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Related Manuals for AESYS York-Shipley Global 400 Series
Summary of Contents for AESYS York-Shipley Global 400 Series
- Page 1 AESYS Technologies, LLC 693 North Hills Road York, PA 17402 Tel: 717-755-1081 Fax: 717-755-0020 website: www.aesystech.com 400 Series 500 Series Boilers FV-20 Burner Section Installation Instructions Service and Parts Manual ID-78-578...
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Page 2: Table Of Contents
TABLE OF CONTENTS Page Preliminary Information ............Protection of Equipment Before and During Installation. -
Page 3: Preliminary Information
PRELIMINARY INFORMATION The most important single point in the successful operation of a York-Shipley Global burner is proper installation. Please read these instructions carefully before starting the installation. For special components and arrangements, refer to factory. Failure to follow these instructions and precautions could result in voiding the York-Shipley warranty on this product. -
Page 4: Removal & Installation Of Burner Assembly
REMOVAL & INSTALLATION OF BURNER ASSEMBLY The entire burner can be removed as a unit as follow: 1. Turn off all power and fuel supply lines. 2. Remove and tag any wiring which would restrict the removal of the burner. 3. -
Page 5: Fuel Connections & Sizes
FUEL CONNECTIONS AND SIZES REQUIRED FOR STANDARD BURNERS Oil: Pipe size of fuel pump (#2, oil) Supply – 1/4" pipe Return – 1/4" pipe GAS TRAIN CONTROLS All standard U/L gas trains for main flame include an upstream shut-off cock and electric gas valve, a downstream shut-off cock with test connection, and a gas volume control (butterfly) valve. -
Page 8: Gas Fuel Systems
GAS FUEL SYSTEMS SIZING GAS HEADER FROM METER TO BURNER Sizing the gas line from the utility service at the meter to the gas pressure regulator at the burner can be important in cases where the gas pressure available limits the pressure drop to a low value. The following sizing method will prove helpful in sizing this line for single or multiple burner installations. - Page 9 PIPE SIZE REQUIRED FOR GAS FLOW AND PRESSURE DROP/100 EQ. FT. Fig. 1 EQUIVALENT LENGTH FOR FITTINGS IN FEET Pipe Size (IPS) 1-1/4 1-1/2 2-1/2 Std, Tee thru Side 12.0 14.0 17.0 22.0 33.0 43.0 55.0 65.0 Std. Ell 12.0 16.0 20.0 26.0...
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Page 10: Sizing Gas Header From Meter To Boiler
SIZING GAS HEADER FROM METER TO BOILER Figure 3 Maximum Firing Required Pressure at Unit (See Notes) Series & HP Rate -CFH STD. 40 & 50 HP – 542-40 1675 FV20A Burner 542-50 2095 542-60 2520 60 to 80 HP – 548-60 2520 FV20B Burner... -
Page 11: Gas Pressure Regulator Requirements
GAS PRESSURE REGULATOR REQUIREMENTS U/L Standard & FM Approval IRI Approval Boiler Press. Req'd Press. Req'd Size & Firing Regulator Regulator Rate Inlet Outlet Size & Model Inlet Outlet Size & Model 1-1/2" RV-81 1-1/2" RV-81 542-40 1675 2-1/2" RV-91 2-1/2"... -
Page 12: Gas Line Feeder Sizes
GAS LINE FEEDER SIZES The size of the piping from the gas header piping to each unit gas regulator in a multiple unit installation should be sized using the maximum gas flow for the individual unit and the pressure drop per 100 feet found in Step #6. In no case should the pipe size be smaller than the unit gas pressure regulator pipe size –... -
Page 13: Suggested Fuel Oil Piping Arrangement
SUGGESTED FUEL OIL PIPING ARRANGEMENT Note #1 – For suction and return line size and allowable length of run see "Light Oil" line sizing information. LIGHT OIL 40 SSU max. @ 100 F - .85 SPG Maximum allowable run and suction return line sizing for #2 oil Burning Units. Line Sizing: For all light oil burners, use individual lines of 1/2"... - Page 14 Maximum Allowable Pipe Run Total Lift (Feet)* Allowable Run (Feet)** * To determine "total lift" for all units, add 4 feet to the vertical distance from the boiler room floor to the bottom of the fuel oil tank. ** If the actual run exceeds the maximum allowable run, an auxiliary pump set must be used.
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Page 15: Fuel Oil Tank
FUEL OIL TANK PIPING #2 OIL FUEL OIL TANK The fuel oil tank should be located as per local and state regulations. Proper size depends on the number of gallons consumed per hour, and the availability of delivery. When possible, the tank should be buried. If this is not possible, the tank should be well protected by masonry construction. -
Page 16: Boiler Room Ventilation
BOILER ROOM VENTILATION Each boiler requires sufficient fresh air to assist the combustion process. Insufficient air will result in smoky fires and large deposits of soot and carbon inside the boiler which will lower the boiler operating efficiency. There are times when incoming air is not desirable. These will be periods of normal shutdown of the equipment. -
Page 17: Oil Nozzle
The oil burning nozzle prepares the oil for burning by properly atomizing the fuel. Therefore, this assembly should be properly adjusted and cleaned. When assembly is removed, careful note should be made of the dimensions and returned as per drawing provided. A detail of the nozzle is provided above. NEW NOZZLES If a new nozzle does not spray properly, polish the orifice with a round sharpened toothpick. -
Page 18: Lubrication Procedure And Requirements For Motors
LUBRICATION PROCEDURES AND REQUIREMENTS FOR STEAM-PAK MOTORS A. Ball Bearing (identified by plugged grease ports) 1. To add grease periodically: a. Check grease level in bearings each month adding grease only if necessary. Too much grease may be just as damaging as too little. Housing should be at least 1/3 full, but never more than 2/3 full. - Page 19 c. Always wipe up surplus oil. Exterior oil is sign of a leak. If found, determine cause and correct. 2. To clean and re-oil sleeve bearings: a. Bearings should be cleaned and re-oiled every six months. However, if oil is dirty and emulsified before this time, clean more often.
- Page 20 4. Marathon Motors: a. Frame 56 Motor Bearings: Sealed lubricated bearings require no attention. b. All Other Frame Sizes: Alvania #2, Shell Oil Company or equivalent. Relubricate approximately every two and one-half years. 5. Reuland Motors: a. Reuland Motors feature lifetime lubricated, sealed ball bearings, grease packed and sealed by the bearing manufacturer.
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Page 21: Starting Instructions
pressure gauge should be used when adjusting the pump pressure. Set pump pressure at 100 PSI. When the burner is fired for the first time, loosen the air damper locking screw and set air damper to allow about one-half of the total opening of the shutter. A finer adjustment may be made after the flame has been maintained in a hot combustion chamber. - Page 22 b. Screw out nozzle strainer and insert. Wash all nozzle parts in very hot water or in carbon tetrachloride, making certain there are no dirt particles in the slots or nozzle orifice. UNDER NO CIRCUMSTANCES USE A PIN OR A NEEDLE TO CLEAN SLOTS AND ORIFICE. Use the edge of a piece of hard paper to clean slots.
- Page 23 If Fire Puffs on Start 1. Follow step A-3. 2. Check for air leaks in suction line on suction side of fuel unit (See C-6). 3. On a two-pipe system, check for leaking check valve in suction line by putting pressure on suction line between fuel unit and check valve with a pressure gauge so placed as to show if pressure is holding or not.
- Page 24 C. If main gas valve will not open after pilot is established, check to see that burner air switch contacts are made. STARTING THE DUAL FUEL BURNER MODEL FV-20-N2 Refer to the Flame Control Bulletin in your instruction package or manual. GENERAL SERVICE A.
- Page 25 FULLY MODULATED LIGHT OIL (#2) BURNERS USING PRESSURE ATOMINZATION (OPTION) As an optional arrangement, pressure atomized light oil burners are available for full range modulation. This is accomplished by using a by-passing nozzle which produces a variable firing rate by by-passing fuel from the nozzle swirl chamber, The nozzles are rated and stamped with the capacity when operating at 100 PSI with the by-pass closed.
- Page 26 TYPICAL SETTINGS FOR FV-20A & B BURNERS Boiler Nozzle Oil Gas Man. Horsepower Fuel Fuel Rate CO % Pressure Pressure 2095 CFH — 2.5" W.C. 40 and 50 15.0 GPH 11.0 115 PSI — 3350 CFH — 5.5" W.C. 60 thru 80 24.0 GPH 11.5 105 PSI...
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Page 28: A & B Light Oil-Gas Combination
PARTS LIST FOR FV-20A & B LIGHT OIL FULL MODULATION BURNER Ref. Part Name Part No. Part Name Part No. Req' Req' Blower Housing, FV-20A 127513 Metering Arm 022665 Blower Housing, FV-20B 136082 Burner Tube Extension 127537 Blast Pipe 127514 Air Whirl Sub-Assembly 127522 Motor, 1 HP, 3450 RPM, Fr. -
Page 30: A Gas Fired Ignition (141809)
PARTS LIST FOR FV-20A & B LIGHT OIL-GAS COMBINATION BURNER Ref. Ref. Req'd Part Name Part No. Req'd Part Name Part No. Blower Housing, FV-20A 127513 Modutrol Motor Mtg. Bracket 138953 Blower Housing, FV-20B 136082 Modutrol Motor M436 106235 Blast Pipe 127514 Metering Arm 045932... -
Page 31: B Gas Fired Gas Ignition (141794)
PARTS REFERENCE DRAWING FOR FV-20 A & B LIGHT OIL SPARK IGNITION BURNERS FV – NOZZLE CHART Burner Unit Nozzle Size Part No. (2) 4.0 GPH x 60 061148 40 HP (1) 3.5 GPH x 60 061147 FV-20A (2) 4.5 GPH x 60 061149 50HP (1) 5.0 GPH x 60... -
Page 32: Nozzle Pipe Assembly (131550)
PARTS LIST FOR FV-20 A & B LIGHT OIL SPARK IGNITION BURNERS Ref. Ref. Req'd Part Name Part No. Req'd Part Name Part No. Blower Housing, FV-20A 127513 Metering Arm 045932 Blower Housing, FV-20B 136082 End Switch Q607A 051768 Blast Pipe 127514 Motor, 1 HP, 3450 RPM, Fr. -
Page 33: Nozzle Pipe Assembly (127515)
PARTS REFERENCE DRAWING FOR FV-20A GAS IGNITION BURNER (141809) -
Page 34: Nozzle Pipe Assembly (131210)
PARTS LIST FOR FV-20A GAS IGNITION BURNER (141809) Ref. Part Ref. Part Req'd Part Name Req'd Part Name Blower Housing, FV-20A 127513 Orifice Plate – When Used on Steam-Pak 127519 Blast Pipe 127514 Orifice Plate –When Used on Conversion Burner 141468 Motor, 1 HP, 3450 RPM, Fr. -
Page 35: Nozzle Pipe Assembly (131553)
PARTS REFERENCE DRAWING FOR FV-20B GAS-FIRED IGNITION BURNER (141791) -
Page 36: Ignitor Assembly (138643)
PARTS LIST FOR FV-20B GAS-FIRED IGNITION BURNER (141791) Ref. Part Ref. Part Req'd Part Name Req'd Part Name Blower Housing, FV-20B 136082 Orifice Plate – When Used on Steam-Pak 145888 Blast Pipe 127514 Orifice Plate –Used on Conversion Burner 141468 Motor, 2 HP, 3450 RPM, Fr. -
Page 37: Ignitor Assembly (131554)
PARTS LIST FOR NOZZLE & ELECTRODE ASSEMBLY FOR FV-20A & B OIL FIRED & SPARK IGNITION FULL MODULATION (131550) Ref. No. No. Req'd Part Name Part No. Ref. No. No. Req'd Part Name Part No. Nozzle Pipe 131544 L.H. Buss Bar 131217 Electrode Holder 127518... - Page 40 PARTS LIST FOR NOZZLE & ELECTRODE ASSEMBLY FOR FV20-A & B OIL FIRED SPARK IGNITION W/PHOTOCELL (131553) Ref. No. No. Req'd Part Part Name Part No. Ref. No. No. Req'd Part Name Nozzle Pipe 127517 Bushing, Hex, 1/4" x 1/8" IPS 050280 Electrode Holder 127518...
- Page 41 PARTS LIST FOR IGNITOR ASSEMBLY FOR FV-20 A W/FLAME ROD GAS IGNITION (138643) Ref. No. No Req'd Part Name Part No. Nozzle Pipe 134099 Ignitor Funnel Sub-Assembly 130498 Electrode Holder 127518 Electrode Assembly 089484 Flame Rod 138642 1/4" 20NC-2 x 1/2" Lg. Set Screw Hex Socket Cup Point 052213 #10-24 3/4"...
- Page 42 PARTS LIST FOR IGNITOR ASSEMBLY FOR FV-20B W/SCANNER GAS IGNITION (131554) Ref. No. No Req'd Part Name Part No. Ref. No. No Req'd Part Name Part No. Nozzle Pipe 134099 Buss Bar 131216 Ignitor Funnel Sub-Assembly 130498 Nozzle Pipe Holder Assembly 140339 Electrode Holder 127518...
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