Page 1 400 & 500 Series Boilers Burner Section Over 400 HP Service Manual AESYS Technologies, LLC 693 North Hills Road York, PA 17402-2211 USA Tel: 717-755-1081 Fax: 717-755-0020 Website: www.aesystech.com ID-65-452...
Page 2: Table Of Contents
TABLE OF CONTENTS PAGE BURNER ASSEMBLY SERIES 582 400 HP #2 Oil (158674) ......3 SERIES 582 400 HP #5 Oil (158676) .
Page 3 PAGE DAMPER ARRANGEMENT SERIES 582 400 HP (187586) ....... . . SERIES 588 500 HP (187586) .
Page 4 PAGE MAIN GAS PIPING ARRANGEMENT Main Gas Piping Arrangement (168783) ......Main Gas Piping Arrangement (168782) ......Main Gas Piping Arrangement (168781) .
Page 5 PAGE HOT WATER HEATER ARRANGEMENT (Used on SPL & SPW Boilers Only) Series 582 400 HP (111485) ....... . . Series 588 500 HP (111485) .
Page 6 BURNERS – CONTROLS All burners on the 500 Series Boilers are completed as individual assemblies, comprising the refractory cone and metal retainer, linkage, Modutrol motor, motors, fans, fuel valves and all necessary components, including the control panel and controls, and is bolted into the boiler with four bolts and removed in the same manner.
Page 7 TO INSPECT REMAINING BURNER PARTS 1. Remove nozzle assembly and ignitor assembly as outlined above. 2. Remove and tag any wiring connected to components mounted on front of burner. 3. Disconnect all fuel lines running to metering arrangement on front of burner. 4.
Page 8 BURNER ASSEMBLY (158674) SERIES 582 400 HP #2 OIL YS7000...
Page 9 PARTS LIST FOR BURNER ASSEMBLY (158674) SERIES 582 400 HP #2 OIL YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187567 Burner Mounting Plate 157218 Air Swirl Assembly 130480 Burner Tube Assembly 119751 Air Cone Nose 130479 Air Adjusting Band 119746 Ignitor Assembly...
Page 10 BURNER ASSEMBLY (158676) SERIES 582 400 HP #5 OIL YS7000...
Page 11 PARTS LIST FOR BURNER ASSEMBLY (158676) SERIES 582 400 HP #5 OIL YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187567 Burner Mounting Plate 157218 Air Swirl Assembly 130480 Burner Tube Assembly 119751 Air Cone Nose 130479 Air Adjusting Band 119746 Ignitor Assembly...
Page 12 BURNER ASSEMBLY (159541) SERIES 582 400 HP #6 OIL YS7000...
Page 13 PARTS LIST FOR BURNER ASSEMBLY (159541) SERIES 582 400 HP #6 OIL YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187567 Burner Mounting Plate 157218 Air Swirl Assembly 130480 Burner Tube Assembly 119751 Air Cone Nose 130479 Air Adjusting Band 119746 Ignitor Assembly...
Page 14 BURNER ASSEMBLY (158653) SERIES 582 400 HP YS7000...
Page 15: Damper Arrangement
PARTS LIST FOR BURNER ASSEMBLY (158653) SERIES 582 400 HP YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187567 Burner Mounting Plate 157218 Air Swirl Assembly 130480 Burner Tube Assembly 119751 Air Cone Nose 130479 Air Adjusting Band 119746 Ignitor Assembly 157281...
Page 16 BURNER ASSEMBLY (157280) SERIES 582 400 HP COMBINATION N2 YS7000...
Page 17 PARTS LIST FOR BURNER ASSEMBLY (157280) SERIES 582 400 HP COMBINATION N2 YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187567 Burner Mounting Plate 157218 Air Swirl Assembly 130480 Burner Tube Assembly 119751 Air Cone Nose 130479 Air Adjusting Band 119746 Ignitor Assembly...
Page 18 BURNER ASSEMBLY (159351) SERIES 582 400 HP COMBINATION N5 YS7000...
Page 19: Series 582
PARTS LIST FOR BURNER ASSEMBLY (159351) SERIES 582 400 HP COMBINATION N5 YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187567 Burner Mounting Plate 157218 Air Swirl Assembly 130480 Burner Tube Assembly 119751 Air Cone Nose 130479 Air Adjusting Band 119746 Ignitor Assembly...
Page 20: Series 582
BURNER ASSEMBLY (157283) SERIES 582 400 HP COMBINATION N6 YS7000...
Page 21: Modulation Arrangement
PARTS LIST FOR BURNER ASSEMBLY (157283) SERIES 582 400 HP COMBINATION N6 YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187567 Burner Mounting Plate 157218 Air Swirl Assembly 130480 Burner Tube Assembly 119751 Air Cone Nose 130479 Air Adjusting Band 119746 Ignitor Assembly...
Page 22 BURNER ASSEMBLY SERIES 588 500 HP (157726) SERIES 588 600 HP (160018) #2 OIL YS7000...
Page 23: Series 588
PARTS LIST FOR BURNER ASSEMBLY SERIES 588 500 HP (157726) SERIES 588 600 HP (160018) #2 OIL YS7000 500 HP 600 HP Ref. No. No. Req’d Part Name Part No. Part No. Windbox Assembly 187567 187502 Burner Mounting Plate 157746 157746 Air Swirl Assembly 130480...
Page 24 BURNER ASSEMBLY SERIES 588 500 HP (158612) SERIES 588 600 HP (159950) #5 OIL YS7000...
Page 25: Series 588
PARTS LIST FOR BURNER ASSEMBLY SERIES 588 500 HP (158612) SERIES 588 600 HP (159950) #5 OIL YS7000 500 HP 600 HP Ref. No. No. Req’d Part Name Part No. Part No. Windbox Assembly 187567 187502 Burner Mounting Plate 157746 157746 Air Swirl Assembly 130480...
Page 26 BURNER ASSEMBLY SERIES 588 500 HP (158275) SERIES 588 600 HP (159080) #6 OIL YS7000...
Page 27: Series 588
PARTS LIST FOR BURNER ASSEMBLY SERIES 588 500 HP (158275) SERIES 588 600 HP (159080) #6 OIL YS7000 500 HP 600 HP Ref. No. No. Req’d Part Name Part No. Part No. Windbox Assembly 187567 187502 Burner Mounting Plate 157746 157746 Air Swirl Assembly 130480...
Page 28: Burner Assembly
BURNER ASSEMBLY SERIES 588 500 HP (158669) SERIES 588 600 HP (160022) YS7000...
Page 29: Series 2110
PARTS LIST FOR BURNER ASSEMBLY SERIES 588 500 HP (158669) SERIES 588 600 HP (160022) YS7000 500 HP 600 HP Ref. No. No. Req’d Part Name Part No. Part No. Windbox Assembly 187567 187502 Burner Mounting Plate 157746 157746 Air Swirl Assembly 120336 120336 Burner Tube Assembly...
Page 30 BURNER ASSEMBLY SERIES 588 500 HP (157574) SERIES 588 600 HP (158963) COMBINATION N/2 YS7000...
Page 31: Series 588
PARTS LIST FOR BURNER ASSEMBLY SERIES 588 500 HP (157574) SERIES 588 600 HP (158963) COMBINATION N/2 YS7000 500 HP 600 HP Ref. No. No. Req’d Part Name Part No. Part No. Windbox Assembly 187567 187502 Burner Mounting Plate 157746 157746 Air Swirl Assembly 120336...
Page 32 BURNER ASSEMBLY SERIES 588 500 HP (157937) SERIES 588 600 HP (157939) COMBINATION N5 YS7000...
Page 33: Series 588
PARTS LIST FOR BURNER ASSEMBLY SERIES 588 500 HP (157937) SERIES 588 600 HP (157939) COMBINATION N5 YS7000 500 HP 600 HP Ref. No. No. Req’d Part Name Part No. Part No. Windbox Assembly 187567 187502 Burner Mounting Plate 157746 157746 Air Swirl Assembly 120336...
Page 34 BURNER ASSEMBLY SERIES 588 500 HP (157747) SERIES 588 600 HP (157735) COMBINATION N6 YS7000...
Page 35: Series 588
PARTS LIST FOR BURNER ASSEMBLY SERIES 588 500 HP (157747) SERIES 588 600 HP (157735) COMBINATION N6 YS7000 500 HP 600 HP Ref. No. No. Req’d Part Name Part No. Part No. Windbox Assembly 187567 187502 Burner Mounting Plate 157746 157746 Air Swirl Assembly 120336...
Page 36: Series
BURNER ASSEMBLY (160277) SERIES 596 700 HP #2 OIL YS7000...
Page 37: Hp #2 Oil (157726)
PARTS LIST FOR BURNER ASSEMBLY (160277) SERIES 596 700 HP #2 OIL YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187330 Burner Mounting Plate Assembly 138450 Burner Tube Assembly 130448 Air Cone Nose 130397 Air Adjusting Band 138381 Ignitor Assembly 130455...
Page 38: Hp #5 Oil (158612)
BURNER ASSEMBLY (157988) SERIES 596 700 HP #5 OIL YS7000...
Page 39: Hp #5 Oil (159950)
PARTS LIST FOR BURNER ASSEMBLY (157988) SERIES 596 700 HP #5 OIL YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187330 Burner Mounting Plate Assembly 138450 Burner Tube Assembly 130448 Air Cone Nose 130397 Air Adjusting Band 138381 Ignitor Assembly 130455...
Page 40: Hp #6 Oil (158275)
BURNER ASSEMBLY (158217) SERIES 596 700 HP #6 OIL YS7000...
Page 41 PARTS LIST FOR BURNER ASSEMBLY (158217) SERIES 596 700 HP #2 OIL YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187330 Burner Mounting Plate Assembly 138450 Burner Tube Assembly 130448 Air Cone Nose 130397 Air Adjusting Band 138381 Ignitor Assembly 130455...
Page 42 BURNER ASSEMBLY (160284) SERIES 596 700 HP YS7000...
Page 43 PARTS LIST FOR BURNER ASSEMBLY (160284) SERIES 596 700 HP YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187330 Burner Mounting Plate Assembly 138450 Burner Tube Assembly 130448 Air Cone Nose 130397 Air Adjusting Band 138381 Ignitor Assembly 130455 Nozzle Assembly 130462...
Page 44 BURNER ASSEMBLY (160283) SERIES 596 700 HP COMBINATION N2 YS7000...
Page 45 PARTS LIST FOR BURNER ASSEMBLY (160283) SERIES 596 700 HP COMBINATION N2 YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187330 Burner Mounting Plate Assembly 138450 Burner Tube Assembly 130448 Air Cone Nose 130397 Air Adjusting Band 138381 Ignitor Assembly 130455...
Page 46 BURNER ASSEMBLY (157989) SERIES 596 700 HP COMBINATION N5 YS7000...
Page 47 PARTS LIST FOR BURNER ASSEMBLY (157989) SERIES 596 700 HP COMBINATION N5 YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187330 Burner Mounting Plate Assembly 138450 Burner Tube Assembly 130448 Air Cone Nose 130397 Air Adjusting Band 138381 Ignitor Assembly 130455...
Page 48 BURNER ASSEMBLY (157928) SERIES 596 700 HP COMBINATION N6 YS7000...
Page 49 PARTS LIST FOR BURNER ASSEMBLY (157928) SERIES 596 700 HP COMBINATION N6 YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187330 Burner Mounting Plate Assembly 138450 Burner Tube Assembly 130448 Air Cone Nose 130397 Air Adjusting Band 138381 Ignitor Assembly 130455...
Page 50 BURNER ASSEMBLY (177548) SERIES 5112 850 HP #2 OIL YS7000...
Page 51 PARTS LIST FOR BURNER ASSEMBLY (177548) SERIES 5112 850 HP #2 OIL YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187427 Burner Mounting Plate Assembly 155472 Burner Mounting Plate Support 138503 Burner Air Plate Assembly 138379 Burner Tube Assembly 130448 Air Cone Nose 155474...
Page 52 BURNER ASSEMBLY (202409) SERIES 5112 850 HP #5 OIL YS7000...
Page 53 PARTS LIST FOR BURNER ASSEMBLY (202409) SERIES 5112 850 HP #5 OIL YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187427 Burner Mounting Plate Assembly 155472 Burner Mounting Plate Support 138503 Burner Air Plate Assembly 138379 Burner Tube Assembly 130448 Air Cone Nose 155474...
Page 54 BURNER ASSEMBLY (159895) SERIES 5112 850 HP #6 OIL YS7000...
Page 55 PARTS LIST FOR BURNER ASSEMBLY (159895) SERIES 5112 850 HP #6 OIL YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187427 Burner Mounting Plate Assembly 155472 Burner Mounting Plate Support 138503 Burner Air Plate Assembly 138379 Burner Tube Assembly 130448 Air Cone Nose 155474...
Page 56 BURNER ASSEMBLY (173135) SERIES 5112 850 HP YS7000...
Page 57 PARTS LIST FOR BURNER ASSEMBLY (173135) SERIES 5112 850 HP YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187427 Burner Mounting Plate Assembly 155472 Burner Mounting Plate Support 138503 Burner Air Plate Assembly 138379 Burner Tube Assembly 130448 Air Cone Nose 155474...
Page 58 BURNER ASSEMBLY (194999) SERIES 5112 850 HP COMBINATION N2 YS7000...
Page 59 PARTS LIST FOR BURNER ASSEMBLY (194999) SERIES 5112 850 HP COMBINATION N2 YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187427 Burner Mounting Plate Assembly 155472 Burner Mounting Plate Support 138503 Burner Air Plate Assembly 138379 Burner Tube Assembly 130448 Air Cone Nose 155474...
Page 60 BURNER ASSEMBLY (155516) SERIES 5112 850 HP COMBINATION N5 YS7000...
Page 61: Nozzle Assembly 155463
PARTS LIST FOR BURNER ASSEMBLY (155516) SERIES 5112 850 HP COMBINATION N5 YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187427 Burner Mounting Plate Assembly 155472 Burner Mounting Plate Support 138503 Burner Air Plate Assembly 138379 Burner Tube Assembly 130448 Air Cone Nose 155474...
Page 62 BURNER ASSEMBLY (201336) SERIES 5112 850 HP COMBINATION N6 YS7000...
Page 63 PARTS LIST FOR BURNER ASSEMBLY (201336) SERIES 5112 850 HP COMBINATION N6 YS7000 Ref. No. No. Req’d Part Name Part No. Windbox Assembly 187427 Burner Mounting Plate Assembly 155472 Burner Mounting Plate Support 138503 Burner Air Plate Assembly 138379 Burner Tube Assembly 130448 Air Cone Nose 155474...
Page 64 BLOWER MOTOR & SILENCER ARRANGEMENT (138616) Ref. No. No Rqd. Part Name Part No. Blower-Chicago, #2000 Type A/4SISWDB, 3600 RPM CCW 106252 Rotation Down Blast w/40 HP Motor, 3600 RPM, Fr. 325S Silencer Assembly 138440 BLOWER MOTOR & SILENCER ASSEMBLY 154020 157733 Ref.
Page 65 BLOWER MOTOR & SILENCER ASSEMBLY (155151) Ref. No. No Rqd. Part Name Part No. Blower & Motor Assembly, 60 HP, 3600 RPM, Fr. #326TS, 108030 Blower 2214-1904 CCW Silencer Assembly 145577...
Page 66 DAMPER ARRANGEMENT (187568) SERIES 582 400 HP SERIES 588 500 HP Ref. No. No Rqd. Part Name Part No. Shaft, Blower Outlet 187559 Blower Outlet Damper 187560 Blower Outlet Damper, Left Hand 187561 Damper Linkage Arm Assembly 187327 Damper Link 187566 Pin, Cotter, 1/8"...
Page 67 DAMPER ARRANGEMENT (187503) SERIES 588 600 HP Ref. No. No Rqd. Part Name Part No. Shaft, Blower Outlet 187498 Blower Outlet Damper 187499 Blower Outlet Damper, Left Hand 187500 Damper Linkage Arm Assembly 187327 Damper Link 187501 Pin, Cotter, 1/8" x 3/4" Lg. 107261 Screw, Socket Hd., 5/16"...
Page 68 DAMPER ARRANGEMENT (187331) SERIES 596 700 HP Ref. No. No Rqd. Part Name Part No. Shaft, Blower Outlet 187322 Blower Outlet Damper 187323 Blower Outlet Damper, Left Hand 187324 Damper Linkage Arm Assembly 187327 Damper Link 187329 Pin, Cotter, 1/8" x 3/4" Lg. 107261 Screw, Socket Hd., 5/16"...
Page 69 DAMPER ARRANGEMENT (187428) SERIES 5112 850 HP Ref. No. No Rqd. Part Name Part No. Shaft, Blower Outlet 187423 Blower Outlet Damper 187424 Blower Outlet Damper, Left Hand 187425 Damper Linkage Arm Assembly 187327 Damper Link 187426 Pin, Cotter, 1/8" x 3/4" Lg. 107261 Screw, Socket Hd., 5/16"...
Page 70 MODULATION ARRANGEMENT (138868) Part Part Name Part No. Part Part Name Part No. Req. Req. Modutrol Motor M941C1014 102854 Linkage Rod, 1/4" x 8" Lg. 022645 Cap Screw 1/4" 20NC2 x 1" Lg. 067994 Metering Arm, 7/16" Hole 024178 Hex Hd. Lockwasher 1/4"...
Page 71 MODULATION ARRANGEMENT 153787 154842 151558...
Page 72 PARTS LIST FOR MODULATION ARRANGEMENT 153787 154847 151558 Arrangement Number 153787 154842 151558 Ref No No. Req. Part Name Part No. Part No Part No. Modutrol Motor M941C1014 102854 102854 102854 Hex Hd. Bolt 1/4" 20NC-2 x 1" Lg. 050948 050948 050948 Lockwasher 1/4"...
Page 73 MODULATION ARRANGEMENT (160285) Part Part Name Part No. Part Part Name Part No. Req. Req. Modutrol Motor M941C1014 102854 Linkage Rod, 1/4" x 8" Lg. 022645 Metering Arm, 7/16" Hole Cap Screw 1/4" 20NC2 x 1" Lg. 067994 024178 Hex Hd. Lockwasher 1/4"...
Page 74 MODULATION ARRANGEMENT (173310) Part Part Name Part No. Part Part Name Part No. Req. Req. Modutrol Motor M941C1014 102854 Metering Arm, 7/16" Hole 024178 Cap Screw 1/4" 20NC2 x 1" Lg. 067994 Hex Hd. Lockwasher 1/4" 050046 Bearing Block 024179 Conduit, Flexible, 3/8"...
Page 75 MODULATION ARRANGEMENT (189523) Part Part Name Part No. Part Part Name Part No. Req. Req. Modutrol Motor M941C1014 102854 Metering Arm, 7/16" Hole 024178 Cap Screw 1/4" 20NC2 x 1" Lg. 067994 Linkage Rod, 1/4" x 6" Lg. 003270 Hex Hd. Lockwasher 1/4"...
Page 76 MODULATION ARRANGEMENT 157987 157973...
Page 77 PARTS LIST FOR MODULATION ARRANGEMENT 157987 157973 Arrangement Number 157987 157973 Ref No No. Req. Part Name Part No. Part No Modutrol Motor M941C1014 102854 102854 Cap Screw 1/4" 20NC-2 x 1" Lg., Hex Hd. 067994 067994 Lockwasher 1/4" Split 105157 105157 BX Conduit 3/8"...
Page 78 NOZZLE TIPS 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 below which describes the air and oil passages.
Page 79: Nozzle Assembly (157301)
NOZZLE ASSEMBLY (130462) Part No. No. Req. Part Name Part No. Nozzle - Monarch C-202, B-50 Cap & 13 103019 Disc. Nozzle & Pipe Support 111694 Elbow, 1/2" IPS, 90 Pipe, 3/8" x 13-3/4" Lg. Thrd. Both Ends 130466 Reducing Coupling, 3/8" x 1/4" IPS 051936 Pipe, 1/4"...
Page 80: Nozzle Assembly (161284)
NOZZLE ASSEMBLY (155463) Part No. No. Req. Part Name Part No. Nozzle - Monarch C-206, B-3 Tip & B4 Disc. 069895 Nozzle & Pipe Support 112711 Elbow, 1/2" IPS 051270 Reducing Elbow, 1/2 x 3/8 IPS, 90 050795 Pipe, 3/8" x 49-1/2" Lg. Thrd. Both Ends 155465 Nozzle Pipe Plate 112712...
Page 81 NOZZLE ASSEMBLY (157301) Part No. No. Req. Part Name Part No. Nozzle - Monarch C-202, B-50 Cap 13 Disc. 103019 Nozzle & Pipe Support 111694 Nozzle Pipe Plate 158304 Nipple, 3/8" x 1-1/2" Lg. 050807 Nipple, 1/4" IPS x 41" Lg. 157722 Swing Check Valve, 1/2"...
Page 82 NOZZLE ASSEMBLY (161284) Part No. No. Req. Part Name Part No. Nozzle - Monarch C-206, B-5 Tip B2 Disc. 108639 Nozzle & Pipe Support 112711 Elbow, 1/2" IPS 051270 Reducing Elbow, 1/2 x 3/8 IPS, 90 050795 Pipe, 3/8" x 49-1/2" Lg. Thrd. Both Ends 155465 Nozzle Pipe Plate 112712...
Page 83: Ignitor Assembly
IGNITOR ASSEMBLY (130455) Ref. No. No Rqd. Part Name Part No. Ignitor Tube 157991 Nozzle & Electrode Holder 111692 Clamp 032254 Electrodes 072074 Connector - Electrode Assembly 130458 Elbow, 1/2 MPT x 5/8" SAE (Brass) 051326 Clamp Sleeve 027282 Set Screw Soc. Hd. 1/4" 20NC2 x 1/4" Lg. 050609 Support Rod 130459...
Page 84: Ignitor Assembly
IGNITOR ASSEMBLY (157281) Ref. No. No Rqd. Part Name Part No. Fireye, Sight Tube Assembly 157282 Ignitor Tube 119729 Nozzle & Electrode Support 111690 Nozzle & Electrode Holder 111692 Clamp 032254 Electrodes 072074 Electrode Connector 119728 Elbow, 1/2" MPT x 5/8" SAE (Brass) 051326 Clamp Sleeve 027282...
Page 85: Ignitor Assembly
IGNITOR ASSEMBLY (157992) Ref. No. No Rqd. Part Name Part No. Ignitor Tube 157991 Nozzle & Electrode Holder 111692 Clamp 032254 Electrodes 072074 Connector - Electrode Assembly 130458 Elbow, 1/2" MPT x 5/8" SAE (Brass) 051326 Clamp Sleeve 027282 Set Screw Soc. Hd. 1/4" 20NC2 x 1/4" Lg. 050609 Support Rod 130459...
Page 86: Series 5112
COMPRESSOR ARRANGEMENT (141332) SERIES 582 400 HP SERIES 588 500 & 600 HP SERIES 596 700 HP #2 & N2 Ref. No. No Rqd. Part Name Part No. Air Compressor, Gast 1065 068272 Motor, 1 HP, #143T Frame 3 Phase 104360 Motor Adjusting Rail Assembly 125684...
Page 87 COMPRESSOR ARRANGEMENT (162163) SERIES 582 400 HP SERIES 588 500 & 600 HP SERIES 596 700 HP #5, #6, N5 & N6 Ref. No. No Rqd. Part Name Part No. Air Compressor, Gast 1065 068272 Motor, 1 HP, #143T Frame 3 Phase 104360 Motor Adjusting Rail Assembly 125684...
Page 88 COMPRESSOR ARRANGEMENT (157994) SERIES 5112 850 HP #2, #5, #6, N2, N5 & N6 Ref. No. No Rqd. Part Name Part No. Air Compressor, Gast 2065 068269 Motor, 1-1/2 HP, #145T Frame 3 Phase 105790 Motor Adjusting Rail Assembly 125684 Belt Guard 161317 Air Filter Assembly...
Page 89 CONSTRUCTION The rotary air pump is a precision product, with only a few thousandths of an inch clearance at the ends and top of the rotor. The vanes take up their own wear and should last from 5,000 to 25,000 hours operation depending on the application.
Page 90 SECTIONAL VIEW OF AUTOMATIC LUBRICATOR Important: Use Violube (#100188), the blue tinted compressor oil, available exclusively from York-Shipley Global...
Page 91 1065-P-22-H AIR COMPRESSOR Dwg. Part No. Part Name Mat. Req. 1065P22H Asm. Complete AC860A Body (Short Feet) D1322 End Plate, Drive D1322A End Plate, Dead D334F Rotor Assy. D332A Rotor Slug C.I. D333A Rotor Shaft D335H Vane Comp. D327 Bearing AA150 Shaft Seal D316...
Page 92 DISASSEMBLING GAST 1065 COMPRESSOR FOR VANE REPLACEMENT 1. Remove the taper pins holding compressor in position. This can be done with a pair of pliers. 2. Remove the four (4) mounting bolts. 3. Treat it right; it’s precision built! 4. Work on a bench. Clean the pump with a solvent or carbon tetrachloride. 5.
Page 93 5. Reinstall the onionskin gasket, making sure it is on properly. Use a little oil to make it stick. 6. Reinstall the dead end plate. Guide the dowel pins into the proper holes. Be careful of the seal so that you do not damage it with the shaft.
Page 94 SERVICING Most failure to build up pressure is due to leaks in pipe lines, a dirty filter, a defective gauge, or sluggish vanes. Vanes may stick in slots of rotor due to lack of oil, too much oil, or too heavy oil. See CLEANING.
Page 95 2065-P-16B AIR COMPRESSOR Dwg. Part No. Part Name Mat. Req. 2065P16B Asm. Complete AC101E Body (Short Feet) AA767C End Plate, Drive AA767B End Plate, Dead AC843 Rotor Assy. AC841 Rotor Slug C.I. AC842 Rotor Shaft AA8A Vane Comp. AA735 Bearing Drive AA755 Bearing Dead AB123...
Page 96 ASSEMBLING #2065 COMPRESSOR Be sure that parts are clean, free from nicks, and that vanes move freely in rotor slot. The smallest chip will bind the rotor and damage it. Remember there is only .002 of an inch between top of rotor and body bore.
Page 97 Repeat procedure in locating dead end of rotor. With a piece of brass, tap lightly and quickly on the drive end of rotor shaft. Press seals into end caps and attach. Attach fan, guard, and pulley. Give compressor ample amount of light oil so it is well lubricated.
Page 98: Pilot Gas Train Arrangement (151557)
PILOT GAS TRAIN ARRANGEMENT (151557) Ref. No. No Rqd. Part Name Part No. Manual Shut-Off Valve, 3/4" 064732 Pressure Regulator, 3/4", Maxitrol R500S 102305 Solenoid Valve, GC K3A-552 068028...
Page 99: Main Gas Piping Arrangement
MAIN GAS PIPING ARRANGEMENT (168783) SERIES 582 400 HP SERIES 588 500 & 600 HP Ref. No. No Rqd. Part Name Part No. Valve, Butterfly, 2-1/2" 057382 Nipple, 2-1/2" IPS x 6 Lg. 051893 Reducer, 3" x 2-1/2" Lg. 061501 Nipple, 3"...
Page 100: Main Gas Piping Arrangement (168782)
MAIN GAS PIPING ARRANGEMENT (168782) SERIES 596 700 HP Ref. No. No Rqd. Part Name Part No. Valve, Butterfly, 4" 057384 Nipple, 4" IPS x 16 Lg. 056569 Union, 4" IPS 052052 Nipple, 4" IPS x 5" Lg. 061649 Nipple, 4" IPS x 19" Lg. 056570 Valve, Lubricated Plug, 4"...
Page 101: Main Gas Piping Arrangement (168781)
MAIN GAS PIPING ARRANGEMENT (168781) SERIES 5112 850 HP Ref. No. No Rqd. Part Name Part No. Valve, Butterfly, 6" 052194 Nipple, 6" IPS x 13-1/2 Lg. 053947 Nipple, 6" IPS x 4-1/2" Lg. 052101 Nipple, 6" IPS x 24-1/2" Lg. 063939 Valve, Lubricated Plug, 6"...
Page 102: Oil Metering Arrangement (157725)
OIL METERING ARRANGEMENT (157725) Ref. No. No Rqd. Part Name Part No. Solenoid Oil Valve K10AB-281 (Normally Closed)* 050657 Solenoid Oil Valve K10A-389 (Normally Closed) 103854 Nozzle Adaptor 115522 Nozzle Monarch 3.0 x 60 Type PLP 061145 Ball Check Valve 1/8" IPS 103000 Solenoid Valve, 2 Way (NO) Asco 8262C31 105491...
Page 103: Oil Metering Arrangement (158966)
OIL METERING ARRANGEMENT (158966) Ref. No. No Rqd. Part Name Part No. Tailpiece Valve Assembly 007464 Valve Body 070133 Hi-Low Metering Valve 128452 Solenoid Oil Valve K10-389 115/60 1/3" Port, 1/2" Pipe 103854 Pressure Gauge 2-1/2" 0-60# Fig. 500S 101739 Temperature Gauge, 3-1/2"...
Page 104 OIL METERING ARRANGEMENT (154147 & 158964) Arrangement: 154147 158964 Ref. No. No Rqd. Part Name Part No. Part No. Tailpiece Valve Assembly 007464 007464 Valve Body 070133 070133 Hi-Low Metering Valve 007510 128452 Solenoid Oil Valve K10AB-281 050657 Solenoid Oil Valve K10-389 115/60 1/3" Port, 1/2" Pipe 103854 Pressure Gauge 2-1/2"...
Page 105: Oil Metering Arrangement (154147)
OIL METERING ARRANGEMENT (155436) Ref. No. No Rqd. Part Name Part No. Pressure Gauge, 2-1/2" 0-60# Fig. 500S 101739 Solenoid Oil Valve K10-389 115/60, 1/2" 103854 Hi-Low Metering Valve 128452 Tailpiece Valve Assembly 007464 Valve Body 070133 Temperature Gauge, 3-1/2" 60 to 120 Marsh, Fig.
Page 106: Oil Metering Arrangement (158964)
OIL METERING ARRANGEMENT (157993) Ref. No. No Rqd. Part Name Part No. Tailpiece Valve Assembly 007464 Valve Body 070133 Hi-Low Metering Valve 128452 Solenoid Oil Valve K10A-389 115/60, 3/8" Port, 1/2" Pipe 103854 Pressure Gauge, 2-1/2" 0-60# Fig. 500S 101739 Temperature Gauge, 3-1/2"...
Page 107: Oil Metering Arrangement (155436)
OIL METERING ARRANGEMENT (177547) Ref. No. No Rqd. Part Name Part No. Pressure Gauge, 2-1/2" 0-60# 101739 Solenoid Oil Valve K10-389, 1/2" 103854 Hi-Low Metering Valve 128452 Tailpiece Valve Assembly 007464 Valve Body 070133...
Page 108: Oil Metering Arrangement (177547)
OIL METERING ARRANGEMENT (138832) Ref. No. No Rqd. Part Name Part No. Pressure Gauge, 2-1/2" 0-60# 101739 Solenoid Oil Valve K10A-389, 1/2" 103854 Hi-Low Metering Valve 128452 Tailpiece Valve Assembly 007464 Valve Body 070133 Strainer 3/4" IPS 065220...
Page 109: Viscosity Compensator Box Assembly
VISCOSITY COMPENSATOR BOX ASSEMBLY #6 & N6 582-588 596-5112 Assembly Number: 122025 138535 Ref. No. No Rqd. Part Name Part No. Part No. Housing 112454 138534 Cover 112462 112462 Gasket, Cover 112989 112989 Inlet Valve Assembly 035694 035694 Valve Seat 035676 035676 Metering Valve Assembly...
Page 110: Oil Pump Set Arrangement
OIL PUMP SET ARRANGEMENT (154853 SERIES 582 400 HP SERIES 588 500 & 600 HP #2& N2 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 151604 Motor Adjusting Rail Assy 125684 Motor 1 HP 1800 RPM, 3 Phase 104360 Pump, Tuthill #3CIG Style A 106839...
Page 111: Series 582
OIL PUMP SET ARRANGEMENT (152180) SERIES 582 400 HP SERIES 588 500 & 600 HP #5 & N5 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 151604 Motor Adjusting Rail Assy 125684 Motor 3/4 HP 1800 RPM #56 Fr., 3 Phase 051375 Pump, Tuthill 3CIG Style A 106839...
Page 112: Series 588
OIL PUMP SET ARRANGEMENT (120471) SERIES 582 400 HP SERIES 588 500 & 600 HP #6 & N6 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 151604 Motor Adjusting Rail Assy 125684 Motor 3/4 HP 1800 RPM #56 Fr., 3 Phase 051375 Pump, Tuthill 3CIG Style A 106839...
Page 113: Series 596
OIL PUMP SET ARRANGEMENT (143523) SERIES 596 700 HP #2 & N2 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 151604 Motor Adjusting Rail Assy 125684 Motor 1-1/2 HP 1800 RPM, 3 Phase 105790 Pump, Tuthill 4CIG Style A 106840...
Page 114: Series 596
OIL PUMP SET ARRANGEMENT (141341 SERIES 596 700 HP #5 & N5 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 151604 Motor Adjusting Rail Assy 125684 Motor 1 HP 1800 RPM, 3 Phase 104360 Pump, Tuthill 4CIG Style A 106840...
Page 115: Series 596
OIL PUMP SET ARRANGEMENT (141342) SERIES 596 700 HP #6 & N6 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 151604 Motor Adjusting Rail Assy 125684 Motor 1 HP 1800 RPM, 3 Phase 104360 Pump, Tuthill 4CIG Style A 106840...
Page 116 OIL PUMP SET ARRANGEMENT (178169) SERIES 5112 850 HP #2 & N2 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 151604 Motor Adjusting Rail Assy 125684 Motor 1-1/2 HP 1800 RPM #145 Fr., 3 Phase 105790 Pump, Tuthill 4CIG 106840...
Page 117 OIL PUMP SET ARRANGEMENT (156154) SERIES 5112 850 HP #5 & N5 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 151604 Motor Adjusting Rail Assy 125684 Motor 1-1/2 HP 1800 RPM #145 Fr., 3 Phase 105790 Pump, Tuthill 4CIG 106840...
Page 118: Series
OIL PUMP SET ARRANGEMENT (160544) SERIES 5112 850 HP #6 & N6 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 151604 Motor Adjusting Rail Assy 125684 Motor 1-1/2 HP 1800 RPM, 3 Phase 105790 Pump, Tuthill 4CIG Style A 106840...
Page 119: General Assembly Of Transfer Pump
GENERAL ASSEMBLY OF TRANSFER PUMP...
Page 120 GENERAL ASSEMBLY OF TRANSFER PUMP Pump Size Stamp Tag Tag No. #825 #825 #825 Symbol "C" indicates fixed land packaged type Symbol "G" indicates spring loaded packing Pump Size 2C1G 5-7/32 3-1/8 2-1/2 3-1/2 6-11/16 25/64 21/32 1-1/2 #606 3C1G 6-5/8 4-1/8 3-7/8...
Page 121 STEAM HEATER ARRANGEMENT (132857) USED ON SPH BOILERS ONLY SERIES 582 400 HP SERIES 588 500 HP #6 & N6 Ref. No. No Rqd. Part Name Part No. Steam Oil Preheater, Alstrom #6ST70 066304 Trap, Expansion, Armstrong 104611 Gauge, Temp., 3-1/2", 60 - 260 , Fig.
Page 122 STEAM HEATER ARRANGEMENT (151692) USED ON SPH BOILERS ONLY SERIES 588 600 HP SERIES 596 700 HP SERIES 5112 850 HP #6 & N6 Ref. No. No Rqd. Part Name Part No. Steam Oil Preheater, Alstrom #6ST120 066304 Trap, Expansion, Armstrong 104611 Gauge, Temp., 3-1/2", 60 - 260...
Page 123 HOT WATER HEATER ARRANGEMENT (111485) USED ON SPL & SPW BOILERS ONLY SERIES 582 400 HP SERIES 588 500 HP SERIES 588 600 HP (SPL ONLY) SERIES 596 700 HP #6 & N6 Ref. No. No Rqd. Part Name Part No. Steam Oil Preheater, Alstrom #6ST120 066304 Circulator, 115/60/1, 1"...
Page 124: Series 582 400 Hp - #6 & N6 (132857)
ELECTRIC HEATER ARRANGEMENT (128466) SPL-SPH SERIES 582 400 HP (#5 & N5) SPL-SPH SERIES 588 600 HP (#6 & N6) Ref. No. No Rqd. Part Name Part No. Electric Preheater Case Assembly 095626 Heater Element 5000 Watt AF-5-230-20 050827 Heater Element 5000 Watt ADF-5-230-20 059284 Strainer, 3/4"...
Page 125 ELECTRIC HEATER ARRANGEMENT (128465) SPL-SPH SERIES 582 400 HP (#6 & N6) SPL-SPH SERIES 588 500 HP (#6 & N6) Ref. No. No Rqd. Part Name Part No. Electric Preheater Case Assembly 095626 Heater Element 3000 Watt AF-3-230-20 050800 Heater Element 3000 Watt ADF-3-230-20 055126 Strainer, 3/4"...
Page 126 ELECTRIC HEATER ARRANGEMENT (128467) SERIES 582 400 HP (#6 & N6) SERIES 588 500 HP (#6 & N6) SPL-SPH SERIES 588 500 HP (#5 & N5) ELECTRIC HEATER ARRANGEMENT (128468) SPL-SPH SERIES 588 600 HP (#6 & N6) SPL-SPH SERIES 596 700 HP (#6 &...
Page 127 CONTROL PANEL ARRANGEMENTS SERIES 582 400 HP SERIES 588 500 HP Fuel #2 Oil #5 Oil #6 Oil Arrangement Number 157640 157643 157644 157642 157641 157645 157646 Part No. Part Part Part Part Part Part Part Req. Req. Req. Req. Req.
Page 128 CONTROL PANEL ARRANGEMENTS SERIES 596 700 HP SERIES 5112 850 HP Fuel #2 Oil #5 Oil #6 Oil Arrangement Number 157654 157657 157658 157656 157655 157659 157660 Part No. Part Part Part Part Part Part Part Req. Req. Req. Req. Req.
Page 129 SIZING GAS HEADER FROM METER TO BOILER 400 THROUGH 850 HP STEAM-PAK Fig. 1 Size, Series Max. Firing Required Pressure at Unit & HP Rate C.F.H.* (See Notes) STD. – FM - IRI 582-400 16,750 15.5" W.C. 588-500 20,950 21.5" W.C. 588-600 25,150 28.5"...
Page 130 SIZING GAS HEADER FROM METER TO BOILER 400 THROUGH 850 HP STEAM-PAK Fig. 2 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...
Page 131 Sizing Gas Header From Meter to Boiler Sizing the gas line from the utility service at the meter to the gas pressure regulator at the boiler 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 boiler installation.
Page 132 Unit 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 from Fig. 3 using the maximum flow for the individual unit and the pressure drop per 100 ft.
Page 133 Gas Pressure Regulator Requirements For 400 through 850 HP Series Units (Chart is for Natural Gas .55 to .65 SpG. Only, 1000 BTU/Cu. Ft.) 13.9" WC = 8 oz. = .5 psi UL Standard & FM Approval Boiler Size CFH Firing Press Req'd Reg.
Page 134 SCHEMATIC GAS PIPING ARRANGEMENT 400 THRU 850 HP - U/L, FM & IRI...
Page 135 LIGHT OIL 40 SSU MAX. @ 100 F - .85 SPG Maximum Allowable Run and Suction and Return Line Sizing for Steam-Pak Boilers 400 through 850 HP #1 and #2 Oil Burning Units Line Sizing (400 through 850 HP) For all light oil Steam-Pak units in this size range, use 1” IPS pipe for both suction and return lines. Maximum Allowable Pipe Run (400 through 850 HP) To determine the maximum allowable pipe run from the pump suction to the bottom of the fuel tank for various lifts and all size units, use the chart below.
Page 136 Fuel Pump Location & Suction & Return Line Sizing For Steam-Pak 500 Series #5 Oil Burning Units Specify #5 Oil Burner for #4 & Cold #5 Oil (18 to 28 API, 50 to 150 SSU @ 100 F Max. Vis.) Fig.1 Fig 2 Boiler Size...
Page 137 Instructions for Sizing Fuel Lines Step #1 From boiler size (HP) determine required suction and return line size. (Fig. 2) Step #2 From plans, determine straight length of pipe run (both horizontal and vertical) from pump suction connection (Fig. 1) to the bottom of the fuel oil tank. Step #3 Determine the number and type of fittings in the length of run (Step #2) and convert these into a length of straight pipe.
Page 138 Step #5 From the plans, the vertical distance from the boiler room floor to the bottom of the fuel tank is found to be 8.5 ft. Step #6 The total lift is then 8.5 ft. + 1.5 ft. (Fig. 1) = 10 ft. Step #7 Fig.
Page 139 500 SERIES #4 & #5 COLD FUEL OIL SYSTEM SINGLE OR DUPLEX...
Page 140 Metering Assembly for #4 & Cold #5 Oil Electric Fuel Oil Heater (Mounted on Unit Only) #4 & Cold #5 Oil Electric Heater Capacity #4 & #5 Oil Size Unit HP SPL-SPH-SPW 2-5000 watts 3-4000 watts 3-5000 watts 3-5000 watts 3-5000 watts...
Page 141 Fuel Oil Tank Piping For #4 & Cold #5 Oil 1. Test suction and return lines by sealing off tank and boiler piping and subjecting closed system to 125 lbs. inert gas pressure. Remove source of gas and allow system to remain full for a period of no less than 8 hours.
Page 142 Fuel Oil Pump Assembly for #4 & Cold #5 Oil Single Unit Fuel Oil Pumps Mounted on Unit Fuel oil pumps are required to transport the fuel oil from the storage tank to the burner and return excess oil to the storage tank.
Page 143 The 500 Series #6 Oil Burner & System Specify #6 Oil Burner For “Hot” #5 Oil & #6 Oil (7 to 22 API, 300 SSF @ 122 F Max. Viscosity) Of all the liquid and gaseous fuels, commercial grade #6 oil has always been the most troublesome to utilize.
Page 144 be so sized that it will reach to within 6” of the tank bottom. A means of access to the connection is required and all prevailing codes and regulations should be noted and complied with. 2) The oil and preheating piping from the tank to the pump suction is a most important link in the #6 oil system.
Page 145 b) In the “on fire” condition, the heated oil from the electric heater passes through the nozzle strainer. Its path is blocked by the closed, manually operated “original start up” valve (D), but a parallel path of oil flow is obtained when the solenoid operated “firing by-pass” valve (A) opens, allowing flow around the “non-firing”...
Page 146 500 SERIES #6 FUEL OIL SYSTEM Single or Duplex...
Page 147 ELECTRIC FUEL OIL HEATER (MOUNTED ON UNIT ONLY) #6 OIL Purpose: To heat the fuel oil at the start and to assist movement of the fuel oil from the storage tank to the burner. The electric heater is also used when the fuel oil is circulated between the storage tank and the metering valves to level off operating fuel temperature while burning.
Page 148 Steam Fuel Oil Heater - Mounted on Unit Only #6 or Hot #5 Oil SPH Units...
Page 149 Below-the-Waterline Heater – Mounted On Units Only (#6 Oil or Hot #5 Oil, SPL or SPW Units) The below-the-waterline heater is needed to assist the electric heater in raising the temperature of the fuel oil. The boiler water is circulating through the heater at all times that the fuel pump assembly is circulating oil in the system.
Page 150 Below the Waterline Fuel Oil Heater – Mounted on Unit Only #6 or Hot #5 Oil, SPL or SPW Units...
Page 151 #6 Oil Single Unit Fuel Oil Pumps Mounted On Unit Fuel oil pumps are required to transport the fuel oil from the storage tank to the burner and return heated oil to the storage tank to maintain even temperature in the hot well within the tank and suction line. The suction temperature should be maintained at approximately 130 to 140 F.
Page 152 FUEL OIL PUMP - MOUNTED ON UNIT #6 OIL WITH CONTINUOUS OIL CIRCULATION...
Page 153 #6 OIL VISCOSITY METERING ASSEMBLY...
Page 154 DETAIL OF INSULATING & WRAPPING TANK HEATER...
Page 155 Fuel Oil Tank Piping #6 or Hot #5 Oil Note: 1. Test suction and return lines by sealing off tank and boiler piping and subjecting closed system to 125 lbs. inert gas pressure. Remove source of gas and allow system to remain full for a period of no less than 8 hours.
Page 156 Auxiliary Heat for Starting #6 Oil Units...
Page 157 TANK HEATER HOT #5 AND #6 OIL Tank Heater Reference Chart Tank Diameter "A" "B" "C" "D" 6'-0" 6'-4" 6'-1-3/4" 5'-10" 5'-11" 7'-0" 7'-4" 7'-1-3/4" 6'-10" 6'-11" 8'-0" 8'-4" 8'-1-3/4" 7'-10" 7'-11" 8'-6" 8'-10" 8'-7-3/4" 8'-4" 8'-5" 10'-0" 10'-4" 10'-1-3/4" 9'-10"...
Page 158 500 SERIES FUEL OIL SYSTEM FOR MULTIPLE UNITS WITH COMMON PUMP #6 OIL & HOT #5 OIL...
Page 159 Pipe Size Chart Heated #5 Oil - #6 Oil 1 Unit 2 Units 3 Units 4 Units A. Return from Burner 2” B. Supply to Burner 2” C. Return to Tank** 2-1/2” 2-1/2" 3" 3" D. Pump Discharge to Burner 2-1/2”...
Page 160 Fuel Pump Location & Suction & Return Line Sizing For Steam-Pak 500 Series Hot #5 & #6 Oil Burning Units Fig.1 Fig 2 Boiler Size Individual Individual (BHP) Suction Return 400 through 850 2-1/2" IPS 2-1/2" IPS Required Individual Suction & Return Pipe Line Size Fig.
Page 161 Instructions for Sizing Fuel Lines Step #1 From boiler size (HP) determine required suction and return line size. (Fig. 2) Step #2 From plans, determine straight length of pipe run (both horizontal and vertical) from pump suction connection (Fig. 1) to the bottom of the fuel oil tank. Step #3 Determine the number and type of fittings in the length of run (Step #2) and convert these into a length of straight pipe.
Page 162 Step #6 The total lift is then 8.5 ft. + 1.5 ft. (Fig. 1) = 10 ft. Step #7 Fig. 4 shows the intersection of 10 ft. of lift and 199 ft. of equivalent length of run to fall within the shaded area. Solution: The use of 2-1/2"...
Page 163 FUEL OIL, ITS SPECIFICATIONS AND OTHER RELATED SUBJECTS There has been much discussion on the specifications of the various grades of available fuel oil, the discussions involving the point of fuel specifications, viscosities, and available heat content. The following deals with this subject in relation to the York-Shipley product. The grades available are identified by their respective number as assigned by the U.S.
Page 164 Only a few broad standards are imposed on #6 fuel oil. Fuel oil marketers and buyers may, and usually do, impose additional limits on the properties of their products and also make the limits of the standard more restrictive, Even so, #6 oil is fundamentally what is left after all lighter and higher cost products are obtained from the crude.
Page 165 INTERMEDIATE FUEL OILS Some #4 and #5 oils are blended at refineries, but there is considerable field blending, with the result that variety in characteristics is great. The ranges can be set down in the following tables: TABLE 3 - APPROXIMATE RANGE OF #5 (HOT) FUEL OIL Gravity Deg.
Page 166 the #6 component, with the #6 at an approximate temperature of 160 F added afterward. Agitation can be provided by pumping from the bottom of the tank and discharging to the top. Not every #2 fuel is compatible with any #6. If blending is done at the refinery, the refiner avoids incompatible stocks.
Page 167 TABLE 6 – GRAVITIES, DENSITIES AND HEATS OF COMBUSTION OF FUEL OILS Values for 10 to 49 Deg. API reprinted from the Bureau of Standards Miscellaneous Publication #97, "Thermal Properties of Petroleum Products". Density @ Total Heat of Combustion Net Heat of Combustion Gravity @ 60/60 F (at Constant Volume) (at Constant Pressure)
Page 168 TABLE 6 (CONT.) – GRAVITIES, DENSITIES AND HEATS OF COMBUSTION OF FUEL OILS Gravity @ 60/60 F Density Total Heat of Combustion Net Heat of Combustion At Constant Volume) (at Constant Pressure) @ 60 Deg. API Specific Lb/Gal. BTU/Lb. BTU/Gal Cal per BTU/Lb.
Page 169 If allowed to persist over any length of time, this acid will harm the boiler tubes or metallic surfaces. This is a very important consideration, especially in those industrial applications where the boiler water temperatures are kept low enough to be below the dew point temperatures of the flue gases. The accumulation of ASH in flues, breeching and the boiler proper has been a subject of much discussion, especially in heavier oil installations.
Page 170 TABLE 7 – FLASH POINTS OF FUEL OILS 100 or legal 130 or legal 130 or legal 150 or legal The flash point, instrument, and method for determining minimum flash point shall be those legally required for the locality in which the oil is sold. In the absence of legal requirements, the minimum flash point shall be determined in accordance with the standard test for flash point by means of the Pensky-Martens closed tester, ASTM designation: D93-46.
Page 171 TABLE 10 REFINERY B – EAST COAST #6 FUEL OIL PROPERTIES Gravity: 14.3 12.9 12.6 12.3 14.0 12.5 12.6 12.3 Viscosity, Furol 122 137.2 173.2 173.5 187.5 115.4 170.3 171.2 196.2 Flash, P-M: Pour: Sulfur, B; % 2.53 2.75 3.17 3.45 2.88 3.28...
Page 172 TABLE 12 REFINERY D – SOUTHWEST #6 FUEL OIL PROPERTIES Gravity: 14.0 14.4 14.8 13.2 16.0 15.3 15.2 14.9 Viscosity, Furol 122 87.1 91.8 82.5 106.0 69.2 66.6 77.2 84.9 Flash, P-M: Pour: Sulfur, B; % 1.03 1.15 0.97 1.22 0.83 1.19 1.19...
Page 173 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 174 3. Motors with special characteristics. a. High speed motors (3450 RPM) should be re-oiled every 3 months. b. Motors 7-1/2 HP or greater should be re-oiled every 3 months. C. Lubricants for Ball Bearings 1. Gould Motors: a. Fractional Horsepower motor bearings: pre-lubricated no further lubrication necessary. b.
Page 175 D. Lubricant for sleeve bearings 1. G.E. Motors: a. SAE 10 viscosity turbine oil for motors up to 1/2 HP. b. SAE 20 viscosity turbine oil for motors 1/2 HP and larger. 2. Westinghouse Motors: a. PD-2268 Westinghouse specification number. b.
Page 176 STARTING INSTRUCTIONS FOR SERIES 500 BOILERS SERIES 500 BOILERS - SPHC – SPLC - SPWC 400 THROUGH 850 HP ALL FUELS NOTE: For use with standard controls only as follows: Fuel Boiler Horsepower Controls Used* #2 Oil 400 thru 850 HP YS7000 #5 Oil 400 thru 850 HP...
Page 177 STARTING THE UNIT After making all connections to the unit, it is ready for operation. The following is the procedure for putting the unit into its normal operating cycle: A. CHECK ROTATION OF MOTORS AND FILL BOILER 1. Turn off all electric supply to unit and close all gas cocks to unit. 2.
Page 178 Note: This circulator will run continuously in the "on fire" and "standby" condition—NEVER CYCLED. This completes the necessary motor and pump rotation check. B. CHECK CONTROLS AND COMBUSTION (REFER TO WIRING DIAGRAM SUPPLIED WITH UNIT). Gas or gas side of #2, #5 & #6 oil combination units. 1.
Page 179 d) Fill oil strainer with light oil for priming the pump and fuel oil system. e) On the below-water-line heater, close the square headed cocks in the circulating lines with circulator turned off. (This step is not necessary with a steam to oil heater, which uses an adjustable thermo trap.) f) Open wide valves "A"...
Page 180 Turn emergency switch ON (limit circuit closes). Allow unit to operate through normal operation. When main fire lights at low fire, allow boiler water temperature to rise to 190 open square headed cocks on water circulating lines of below-the-waterline heater. Turn circulator manual operated switch ON (circulator to run continuously).
Page 181 limit circuit is opened. While firing at low fire, set electric heater (#5 only) for 130 -150 (see start-up sheet). Check the low-fire combustion record for the results. Set modulation motor to high-fire. Motor arm will modulate to high-fire flame. Check the high-fire combustion and record the results.
Page 182 CHECK OF LINKAGES Make sure all set screws and nuts are tight on the air-oil control linkages. CHECK OF BURNER HEAD Make sure all set screws in the burner and nozzle holder are tight and that the electrodes and gas ignition torch are well locked in position.

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