 4156 6812 10612 17387 260 "544 2756 43.3 7070 "1013 18045 270 1600 2857 447 1 7328 11415 18703 280 1657 2957 4628 7585 11816 19360 290 1713 3058 4785 7843 12218 20018 300 1769 3158 4942 81 01 12619 20676
Series6000 .. '
Capacities
I I
Set Pressure - Orifice Area, cm2 [barg] D E F G H J
[0.781 ] [1.394] [2.180] [3 .574] [5 .567] [9 .1 23]
1.5 95 170 266 436 680 1114
2.0 113 202 316 519 808 1324 2.5 131 234 367 601 936 1534
3.0 149 266 417 683 1064 1744 3.5 i67 299 467 765 i i92 1954
4.0 185 331 517 848 1320 21 64 4.5 203 363 567 930 1449 2374
5.0 222 396 619 1014 1580 2589 5.5 240 429 670 1099 1712 2806
6.0 259 462 722 1184 1844 3022 6.5 277 495 774 1269 1976 3238
7.0 296 528 826 1353 2108 3455 7.5 314 561 877 1438 2240 3671
8.0 333 594 929 1523 2372 3887 8.5 351 627 981 1608 2504 4104
9.0 370 660 1032 1692 2636 4320 9.5 388 693 1084 1777 2768 4537
10.0 407 726 1136 1862 2900 4753 10.5 425 759 1187 1947 3032 4969
11.0 444 792 1239 2031 3164 5186 11.5 462 825 1291 2116 3296 5402
12.0 481 858 1343 2201 3428 5618 12.5 499 892 1394 2286 3560 5835
13.0 518 925 1446 2371 3692 6051 13.5 537 958 1498 2455 3824 6267
14.0 555 991 1549 2540 3957 6484 14.5 574 1024 1601 2625 4089 6700
15.0 592 1057 1653 2710 4221 6917 15.5 61' 1090 1704 2794 4353 7133
17.0 629 11 23 1756 2879 4485 7349 17.0 666 1189 1860 3049 4749 7782
18.0 703 1255 1963 3218 5013 821 5 19.0 740 132' 2066 3388 5277 8647
20.0 777 1387 2170 3557 5541 9080
ElWt?Tt'''
Capacities
Set Pressure Orifice, Area in2 [cm2] (psig) 0 E F G H J [barg] 0.121 0.216 0.338 0.554 0.863 1.414
[0.781] [1.394] [2.180] [3 .574] [5.567] [9.1 23]
15 190 338 530 868 1352 221 5 [ 1.0] [86] [153] [240] [394] [6 13] [1005]
Specifications
Seat/Sea l Materials Service Recommendation
Viton® A ( -15 to 406°F) [ -26 to 208°C] Air and Gas
Ethylene Propylene (-70 to 400°F) [-57 to 205°C] Steam Teflon® Steam
enes
Ordering Information
ASME Section I and VIII , Steam, ASME Section VIII, Air/Gas National Board Certified. Models 6930, 6933, 6935 ASME Section IV, National Board Certified
Model Number Position
2 3 4 5 6 7 7 8 9 10 11 12 13 14 15
Example
Model 6010 602 1 6030 6182 6121
Orifice
6 0
6130 6186 6283 6221
D G E H F J
Inlet Size c- ' /2' D - 3f.,' E - 1'
F - '"/"'
[1 2.7; [19.0] [25.4] [31.8]
Seat Material M Metal E EPR V Viton®
Variation (01 to 99) 01 - Plain lever
6230 6933 6934 6935
0 H G M 0
G- 1"/?' [38.• ] H - 2 [50.8] J- 2"12' [63.5)
02 - Plair; lever w'tfl vibration oampener 03 - Pla1n lever ~~ tn gag 60 - BSP Threads
Design Revision Indicates non-interchangeable rev1sior Dash (-) 1' orig1na1 design.
Valve Service A - Steam ASME SectiOn I K - Air'Gas ASiviE Sec,tor VIII L -Steam ASME Sec;icr \'II G - Stearr ASME Sectior L (Models 6933 6934 6935 o~ 1 )
P - Steam Non-code N - A r. Non-code
Spring Material M - ss
Set Pressure 0015 - 15 psig [1.0 barg] only for Models 6933, 6934,6935
I IJJVI I 953 Old U.S. Highway 70 Black Mountain, North Carolina 28711-2549 Customer Service Phone: 1-828-669-3700
A M 0 5 0
www.kunklevalve.com
Tyco Flo:t Control (TFC) provides the in~orma:ion heron 1n gooo fa th but mal<es no representatiOn as to Its comprehens,ver.ess or accuracy. Th s data sheet Is 1n:ended only as a gu·de to TFC prc<lucts and serv.ces tnd.vidua's us·ng th's data sheet must exorc>se the'r independent judgment in eva'uat•ng product selection and de:erm·n·ng prc<luct appropriateness lor the r pan.cu'ar purpose and system requ·rements TFC f.'Al<ES IXO REPRESENTATIONS OR WARRANTIES. EITHER EXPRESS OR If/PLIED. INCLUD:NG I'IITHOUT LIMITATION ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THi: INFORf.<ATIOtl SET FORTH HEREIN OR THE FRODUCT(S) TO WriiCH THE IIXFORMATION REFERS ACCORDINGLY, TFC WILL NOT BE RESPONS'BLE FOR DAMAGES (OF ANY KIND OR NATURE, INCLUDING INCIDENTAL. DIRECT, INDIRECT, OR CONSEOUEHTI.AL DA'!.AGES) RESULTING FROM THE USE CF OR REUA!>:CE UPON THIS II'FOR\1ATION Pa~ents and Paten!s Pend ng •n tre U.S and fOI'e.gn ccx.nJ•es Tyee rc~C!rves lhe ngta to changa product des·gns and spec '1cat:ons \'. ttt",out notice A'l reg·s!ercd trademarks are the pmpeny of the r respective o:.ners Pr n:ed 1n the USA.
., .
~ITT ® (@ <§> APPROVED
Series 93/193 and Series 94/194 Low Water Cut-Off/Pump Controllers For Steam Boilers and Level Control Applications
Typical Applications:
- Primary or secondary pump contro ller/ low water fuel cut-off for steam boilers
- Motorized valve controller
- Proportional valve controller
- Low water cut-off
- High water cut-off
- Alarm actuation Series 93 or Series 94
A WARNING
McDonnell & Miller Insta llation & Maintenance
Instructions MM-404(H)
Series 193 or Series 194
~, • Before using this product read and understand instructions.
\~ • Save these instructions for future reference.
1---------t • All work must be performed by qualified personnel trained in the proper application, instal--"' e lation , and maintenance of plumbing, steam, and electrical equipment and/or systems in ~ accordance with all applicable codes and ordinances.
• To prevent seriou s burns, the boiler must be cooled to ao·F (27.C) and the pressure must be 0 psi (0 bar) before servicing.
• To prevent electrical shock, turn off the electrical power before making electrical connections.
• This low water cut-off must be insta lled in series with all other limit and operating controls installed on the boiler. After installation, check for proper operation of all of the limit and operating controls, before leaving the s ite.
• We recommend that secondary (redundant) Low Water Cut-Off contro ls 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 with the burner control circuit to provide safety redundancy protection should the boiler experience a low-water condition. Moreover, at each annual outage, the low water cutoffs should be dismantled, inspected, cleaned, and checked tor proper calibration and performance.
t--~=~==-~ • To prevent serious personal injury from steam blow down, connect a drain pipe to the control opening to avoid exposure to steam discharge.
• To prevent a fire, do not exceed the switch contact rating.
Fa ilure to follow this warning cou ld cause property damage, personal injury or death.
Engineered for life
OPERATION
Electrical Ratings Models with 5 or 5-M Switch
Pump and Burner Switch Contact Ratings Voltage Pilot Duty Only
120 VAG 345 VA
240 VAG
Switch Settings Values are ± 1Ja" (3mm)
2
Models with 5 or 5-M Switches
Approximate Distance Above
Setting
Pump Off
Pump On
Burner On
Burner Off
23ha" (56mm)
PUMP ~OFF
BURNER t OFF
11ha" (27mm)
Cast Line ln. (mm)
23/16 (56)
11/a (29)
13/a (35)
0
PUMPOFF~- -PUMPON t- - -
13/s" (35mm)
BURNERON ~BURNER OFF t-
Differential ln. (mm)
11/16 (27)
13/a (35)
BURNER "CUT-OFF LEVEL" AT CAST LINE
Maximum Pressure: Series 93/193: 150 psi (1 0.5 kg/cm2) Series 94/1 94: 250 psi (17.6kg/cm2)
Models with 78 or 78-M Switch
Switch Ratings
Burner Valve
120 VAG 345 VA 0- 135 ohms@ 24 VAG
240 VAG
Models with 7B or 7B-M Switches
Setting
Valve Full Closed
Valve Full Open
Burner On
Burner Off
Approximate Distance Above
Cast Line ln. (mm)
23116 (56)
11/a (29)
13/a (35)
0
23ha" (56mm)
Differential ln. (mm)
11/16 (27)
13/a (35)
MOTORIZED I VALVE ____t - ~~~~L
CLOSED
BURNER - -t OFF
11/16" MOTORIZED (2?mm)
VALVE ~ CLOSED -
MOTORIZED--t -VALVE OPEN
13/s" (35mm)
BURNER ON ~-BURNER OFF t-
BURNER "CUT·OFF LEVEL:' AT CAST LINE
BURNER "CUT-OFF LEVEL:' AT CAST LINE
NOTE: Due to the slower operation of some motorized valves, complete valve opening or closing may occur at slightly different levels than indicated above.
INSTALLATION TOOLS NEEDED: Two (2) pipe wrenches, one (1) flathead screw driver, and pipe thread dope.
IMPORTANT: Follow the boiler manufacturer's instructions along with all applicable codes and ordinances for piping, blow-down valve, water gauge glass, tri -cock and electrical requirements.
STEP 1 - Determine the Position of the Low Water Cut-Off/Pump Controller
If the centro! vJ!!! be the primary !o\AJ water fuel cut-off, size the steam (top) and water (bottom) equalizing pipe lengths so that the horizontal cast line on the body is 1 1/2" (38mm) below the boiler's normal water level, but not lower than the lowest safe permissible water level, as determined by the boiler manufacturer.
OR
If the control will be the secondary low water fuel cut-off, size the steam (top) and water (bottom) equalizing pipe lengths so that the horizontal cast line on the body is at or above the lowest safe permissible water level, as determined by the boiler manufacturer.
_l / -f
LOWEST PERMISSIBLE WATER LEVEL
BURNER OFF
"-, ~
LOWEST PERMISSIBLE WATER LEVEL
WATER/ EQUALIZING
PIPE
STEAM EQUALIZING PIPE
/
AS A PRIMARY LOW WATER CUl'OFF/PUMP
~---- CONTROLLER
- - NORMAL BOILER WATER LINE
BURNER "CUl'OFFLEVEL AT CAST LINE
~- VERTICAL EQUALIZING PIPE
/ STEAM EQUALIZING PIPE
~<--" . .Fh,
AS A SECONDARY ----- LOW WATER CUT·OFFIPUMP
CONTROLLER
BURNER 'CUl'OFFLEVEL AT CAST LINE
~-VERTICAL EQUALIZING PIPE
3
STEP 2 - Installing the Low Water Cut-Off/Pump Controller For Series 93/193 or 94/194 (except 94-A, 193-0 and 193-G Models)
a. Mount and pipe the control (A) on vertical equalizing pipes (B) at the required elevation as determined in Step 1.
Install a full-ported blow-down valve (C) directly below the lower cross.
NOTE: 1" (25mm} NPT tappings are provided on Series 93/193 controls.
1 1/4" (32mm) NPT tappings are provided for Series 94/194 controls and 193-B Model.
For 94-A and 193-G Models
a. Mount and pipe the control (A) with a vertical upper (D) and horizontal lower (E) equalizing piping at t11e required elevation as determined in Step 1.
Install a full-ported blow-clown valve (C) on the lower body connection.
NOTE: 1 1/4" (32mm) NPT tappings are provided for 94-A Model control.
1" (25mm) NPT tappings are provided for 193-G Model control.
For 193-D Models
a. Mount and pipe the control (A) with a horizontal upper and lower (G) equalizing piping at the required elevation as determined in Step 1.
Install a full-ported blow-down valve (C) on the lower body connection.
NOTE: 1" (25mm) N PT tappings are provided for 193-D Model control.
w
I I I I
STEP 3 - Removing Float Blocking Plugs and Dowels
.A CAUTION The plug and rod must be reinstalled before control is shipped installed on the boiler, and removed after boiler is placed and installed. Failure to follow this caution may damage the float and operating mechanism.
a. Using a pipe wrench, remove the float blocking plugs (I) and dowels (H) from the control as shown below.
b. Using a pipe vvrench, screvv the pipe plugs provided vvith control into the open tappings.
Series 193 / 194 Series 93 I 94
5
STEP 4 - Installing a Water Gauge Glass and Tri-Cocks
NOTE: A separate water column for installation of with a Series 93 or Series 94 control. Follow the gauge glass and tri-cocks may be required for boilers manufacturer's instructions to install the water column.
a. Determine pipe size of tri-cock and sight glass tappings for the control being installed including center distance of sight glass tappings.
NOTE: These items are not provided with controi and must i.Je purchased separately
Tri-Cock Tapping
Unit B c D
193 Y2 (15) Y2 (15) Y2 (15)
193-A Y2 (15) Y2 (15) Y2 (15)
193-B % (20) %(20) %(20)
193-0 Y2 (15) Y2 (15)
193-G Y2 (15) Y2 (15)
194 Y2 (15) Y2 (15) Y2 (15)
194-A Y2 (15) Y2 (15) Y2 (1 5)
194-B o/4 (20) o/.t (20) o/4 (20)
Gauge Glass Tapping Pipe Size
E F H
Y2 (15)
Y2 (15) Y2 (15)
%(20)
Y2 (15)
Y2 (15)
Y2 (15) Y2 (1 5)
Y2 (15)
o/4 (20)
b. Install tri-cocks and gauge glass following manufacturer's instructions.
GAUGE GLASS (TYPICAL)
J
Y2 (15)
o/.t (20)
Y2 (1 5)
o/.; (20)
Gauge Glass Tap11ing Center Distance K
11 Y2 (292)
11 Y2 (292)
11 Y2 (292)
11% (295)
TRI-COCK (TYPICAL)
L
12% (324)
12% (324)
12Ve (327)
12Vs (327)
I I
I I
STEP 5 - Electrical Wiring
A WARNING
~ • To prevent electrical shock, turn off the electrical power before making electrical connections .
• This low water cut-off must be installed in series with all other limit 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 .
• Failure to follow this warning could cause electrical shock, an explosion and/or a fire, which could result in property damage, personal injury or death.
Wiring Diagrams
NOTE: The following diagrams are provided for reference only. If available, manufacturer's wiring diagrams
should always be followed to connect the device being operated.
Switch Operation For Series 93/193 or 94/194 with 5 or 5-M Switch
Red switch terminals 1 and 2 are for burner circuit contacts, terminals 3 and 4 are for the low level alarm circuit contacts. Blue switch terminals 3 and 4 are for feeder/pump control contacts, terminals 1 and 2 are for high level alarm circuit contacts.
BOILER FEED PUMP OFFBURNER ON-ALARM OFF
BOILER FEED PUMP ONBURNER ON-ALARM OFF
Pump Control, Low Water Cut-Off and Alarm
NO.5 SWITCH
TO PUMP
ALARI.I
TRANS.
LINE
TO BURNER
(;~~ ~~
BOILER FEED PUMP ONBURNER OFF-ALARM ON
7
Low Water Cut-Off Only
Pump Control Only
Low Water Alarm Only
8
LOW WATER CUT-OFF CIRCUIT
PUMP CONTROL CIRCUIT
NO. 5 SWITCH
PUMP STARTER
ALARM CIRCU IT
LINE
ALAR~!
TRANS.
NEUTRAL
'----LINE
)
For Series 93/193 or 94/1 94 with 78 or 78-M
Red terminals 1 and 2 are the burner circuit contacts, terminals 3 and 4 are the low level alarm circuit contacts. Blue terminal 3 is the common contact, terminals 1 and 4 are the output contacts.
BURNER ON- ALARM OFF VALVE CLOSED
BURNER ON- ALARM OFF VALVE OPEN
NOTE: The 78 switch is a 135 ohm potentiometer slide wire control for use with an electric valve operator with the same rating.
Proportional Control, Low Water Cut-Off and Alarm
COMMON
BURNER OFF- ALARI.I ON VALVE OPEN
NO. 7B SWITCH
'--f--{) CLOSING CIRCUIT
LINE
TO BURNER
9
Wiring Connections
10
a. Remove two screws (A) and lift off switch cover.
b. Connect BX armored cable or Thinwall electrical metal tubing to the integral fitting 11ub. Connect wires to terminals following appropriate wiring diagram from pages 8 and 9 for your application.
NOTE: Follow local codes and standards when selecting the types of electrical fittings and conduit to connect to control.
c. Replace switch cover and fasten with two screws (A).
J ® l 1
~~~- SWITCH e- j . ifCOVER I
)
STEP 6 -Testing
- Dimensions shown are typical. - The following testing procedure is only meant to serve
as a verification of proper operating sequence.
a. Turn on power to boiler and pump circuits. With the boiler empty, the pump should turn on (5 or 5-M switch models) or the valve open (78 or 78-M switch models). The burner should remain off and boiler should begin to fill with water.
CAUTION A Immed iately turn off all power if the burner turns on with no water in the gauge glass. Investigate further before continuing procedure.
b. For Automatic Reset Models When water level in the gauge glass is approximately 1 3/8" (35mm) above the horizontal cast line, the burner should turn on.
For Manual Reset Models When water level in the gauge glass is approximately 1 3/8" (35mm) above the horizontal cast line, press the manual reset button and the burner should turn on.
c. For 5 or 5-M Switch Models When water level in the gauge glass is approximately 2 3/16" (56mm) above the horizontal cast line, the pump should turn off.
For 78 or 7B-M Switch Models When water level in the gauge glass is approximately 2 3/16" (56mm) above the horizontal cast line, the valve should be closed.
A, CAUTION If pump does not turn off or valve close, turn off water supply to boiler. Investigate further before continuing procedure.
d. With the water in the boiler at its normal level and burner on, SLOWLY open the blow-clown valve until it is fully open. As the water level in the gauge glass begins to drop, verify t11at the following occurs. For 5 or 5-M Switch Models When water level drops to approximately 1 1/8" (29mm) above tile horizontal cast line, the pump should turn on. When water level drops to the hori zontal cast line, the burner should turn off.
For 7B or 7B-M Switch Models As the water level drops, the valve should begin to open. When the water level drops to approximately 1 1/8" {29mm) above the horizontal cast line, the valve should be full open. When the water level drops to the horizontal cast line, the burner should turn off.
e. Close the blow-down valve after burner turns off and restore water level to normal operating level.
f. Repeat testing procedure several times to ensure proper operation of control.
g. After testing and verification of control operation, t11e boiler can be returned to service.
TROUBLESHOOTING Erratic operation of the control is the most common symptom that occurs. Erratic operation can be defined as pump and/or burner switches not switching at proper levels. Refer to the following list of items to check if the control is not operating properly.
1. Float Ball is Crushed Crushed floats are typically caused by improper blowdown. Drain piping from blow-down valve to drain should be checked for proper pitch and the blow-down procedure followed when blowing down the control. Purchase and install a new float ball after investigating and correcting the problem.
2. Float Ball is Filled with Water The seam weld on the float can sometimes deteriorate. This can be caused by the type of chemical treatment used in the boiler. While this is a rare occurrence, the chemical treatment supplier should be consulted to determine if a reaction could occur. Purchase and install a new float ball after investigating and correcting the problem.
3. Float Arm Springs are Bent The pivot springs located on either side of the float rod should be flat and straight. If they become bent, the usual cause is mishandling of the unit during installation or improper blow-down. The control should never be picked up by the float ball or allowed to hang from the bowl by the float. Drain piping from blow-down valve to drain should be checked for proper pitch and the blow-down procedure followed when blowing down control. Purchase and install new control or head mechanism after investigating and correcting the problem.
4. Switch Contact Springs Broken Tl1e contact springs can break if the electrical rating is exceeded. Purchase and install new switcl1 assembly or head mechanism after investigating and correcting the problem.
5. Switch Contact Springs Misaligned Misalignment of the contact arms is usually associated with damage to the control during shipment or installation. Purchase and install new switch assembly or head mechanism after investigating and correcting the problem.
6. Internal (Wetted) Parts Dirty The internal parts can operate improperly if dirt, scale or rust is allowed to build. This condition can be a result of not blowing down the control as recommended and/or improper boiler water chemical treatment. Purchase and install new control or head mechanism after investigating and correcting the problem.
11
MAINTENANCE
SCHEDULE: Blow down control as follows when boiler is in operation.
• Daily if operating pressure is above 15 psi. • Weekly if operating pressure is below 15 psi.
NOTE More frequent blow~down may be necessary due to dirty boiler water and/or local codes.
• Remove head assembly and inspect water s ide components annually. Replace head assembly if any of the internal components are worn, corroded or damaged or if control no longer operates properly.
• Inspect the float chamber and equalizing piping annually. Remove all sediment and debris.
NOTE The contro l may need to be inspected and cleaned more frequently on systems where there is the potentia l of excessive scale or sludge build~up. This includes systems:
• With high raw water make~up
• With no condensate return • With untreated boiler water • Where significant changes have been
made to the boiler~water chem ica l treatment process
• With oil in the boiler water
Replace head mechanism every 5 years. More frequent replacement may be required when severe conditions exist. Replacement parts are available from your local authorized McDonnell & Miller Distributor. Tile use of parts or components other than those manufactured by McDonnell & Mi ller will void all warranties and may affect the units compliance with listings or regulating agencies.
ITT 8200 N. Austin Ave. Morton Grove, l l 60053 tel: 847-966-3700 fax: 847-966-9052 www.mcdonnellmiller.com
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BLOW DOWN PROCEDURE:
A CAUTION To prevent serious personal injury from steam pipe blow down, connect a drain pipe to the control opening to avoid exposure to steam discharge.
Failure to follow this caution could cause personal injury.
When blowing down a control at pressure, the blow down valves should be opened slowly. The piping needs to be warmed up and stagnant water in the drain piping needs to be pushed out. Suddenly opening a blow down valve causes steam to condense, which creates water hammer. Damage to components can occur when water hammer occurs due to improper blow down piping. For these reasons, McDonnell & Miller recommends a dual valve blow-down system for each control. Blow down the control when the water in the boiler is at its normal level and the burner is on. NOTE: Refer to page 2 for switch operating points. • Open upper valve (#1) • Slowly open the lower valve (#2) • Water in the sight glass should lower. • As the water in the sight glass lowers, the
pump should turn on. • As the water continues to lower in the sight
glass, the burner should turn off. • Slowly close the lower valve (#2). • Close the upper valve (#1 ) • The water level in the sight glass should rise, first turning on the burner and then turning off the pump. NOTE: On manual reset models, the reset button will need to be pressed after the water level has been restored before the burner wi ll operate.
NOTE If thi s sequence of operation does not occur as described, immediately close all the valves, turn off the boiler and correct the problem. Inspection/cleaning of the float mechan ism may be required to determine why the control was not working properly. Retest the control after the problem has been identified and corrected.
© 2008 ITT Corporation Printed in U.S.A 12-08 246043