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Summary of Contents for York-Shipley 4 Series
- Page 1 4 Series Packaged Firetube Boilers Installation, Operation and Maintenance Manual 25-850 Horse Power Light Oil, Heavy Oil, Gas and Combination Wetback and Dryback Designs Power Mechanical, Inc. ID O&M 400-B R3/09 All Rights Reserved...
- Page 3 To: Owners, Operators and Maintenance Personnel This operation and maintenance manual presents information to properly install, operate, and care for the York-Shipley Global 400 Series Boilers. Study its contents in its entirety. The York-Shipley Global Boiler will provide efficient, continued reliability, if properly operated and maintained.
- Page 4 The water side condition of the boiler is of extreme importance. The absence of water treatment, or improper water treatment, will result in serious damage to the boiler and/or related boiler room equipment, which is not covered by York-Shipley Global’s Standard Limited Warranty, or any other warranty or guarantee. Waterside surfaces must be frequently inspected for the presence of mud, sludge, scale and corrosion.
- Page 5 400 Series O&M Manual C A U T I O N This product may utilize combustible fuel(s) and may utilize, or generate, hot water and/or steam elevated temperatures above atmospheric pressure (14.7 PSIA/101.32KPa). Installers and operators of this equipment, as well as maintenance personnel should be properly trained and are cautioned that improper or careless actions may result in a hazardous condition and/or personal injury.
- Page 6 These Data Sheets present detailed warnings on the hazards from materials used in the manufacture of boilers. They also present recommendations on the special precautions required to avoid health and safety risks. York-Shipley Global Division of Power Mechanical, Inc. 4811 Commerce Drive...
- Page 7 400 Series O&M MANUAL TABLE OF CONTENTS Paragraph Page Preface ....................Table of Contents ................... Section I General Description 1-1. Purpose ..................1-1 1-2. Arrangement ................1-1 1-3. General Description ..............1-2 1-4. The Boiler ..................1-2 1-5. Description of Boiler Components ..........1-3 1-6.
- Page 8 400 Series O&M MANUAL TABLE OF CONTENTS Section III Installation and Arrangement (Continued) Section III Part 1- High & Low Pressure Steam Boilers Series 482, 488, 496 and 4112 3-14. Boiler Room Arrangement ............3-33 3-15. Boiler Dimensions ............... 3-34 3-16.
- Page 9 400 Series O&M MANUAL TABLE OF CONTENTS Section III General Installation and Arrangement Information Section III Part 3 - Hot Water & Steam Boilers 3-36. Electrical Service and Wiring ............3-69 3-37. Fuel Connections ................ 3-70 3-38. Oil Tanks ..................3-72 3-39.
- Page 10 400 Series O&M MANUAL TABLE OF CONTENTS Section V (Continued) Startup, Adjustment and Operating Procedures 5-10. Gas-Fired Testing ................ 5-11 5-11. Combustion Efficiency ..............5-11 5-12. Routine Boiler Operation ............. 5-12 5-13. Boiler Start-up ................5-12 5-14. Boiler Support Systems Start-up ..........5-12 5-15.
- Page 11 400 Series O&M MANUAL TABLE OF CONTENTS Appendixes Periodic Testing of Controls and Safety Devices ..... Appendix-A Boiler Service School ............Appendix-B Material Safety Data Sheets (MSDS) ......Appendix-C Steel Mill Products ..............Metallic Coated Steel Products ........... C-13 Fiberfrax Rope ................C-23 Rubberized Fiberglass Cloth ............
- Page 13 SECTION I - GENERAL DESCRIPTION Section I Introduction & General Description 1-1. Purpose This technical manual provides the necessary information to install, start-up, operate, service, store and maintain the York Shipley Global 400 Series Packaged Firetube Boilers manufactured by Power Mechanical, Inc. Throughout this manual the York Shipley Global 400 Series Boiler will be referred to as the 400 Series Boiler, the packaged boiler, or more simply the boiler.
- Page 14 SECTION I - GENERAL DESCRIPTION 1-3. General Description The information in this manual is directly applicable to the York Shipley Global 400 Series Hot Water, High Pressure & Low Pressure Steam Boilers with the following Model Series from 30 HP to 1300 HP. 442, 448, 460, 464, 476, 482, 488, 496 and 4112.
- Page 15 SECTION I - GENERAL DESCRIPTION which holds the firing tube and convective tubes. The turning box areas are located outside the tube sheet on both ends. The burner supplies the fuel and combustion air to the firing tube in a state that is prepared to combust and begin the generation of steam or hot water.
- Page 16 SECTION I - GENERAL DESCRIPTION Figure 1-1a. Dual Fuel Firetube Steam Boiler Basic Components Side View (Reference Table 1-1. and Table 1-2.) 1 - 5...
- Page 17 SECTION I - GENERAL DESCRIPTION Figure 1-1b. Dual Fuel Firetube Steam Boiler Basic Components Front View (Reference Table 1-1. and Table 1-2.) 1 - 6...
- Page 18 SECTION I - GENERAL DESCRIPTION Figure 1-1c. Dual Fuel Firetube Hot Water Boiler Basic Components (Reference Table 1-1. and Table 1-2.) 1 - 7...
- Page 19 SECTION I - GENERAL DESCRIPTION 1-5. Description of Boiler Components Proper operation of the boiler requires that the operator understand the interface and operation of each of the components. Efficient control of the boiler is only possible when the operator understands the function and operation of each of the major components of the boiler systems.
- Page 20 SECTION I - GENERAL DESCRIPTION Table 1-2. List of Basic Firetube Boiler Components COMPONENT DESCRIPTION The Gas Flow Control Valve regulates the flow rate of natural gas to the burner. The power output of the boiler is controlled in this fashion. The Gas Flow Control Valve Gas Flow position is controlled by a Modulating Motor and operates Control Valve...
- Page 21 SECTION I - GENERAL DESCRIPTION Table 1-2. List of Basic Firetube Boiler Components COMPONENT DESCRIPTION The Ignition System Transformer steps up the voltage Ignition System to supply the high voltage necessary for spark ignition. Transformer Should the gas main pressure change dramatically the operator may need to adjust the gas pressure regulator.
- Page 22 SECTION I - GENERAL DESCRIPTION Table 1-2. List of Firetube Boiler Basic Components COMPONENT DESCRIPTION The Pump Control and Low Water Cutoff responds to the level of boiler water. Typically, this control is float operated. It performs two distinct functions: The first is Pump Control to stop the firing of the boiler when the boiler water is below the safe operating level, the second is to control...
- Page 23 SECTION I - GENERAL DESCRIPTION 1-6. Warning and Caution Label Identification Read and understand each label placed on the boiler and boiler room equipment. 1-7. DEFINITION OF DANGER, WARNING AND CAUTION DANGER used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.
- Page 24 SECTION I - GENERAL DESCRIPTION Label 1. Newport News, VA 23607 USA Telephone: 855-211-YORK (9675) FAX: 800-317-3901 116720 Label 2. NAT'l BD NO CERTIFIED BY MAX WORKING PRESSURE STEAM HEATING SURFACE SERIAL NO YEAR SHIPPED TYPE OF CONST MAX STEAM CAP INS CO SER NO MOTOR -----VOLTS FIRING RATE...
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Page 25: Electrical Data
SECTION I - GENERAL DESCRIPTION Label 3. Fuse Component Data Volts Amps Phase Freq Ampacity Amps 1. Blower Motor 2. Fuel Pump Mtr 3. Com'pr Motor 4. Elec Htr #1 5. Elec Htr #2 6. Elec Htr #3 7. Control Circuit Min Circ Max Fuse Total... - Page 26 SECTION I - GENERAL DESCRIPTION Label 4. IMPORTANT In order to insure the maximum life of your boiler, it is essential that proper boiler water treatment be used. If this is not done, it is almost certain that scale, pitting and other effects of untreated water, on the internal surfaces of the boiler, will cause damage to the boiler.
- Page 27 SECTION I - GENERAL DESCRIPTION Label 5. MFD BY York - Shipley Global Newport News, VA SIZE SERIAL NO TYPE MTR HP VOLTS PHASE CYCLE BURNER MTR CURRENT AMPS HEATER CURRENT AMPS CONTROL CURRENT AMPS FIRING RATE BTUH FIRING RATE MAX LOW FIRE MP-1445 UNDERWRITERS...
- Page 28 SECTION I - GENERAL DESCRIPTION Label 7. MP-1445 UNDERWRITERS LABORATORIES INC ® OIL-FIRED BOILER ASSEMBLY ___________________ ______ INTEGRAL GROUP FOR USE WITH PRIMARY SAFETY CONTROLS OIL NOT HEAVIER THAN NO. ___ Label 8. WARNING Allow the boiler to cool before opening any access ways. Whenever the rear door, manway, hand holes, etc.
- Page 29 SECTION I - GENERAL DESCRIPTION Label 9. PROBE L.W.C.O. RELAY RELAY MUST BE RESET AFTER LOW WATER CONDITION OR POWER FAILURE. RESET BUTTON UNDER COVER. N-149014-A Label 10. CAUTION REPLACE OIL EVERY 3 MONTHS. USE COMPRESSOR LUBRICATING OIL IN FILTER. FILL TO BEAD BELOW 87342 Label 11.
- Page 30 SECTION I - GENERAL DESCRIPTION Label 12. WARNING When Lifting, Use a Spreader Bar to Prevent Damage to the Boiler SPREADER BAR Label 13. IMPORTANT Be sure to flush your boiler water level control DAILY while boiler is in operation. Failure to follow this procedure can cause the control to malfunction resulting in serious boiler damage.
- Page 31 SECTION I - GENERAL DESCRIPTION Label 14. Remove this Block and Install Pipe Plug before Starting this Unit PART NO. 710651 Label 15. REMOVE COVER AND REMOVE PAPER BLOCKING AROUND MERCURY SWITCHES. PART NO. 710652 Label 16. WARNING This pump should be used with two pipe system only. It is specifically designed and built to eliminate air from nozzle pipe and minimize after drip.
- Page 32 SECTION I - GENERAL DESCRIPTION Label 17. WARNING AVOID THERMAL SHOCK Rapid replacement of your boiler's hot water with return water at a temperature below the boiler manufacture's recommendations can cause serious damage to your boiler. DO NOT ALLOW THIS TO HAPPEN. Do not fire the burner until after water flow has been established in all zones and through the boiler.
- Page 33 SECTION I - GENERAL DESCRIPTION THIS PAGE LEFT BLANK INTENTIONALLY 1 - 22...
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