Page 1 500 Series Boilers C-Section Sizes 40 thru 150 HP Service & Parts 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-64-413...
Page 2 TABLE OF CONTENTS PAGE NO. BURNERS - CONTROLS ..........REMOVAL &...
Page 3 PAGE NO. Servicing, Inspection, Disassembly Gast 2065 Compressor....2065-P-16B Air Compressor......... . . Assembling 2065 Compressor.
Page 4 PAGE NO. SPL-SPH Series 560 100 & 125 HP #6 & N6 (095644) ... . Series 548 70 & 80 HP #6 & N6 (095645) ....Series 560 150 HP #5 &...
Page 5 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 6 3. Disconnect all fuel lines (unions and/or flare fittings) 4. Remove the _” nuts holding the burner mounting plate to boiler. (Note: It is not necessary to remove the cap screws folding the burner to this plate – 542 and 548 Series only.) 5.
Page 7 BURNER & BLOWER ARRANGEMENT (095751) SERIES 542 40 THRU 60 HP #5 OR #6 OIL D20-5023 When drawing or part number lists more than one item, specify item desired and electrical characteristics.
Page 8 BURNER & BLOWER ARRANGEMENT (095751) SERIES 542 40 THRU 60 HP #5 OR #6 OIL D20-5023 PARTS LIST Part Part Name Part No. Part Part Name Part No. Req. Req. Blwr Mtr & Fan Wheel Assy See Chart Gas Burner Head 073586 Brnr Tube &...
Page 9 BURNER & BLOWER ARRANGEMENT (095750) SERIES 542 40 THRU 60 HP N5 – N6 COMBINATION D20-5023 When drawing or part number lists more than one item, specify item desired and electrical characteristics.
Page 10 BURNER & BLOWER ARRANGEMENT (095750) SERIES 542 40 THRU 60 HP N5 – N6 COMBINATION D20-5023 PARTS LIST Part Part Name Part No. Part Part Name Part No. Req. Req. Blwr Mtr & Fan Wheel Assy See Chart 1-1/2" Nipple, 9-1/2" Lg. 056540 Brnr Tube &...
Page 11 BURNER & BLOWER ARRANGEMENT (098131) SERIES 240 50 & 60 HP #5 OIL D20-5023 When drawing or part number lists more than one item, specify item desired and electrical characteristics...
Page 12 BURNER & BLOWER ARRANGEMENT (098131) SERIES 240 50 & 60 HP #5 OIL D20-5023 PARTS LIST Part Part Name Part No. Part Part Name Part No. Req. Req. Blwr Mtr & Fan Wheel Assy N-95605C #10 Lockwasher 050573 Brnr Tube & Mntng Plate Assy N-98137C _”...
Page 13 BURNER & BLOWER ARRANGEMENT (098132) SERIES 240 50 & 60 HP COMBINATION N5 D20-5023 When drawing or part number lists more than one item, specify item desired and electrical characteristics...
Page 14 BURNER & BLOWER ARRANGEMENT (098132) SERIES 240 50 & 60 HP COMBINATION N5 D20-5023 PARTS LIST Part No Part Name Part No. Part Part Name Part No. Req. Req. Blwr Mtr & Fan Wheel Assy N-95605C _” IPS Short Nipple 051008 Brnr Tube &...
Page 15 BURNER & BLOWER ARRANGEMENT (095606) SERIES 548 60THRU 80 HP #5 & #6 OIL D20-5023 When drawing or part number lists more than one item, specify item desired and electrical characteristics...
Page 16 BURNER & BLOWER ARRANGEMENT (095606) SERIES 548 60 THRU 80 HP #5 & #6 OIL D20-5023 PARTS LIST Part Part Name Part No. Part Part Name Part No. Req. Req. Blwr Mtr & Fan Wheel Assy N-95605C #10 Lockwasher 050573 Brnr Tube &...
Page 17 BURNER & BLOWER ARRANGEMENT (095607) SERIES 548 60 THRU 80 HP COMBINATION N5 & N6 D20-5023 When drawing or part number lists more than one item, specify item desired and electrical characteristics...
Page 18 BURNER & BLOWER ARRANGEMENT (095607) SERIES 548 60 THRU 80 HP COMBINATION N5 & N6 D20-5023 PARTS LIST Part Part Name Part No. Part Part Name Part No. Req. Req. Blwr Mtr & Fan Wheel Assy N-95605C 1/2" 13NC2 x 1-1/2 Sq. Hd. Cone 101229 Pt.
Page 19 PARTS REFERENCE DRAWING (198489 60 Hz) (200065 50 Hz) FOR FV-40 #5 OIL BURNER (AIR ATOMIZATION)
Page 20 PARTS LIST FOR FV-40 #5 OIL BURNER (198489 60 Hz) (200065 50 Hz) (AIR ATOMIZATION) Ref. No. No. Req’d Part Name Part No. Burner Tube Assembly 157348 Gasket 157410 Inner Tube Extension Assembly 198492 Nut, Hex, _” 13 NC 053689 Washer, Lock, Internal/External Tooth Assembly 108170 Damper Blower Motor Assembly –...
Page 21 PARTS REFERENCE DRAWING (198491 60 Hz) (200067 50 Hz) FOR FV-40 #6 OIL BURNER (AIR ATOMIZATION)
Page 22 PARTS LIST FOR FV-40 #6 OIL BURNER (198489 60 Hz) (200067 50 Hz) (AIR ATOMIZATION) Ref. No. No. Req’d Part Name Part No. Burner Tube Assembly 157348 Gasket – Burner Tube to Inner Tube Extension 157410 Inner Tube Extension Assembly 198492 Nut, Hex, _”...
Page 23 PARTS REFERENCE DRAWING (198488 60 Hz) (200064 50 Hz) FOR FV-40 GAS/#5 OIL BURNER (AIR ATOMIZATION)
Page 24 PARTS LIST FOR FV-40 GAS/#5 OIL (198488 60 Hz) (200064 50 Hz) (AIR ATOMIZATION) Ref. No. No. Req’d Part Name Part No. Burner Tube Assembly 157348 Gasket 157410 Inner Tube Extension Assembly 198492 Nut, Hex, _” 13 NC 053689 Washer, Lock, Internal/External Tooth Assembly, 1/2" 108170 Damper Blower Motor Assembly –...
Page 25 PARTS REFERENCE DRAWING (198490 60 Hz) (200066 50 Hz) FOR FV-40 GAS/#6 OIL BURNER (AIR ATOMIZATION)
Page 26 PARTS LIST FOR FV-40 GAS/#6 OIL BURNER (198490 60 Hz) (200066 50 Hz) (AIR ATOMIZATION) Ref. No. No. Req’d Part Name Part No. Burner Tube Assembly 157348 Gasket 157410 Inner Tube Extension Assembly 198492 Nut, Hex, _” x 13 NC 053689 Washer, Lock, Internal/External Tooth Assembly, 1/2"...
Page 27 DAMPER – BLOWER – MOTOR ASSEMBLY (200060 60Hz) Ref. Part Name Part No. Reqd. Air Damper Assembly 198505 Nut, Hex., 1/4" 20NC2 058567 Washer, Lock, Internal/External Tooth 1/4" 108169 Blower Housing Assembly 198499 Motor Housing Plate 096126 Lock, Washer, Internal/External Tooth, 3/8" 057432 Screw, Cap.
Page 28 DAMPER – BLOWER – MOTOR ASSEMBLY (200061 50Hz) Ref. Part Name Part No. Rqd. Air Damper Assembly 198772 Nut, Hex., 1/4" 20NC2 058567 Washer, Lock, Internal/External Tooth 1/4" 108169 Blower Housing Assembly 198767 Motor Mounting Plate 191657 Lock, Washer, Internal/External Tooth, 3/8" 057432 Screw, Cap.
Page 29 BURNER ADAPTER (154894) Ref. Reqd. Part Name Part No. Plate & Tube Weldment 154893 290# Refractory, Hydrecon 3000 109505 Insulation Block 202163...
Page 30 BURNER ADAPTER (159474) Ref. Part Name Part No. Reqd. Plate & Tube Weldment 159471 100# Refractory, Hydrecon 3000 109505...
Page 31 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 32 BURNER MOUNTING TUBE & BURNER PLATE ASSEMBLY (95268) #5 & #6 OIL – N5 & N6 Part Part Name Part No. Part Part Name Part No. Req. Req. Burner Mtg. Plate Assembly N91324A 5/16” 18 NC2 x _” Lg Hex Hd Bolt 050600 5/16”...
Page 33 BURNER MOUNTING TUBE & BURNER PLATE ASSEMBLY (95269) #5 & #6 OIL – N5 & N6 COMBINATION Part Part Name Part No. Part Part Name Part No. Req. Req. Burner Mtg. Plate Assembly N95271A Gasket – Blower Housing Pl. N43931B 5/16”...
Page 34 BURNER MOUNTING TUBE & BURNER PLATE ASSEMBLY (95663) #5 & #6 OIL – N5 & N6 Part Part Name Part No. Part Part Name Part No. Req. Req. 5/16” 18 NC2 x 1-_” Lg Hex Hd Bolt Burner Plate & Tube Assembly N96160A 051456 5/16”...
Page 35 BURNER MOUNTING TUBE & BURNER PLATE ASSEMBLY (99430) #5 & #6 OIL – N5 & N6 Part Part Name Part No. Part Part Name Part No. Req. Req. Burner Plate & Tube Assembly N96160A 5/16” 18 NC2 x2-1/4” Lg Hex Hd 058710 Bolt Air Cone Refractory (4 pcs)
Page 36 BURNER TUBE & MOUNTING PLATE ASSEMBLY (130102) #5 & #6 OIL - N5 & N6 Part Part Name Part No. Part Part Name Part No. Req. Req. Burner Plate & Tube Assembly N96160A 5/16” 18 NC2 x 1-_” Lg Hex Hd Bolt 051456 5/16”...
Page 37 BURNER MOUNTING TUBE & BURNER PLATE ASSEMBLY (098137) #5 OIL - GAS COMBINATION Part Part Name Part No. Part Part Name Part No. Req. Req. Burner Mtg. Plate Assembly N98136A Gasket Blower Housing Plate N43930B Burner Mtg. Plate Refractory N84054B 5/16”...
Page 38 BURNER TUBE & MOUNTING PLATE ASSEMBLY (095662) #5 & #6 OIL - N5 & N6 Part Part Name Part No. Part Part Name Part No. Req. Req. 5/16” 18 NC2 x 1_” Lg Hex Hd Bolt Burner Mtg. Tube & Windbox 95617A 051456 Assy...
Page 39 BLOWER & MOTOR SUB-ASSEMBLY (095188) #5 & #6 OIL - N5 & N6 Part No. No. Req. Part Name Dwg. or Part No. Blower Housing N43791C Motor Mounting Plate N43916A Motor - 1 HP 3450 RPM 3 Ph. Fr. J56C 061213 3/8"...
Page 40 NOZZLE & ELECTRODE ASSEMBLY (090436) SERIES 542 40 THRU 60 HP #5, #6, N5 & N6 Part No. No. Req. Part Name Part No. Nozzle Pipe & Electrode Holder 090365 Electrode Assembly 072970 Clamp Sleeve 027282 3/8" IPS Pipe Nipple, 3" Lg. 051109 1/2"...
Page 41 NOZZLE & ELECTRODE ASSEMBLY (099789) SERIES 240 50 HP #5 & N5 Part No. No. Req. Part Name Part No. Nozzle Pipe & Electrode Holder N90365C Electrode Assembly N72970B Clamp Sleeve DBS27282 3/8" IPS Pipe Nipple, 4-1/2" Lg. T.O.E. 051687 3/8"x _”...
Page 42 NOZZLE & ELECTRODE ASSEMBLY (122449) SERIES 240 60 HP SERIES 548 60 THRU 80 HP #5, #6, N5 & N6 Part No. No. Req. Part Name Part No. Nozzle Pipe & Electrode Holder N124360C Electrode Assembly N72970B Clamp Sleeve D27282A 3/8"...
Page 43 NOZZLE & ELECTRODE ASSEMBLY (090434) SERIES 548 100 O.S. HP SERIES 560 100 HP #5, #6, N5 & N6 Part No. No. Req. Part Name Part No. Nozzle Pipe & Electrode Holder N124360C Electrode Assembly N72970B Clamp Sleeve D27282A 3/8" IPS Pipe Nipple x 4-1/2" Lg. T.O.E. 051687 3/8"x 90 Elbow...
Page 44 NOZZLE PIPE ASSEMBLY (198529) Ref. No. No Rqd. Part Name Part No. Nozzle, Monarch C-206-A3-A4 069893 Nozzle & Pipe Support 201787 Nipple, Black 1/4" IPS x 35" Lg. 157608 Nipple, Black 1/4" IPS x 36-1/2" Lg. 157607 Valve, Swing Check, 3/8" IPS 058898 Elbow 90 , 1/4"...
Page 45 IGNITOR DRAWER ASSEMBLY (198509) FOR FV-40 BURNER Ref. No. No Rqd. Part Name Part No. Burner Head Assembly 198510 Connector, 3/8" x 1/2" SAE 051550 Elbow, Reducing, 1/4" x 3/8" 90 051754 Screw, Stainless Steel, #10 x 1" 109408 Nut, Hex., #10 054174 Nipple, 1/4"...
Page 46 COMPRESSOR ARRANGEMENT (095124) SERIES 240, 542 & 560 100 HP HEAVY OIL & GAS - HEAVY OIL COMBINATION Part No No. Req. Part Name Part No. Part No No. Req. Part Name Part No. Air Compressor, Gast 1065 068272 Screw, Cap, Hex Hd., 3/8" 16NC-2 x 057400 1"...
Page 47 COMPRESSOR ARRANGEMENT (110548) SERIES 560 125 & 150 HP HEAVY OIL & GAS - HEAVY OIL COMBINATION Part No No. Req. Part Name Part No. Part No No. Req. Part Name Part No. Air Compressor, Gast 1065 068269 Screw, Cap, Hex Hd., 3/8" 16NC-2 x 057400 1"...
Page 48 COMPRESSOR & ELECTRIC HEATER ASSEMBLY (099686) Ref. No. No Rqd. Part Name Part No. Air Compressor, Gast #1065 068272 Motor, 1 HP, Frame #143T 104360 Motor Starter, Furnas #16BE32AF 108031 Mounting Base Assembly 093693 Belt Guard 161317 Air Filter Assembly 087879 Motor Sheave, 4.3-5.3, 1A x 7/8"...
Page 49 COMPRESSOR & ELECTRIC HEATER ASSEMBLY (099688) Ref. No. No Rqd. Part Name Part No. Air Compressor, Gast #1065 068272 Motor, 1 HP, Frame #143T 104360 Motor Starter, Furnas #16BE32AF 108031 Mounting Base Assembly 093693 Belt Guard 161317 Air Filter Assembly 087879 Motor Sheave, 4.3-5.3, 1A x 7/8"...
Page 50 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. Protect the pump against the entrance of dirt, lubricate it, and it will provide years of trouble-free service.
Page 51 1065-P-22-H AIR COMPRESSOR Dwg. No. Part No. Part Name Mat. No. 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...
Page 52 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 53 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 54 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 55 2065-P-16B AIR COMPRESSOR Dwg. No. Part No. Part Name Mat. No. 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...
Page 56 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 same. Remember there is only .002 of an inch between top of rotor and body bore.
Page 57 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 58 OIL PUMP SET ARRANGEMENT (097450) SERIES 542 40 THRU 60 HP SERIES 240 50 HP SERIES 548 60 THRU 80 HP #5 & N5 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 154259 Motor Adjusting Rail Assy 125684 Motor 1/4 HP 1725 RPM #48 Fr., 3 Phase...
Page 59 OIL PUMP SET ARRANGEMENT (097835) SERIES 548 100 O.S. HP SERIES 560 100 THRU 150 O.S. HP #5 & N5 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 154259 Motor Adjusting Rail Assy 125684 Motor 1/2 HP 1800 RPM #56 Fr., 3 Phase 052378...
Page 60 OIL PUMP SET ARRANGEMENT (097452) SERIES 542 40 THRU 60 HP SERIES 548 60 THRU 80 HP #6 & N6 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 154259 Motor Adjusting Rail Assy 125684 Motor 1/4 HP 1800 RPM #48 Fr., 3 Phase 052380...
Page 61 OIL PUMP SET ARRANGEMENT (097836) SERIES 548 100 O.S. SERIES 560 100 THRU 150 O.S. HP #6 & N6 THREE PHASE MOTOR Ref. No. No Rqd. Part Name Part No. Pump & Motor Base 154259 Motor Adjusting Rail Assy 125684 Motor 1/2 HP 1800 RPM #56 Fr., 3 Phase 052378 Pump, Tuthill #2CGx737 Style A...
Page 62 GENERAL ASSEMBLY OF OIL PUMP (AIR ATOMIZATION)
Page 63 (AIR ATOMIZATION) Pump Size Stamp Tag Tag No. #825 #825 #825 Pump Size 3-7/32 3-1/8 3-1/2 3-1/2 6-11/16 25/64 21/32 1-1/2 #606 6-5/8 4-1/8 3-7/8 8-3/4 29/64 21/32 1-31/32 #606 6-1/2 4-1/8 3-7/8 29/64 21/32 2-5/16 #606 Pump Size 1-1/4 1-15/16 7-9/16 2-15/16...
Page 64 OIL METERING ARRANGEMENT (191884) Ref. No. No Rqd. Part Name Part No. Fitting, 90 , 1/4" IPS x 3/8" SAE 051543 Tailpiece Valve Assembly 007464 Valve Body 070133 Hi-Lo Metering Valve 007510 Nipple, Short, 1/2" IPS 051008 Valve, Oil, Solenoid K10AB281 050657 Elbow 90 , 1/2"...
Page 65 PARTS REFERENCE DRAWING (198534) FOR FV-40 #6 OIL METERING ARRANGEMENT...
Page 66 PARTS LIST FOR FV-40 #6 OIL METERING ARRANGEMENT (198534) Ref. No. No Rqd. Part Name Part No. Viscosity Compensator Assembly 112988 Nipple, _” x 3-1/2” Lg. 050776 Tee, _” IPS 051092 Nipple, Close, _” IPS 050650 Temperature Gauge 60 -260 , 3-1/2”, Fig.
Page 67 STEAM HEATER ARRANGEMENT (095603) USED ON SPH BOILERS ONLY SERIES 542 40 HP SERIES 548 60 HP #6 & N6 Ref. No. No Rqd. Part Name Part No. 1” IPS Short Nipple 051142 _” IPS x _” SAE x 90 Male Connector 051783 _”...
Page 68 STEAM HEATER ARRANGEMENT (095602) USED ON SPH BOILERS ONLY SERIES 542 50 & 60 HP SERIES 548 70 THRU 100 O.S. HP SERIES 560 100 HP #6 & N6 Ref. No. No Rqd. Part Name Part No. 1” IPS Short Nipple 051142 _”...
Page 69 STEAM HEATER ARRANGEMENT (095604) USED ON SPH BOILERS ONLY SERIES 560 125 & 150 HP #6 & N6 Ref. No. No Rqd. Part Name Part No. 1” IPS Short Nipple 051142 _” IPS x _” SAE x 90 Male Connector 051783 _”...
Page 70 HOT WATER HEATER ARRANGEMENT (095275) USED ON SPL & SPW BOILERS ONLY SERIES 542 40 HP SERIES 548 60 HP #6 & N6 Part No No. Req. Part Name Part No. Part No No. Req. Part Name Part No. IPS E.H. Whole Coupling 051114 3/8"...
Page 71 HOT WATER HEATER ARRANGEMENT (095273) USED ON SPL & SPW BOILERS ONLY SERIES 542 50 & 60 HP SERIES 548 70 TO 100 O.S. HP SERIES 560 100 HP #6 & N6 Part No Part Name Part No. Part Part Name Part No.
Page 72 HOT WATER HEATER ARRANGEMENT (095276) USED ON SPL & SPW BOILERS ONLY SERIES 560 125, 150 & 150 O.S. HP #6 & N6 Part No Part Name Part No. Part Part Name Part Req. Req. IPS E.H. Whole Coupling 051114 3/8"...
Page 73 ELECTRIC HEATER ARRANGEMENT (095641) ELECTRIC HEATER ARRANGEMENT (095642) SPL-SPH SERIES 542 45 THRU 60 HP (#6 & N6) SPL-SPH SERIES 542 40 HP (#6 & N6) SPL-SPH SERIES 548 60 HP (#6 & N6) SPL-SPH-SPW SERIES 542 40 THRU 60 HP (#5 & SPL-SPH-SPW SERIES 548 70 THRU 100 O.S.
Page 74 ELECTRIC HEATER ARRANGEMENT (095639) SERIES 548 100 O.S. HP (#6 & N6) SERIES 560 100 & 125 HP (#6 & N6) ELECTRIC HEATER ARRANGEMENT (095640) SERIES 560 150 HP (#6 & N6) Part No No. Req. Part Name Part No. Part No No.
Page 75 SIZING GAS HEADER FROM METER TO BOILER Fig. 1 Size, Series Max. Firing Required Pressure at Unit** & HP Rate C.F.H.* STD. 542 - 40 1675 5.0" W.C. 5.0" W.C. 6.0" W.C. 542 - 45 1885 6.0" W.C. 6.0" W.C. 7.0"...
Page 76 GAS PILOT TRAIN ASSEMBLY (191851) Ref. No. No Rqd. Part Name Part No. Tee, 3/8” 051703 Plug, 3/8” IPS 064486 Connector, Straight, _” SAE x 3/8” IPS 051609 Nipple, 3/8” IPS x 1” Lg. 050799 Valve, Gas, 3/8” IPS 106847 Nipple, 3/8”...
Page 77 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 26.0 31.0 10.0 12.0 15.0 Globe Valve 27.0 40.0 43.0 45.0 65.0...
Page 78 Sizing Gas Header From Meter to Boiler 24 through 150 HP 500 Series 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 79 Sizing Gas Header From Meter to Boiler Sample Problem What size gas header should be run to handle two 150 HP hot water boilers and a single 50 HP high pressure steam boiler? The boilers are to be furnished to meet FM requirements. The gas is natural, .6 Sp.G and 1000 BTU/cu.ft.
Page 80 Step #7A The new pressure drop available in the header per 100 ft. of pipe is now 3.4" WC (Step #4) divided by 3.175 (Step #6A) = 1.07 "WC/100 ft. Step #8A Referring to Fig. 3 and locating the intersection of 14,259 CFH (Step #1) and 1.07" WC/100 ft.
Page 81 Gas Pressure Regulator Requirements For 40 through 150 HP Series Units (Chart is for Natural Gas .55 to .65 SpG. Only) 13.9" WC = 8 oz. = .5 psi UL Standard & FM Approval FIA Approval Boiler Size CFH Firing Press Req'd Reg.
Page 82 SUGGESTED GAS PIPING...
Page 83 SUGGESTED GAS PIPING...
Page 84 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 85 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 86 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 87 500 SERIES #4 & #5 COLD FUEL OIL SYSTEM SINGLE OR DUPLEX...
Page 88 Metering Assembly for #4 & #5 Oil Electric Fuel Oil Heater (Mounted on Unit Only) #4 & #5 Oil Electric Heater Capacity #4 & #5 Oil Size Unit HP SPL-SPH-SPW 40 & 45 1000 watts 50 thru 80 2000 watts 100 &...
Page 89 Fuel Oil Tank Piping For #4 & #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 90 Fuel Oil Pump Assembly for #4 & #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 91 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 92 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 93 tank heater to maintain 140 F. at the suction connection on the pump when the unit is not firing, i.e. this amount of heated oil compensates for the heat loss from the piping. b) In the “on fire” condition, the heated oil from the electric heater passes through the nozzle strainer.
Page 94 500 Series #6 Fuel Oil System Simplex or Duplex...
Page 95 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 96 Steam Fuel Oil Heater - Mounted on Unit Only #6 or Hot #5 Oil SPH Units...
Page 97 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 98 Below the Waterline Fuel Oil Heater – Mounted on Unit Only #6 or Hot #5 Oil, SPL or SPW Units...
Page 99 #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 .
Page 100 FUEL OIL PUMP - MOUNTED ON UNIT #6 OIL WITH CONTINUOUS OIL CIRCULATION...
Page 101 #6 OIL VISCOSITY METERING ASSEMBLY...
Page 102 DETAIL OF INSULATING & WRAPPING TANK HEATER...
Page 103 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 104 Auxiliary Heat for Starting #6 Oil Units...
Page 105 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" 10'-11" 10'-6" 10'-10" 10'-7-3/4" 10'-4" 11'-5"...
Page 106 500 SERIES FUEL OIL SYSTEM FOR MULTIPLE UNITS WITH COMMON PUMP #6 OIL & HOT #5 OIL...
Page 107 Pipe Size Chart Heated #5 Oil - #6 Oil 1 Unit 2 Units 3 Units 4 Units 1-1/2" A. Return from Burner B. Supply to Burner 1-1/2" 2" 2" 2" 2" C. Pump Discharge D. Pump Discharge to Burner 2" 2"...
Page 108 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 40 through 150 2" IPS 2" IPS Required Individual Suction & Return Pipe Line Size Fig.
Page 109 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 110 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 111 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 112 The table shows that the lower the API the greater the heat content of the fuel, and the higher the density the greater the heat content. The values shown are for pure hydrocarbons. If substantial amounts of sulfur, water or sediment are present, corrections should be made.
Page 113 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 114 BLENDING OF FUELS Blending of #6 and #2 fuels to make a #4 and #5 fuel must be done under certain conditions to be effective and lasting. If improperly done, the blending may not be permanent and the two components may stratify.
Page 115 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 116 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 117 from the superheater tubes and hangers, indicates that the entire mass had been in a molten state and flowed like lava. It is, of course, in the molten state that V causes corrosive attacks by fluxing with the protective oxide layer on the steel. In this state it also soaks into porous refractory, causing extensive damage.
Page 118 Flash and fire points depend on the nature of the original crude oil, the viscosity, and the method of refining. For the same viscosities and degree of refinement, the paraffinic oils are higher than the napthenic flash and fire points. The flash point of an oil is important with regard to safety in handling and storage.
Page 119 FUEL OIL PROPERTIES VERSUS REFINERY LOCATION As mentioned previously, the properties of the fuels will vary according to the refinery location. Tables 9, 10, 11, and 12 represent an actual check of a major fuel oil supplier. Note that while the ash remains fairly constant in all four refineries, the sulfur and vanadium pentoxide vary widely.
Page 120 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 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 3.35...
Page 121 TABLE 11 REFINERY C – MIDWEST #6 FUEL OIL PROPERTIES Gravity: 12.3 12.0 11.7 11.4 11.7 12.3 12.6 11.5 11.7 11.8 Viscosity, Furol 125.7 141.3 150.2 155.4 149.1 102.9 93.4 134.4 137.0 103.6 Flash, P-M: Pour: Sulfur, B; % 0.82 0.89 0.82 0.83...
Page 122 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 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 0.94...
Page 123 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 124 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 125 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. 6. Baldor Motors: a.
Page 126 STARTING INSTRUCTIONS FOR SERIES 500 BOILERS SERIES 500 BOILERS SPV – SPL – SPW 30 THROUGH 150 HP HEAVY OIL & HEAVY OIL/GAS COMBINATION NOTE: For use with standard controls only as follows: Fuel Boiler Horsepower Controls Used* #5 Oil 30 thru 150 D20-5023 #6 Oil...
Page 127 TRIAL FOR IGNITION After proper pre-purging, proving of the 3 to P circuit and proved closing of the low-fire start end switch the Flame Safeguard Control will proceed to the TFI (Trial For Ignition) position. The TFI indicator (LED) lights and the pilot valve and ignition transformer are powered. NOTE: If the low-fire start switch does not close electrically after pre-purge the control will not move on to the TFI mode, the blower motor will continue to operate.
Page 128 HEAVY OIL PUMP SET On #6 oil units, the pump set should run continuously when operating an when on standby. On #6 oil units, the below-water-line-heater circulator should run continuously when operating and when on standby. 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.
Page 129 a) When motors are of the 3-phase type and operating in the wrong rotation, this rotation can be reversed by interchanging any two of the main feed lines to the motor starter. b) When motors are of the single-phase 110V or 220V type, a wiring change will have to be made internally at the motor junction box.
Page 130 good reading had been obtained, open burner control switch and place the "test-run" switch in the run position. The D20-5023 or D10-5022 should now function as described earlier. When first establishing main flame, hold modulation motor in the low fire position. After establishing a good low main flame, reconnect modulation circuit to allow unit to go to high fire to check combustion at high fire.
Page 131 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" & "B", disconnect linkage to valve "C". Line the drilled hole in stem of valve "C"...
Page 132 setting is satisfied. Post purge will occur after this point. While firing at low fire, the nozzle solenoid valves are open, the by-pass solenoid valve “B” is open, allowing oil to pass over temperature gauge through valve “C” to the nozzle solenoids, also some oil passes back through valve “A”...
Page 133 b) Open suction and return shut-off valve to fuel oil tank. Fill oiler on air compressor with proper oil. (See detailed instructions on compressor lubrication.) c) Start fuel pump by setting fuel valve switch on the OFF position. This will also start the blower and compressor.
Page 134 combustion record for results. Set modutrol motor switch on open (high-fire-hold). Motor arm will modulate to high fire flame. Check high fire combustion and record the results. If high and low fire are proper, set CO low to high fire; on oil 9 to 12%. When operating on high- fire, start closing high-fire valve until a slight pressure occurs on nozzle oil pressure gauge.
Page 135 RELIEF VALVE OPENING TEST While unit is in operation, increase the water pressure to exceed the setting marked on the body of the relief valve (30 psi). The opening point of the relief valve must not exceed the 30 psi setting. However the relief valve may open at 28 psi.

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