Universal Boiler Works BF100W4 Operating manual

Operating and
Maintenance Manual
U-I 5647
Pf~er
BF100W4
Water; ASME Section 4
Ship Date: 1/24/2000
UNIVERSAL BOILER WORKS, INC.
1207 S.E. SECOND STREET - GALVA, IL 61434
T: [phone] F : [phone]
ubwl @inw.net - www.universalboiler.com

1207 S.E. Second St.
Tel: [phone]
Galva,lllimis61434 Fax: [phone]
www.unidtmk.~
OPERATING AND MAINTENANCE
INFORMATION
BOILER MODEL #:
UNIVERSAL ORDER #:
,!WlER SERIAL #:
BURNER MODEL #:
W.O. I INVOICE #:

CHAPTER I
GENERAL DESCRIPTION
MODEL BF HOT WATER BOILER
A. The Boiler
The Universal Boiler Works, Inc, (UBW) Model
BF, is a 5 pass steel wa&tube boiler of the "0"
type design. It consists of the upper and lower
headers with interconnecting downcomer and
flexible tangent tubes, The tubes are
symmetrically installed to provide uniform gas
side and water side fluid flow.
A11 boiler tubes are a minimum of 1.5 inches:
meter, 0,095" wall through 700 horsepower
kid 2 in- diameter 0.105" wall for units
above 700 horsepower. Each tube is fitted with
a fed at each end, which is press fitbed into
each drum hole. This method of tube
attachment permits easy replamment of tubes
without the need for welding or ding. (See
Figure 1-1)
Multi-bend tangentially mmgd watertubes
form the combustion chamber (furnace) and
convection gas passes. Specific tube
arrangements and the front and rear walls
provide the means for gas flow direction
without the use of baffles. (See Figure 1-2)
In accordance with the ASME (American
Society of Mechanical Engineers) Code, the
boiler is designed, fabricated, tested, and
inspcted following the mtes of Section W for
(operating at less than 2500 F.)
I Power Boil= (operation at greater
'irran 2500 F. or above 1 60 psig), and stamped
accordingly. The location of the authorized "H"
or "S" stamp is located on the upper header near
the rear ofthe unit.
As a complete package, the pressure vesse1 is
mounted on a 4" high insdated base frame.
This base frame includes the lifting Iugs for
rigging purposes. Over 200 horsepower, the
base is 6").
A series of 11 gauge steel panels, which are
bolted md sealed, provide a gas tight inner
casing of up to 3" W.C. Attached to this inner
casing is a 2.0 inch thick fikrgiass insulation
blanket rated at 2,3000 F.
The outer casing is fabricated of 14 gauge
corrugated aluminized steel panels, underlayed
with 1P2" thick fiberglass blanket insulation. A
2 inch air space between the inner and outer
jackets provides additional cooling of the outer
surfaces of the boiler. (See Figure 1-3 and
Figure 14)
The combustion chamber floor is insulated with
ceramic fiberboard rated at 2,000O F and the
front and rear walls are poured refractory rated
at 2,8000 F, For Section 1 Boilers, the lower
drum is insulated with a 2,3000 F fiberglass
blanket.

Universal Boiler Works. tnc,
Chptcr I General Description of Hat Water Boiler
Please refer to Figure 1-5 for a visual
undcrstand~ng of the parts and connection points
that cornprlst the boiler. This will help in
understanding your unit before start-up and for
any questions that may arise, for which you
require answers. Refer to the Gend
Arrangement drawing fur specific connections
sizes and location dimensions. The General
Arrangement drawing will also depict optional
items that were added in accordance with the
project specifications.
C. Pressure Parts
The BF hot watcr baiIer has two (2) dmm or
headers, one uppw and onc Iowtr. The upper
dnun is supported by the rear down~~mcr, front
and rear walls, and steel structm. Tappings for
the water temperature sensing controls arc
Iocated at the front of the upper drum including
the tapping for the primary low water cutoff
control. At the rear of the upper dnun are the
tappings for the safety relief valves. The
conn&on of the bailer water supply to the
system is located at the kont of the upper dnun.
On the top centerline of the upper drum at the
front, is the vent connection. This should be
piped to the expansion tank.
The lower h, sometime refd to as the
mud drum contains the drain connection,
located at the rear bottom ctnbrlhe. A drain
valve should be instalIed to this connection by
the installing contractor ad piped to a safe
discharge point. -hD8~h&
NOTE: The Model BF hot water boiler does
not include
tappings for fresh water make-up,
Treated water make-up when needed, should be
added via the expansion tank, A tight hot water
system should have a minimal amount of make-
up and a water meter is recommended to
monitor the amount of water make-up.
The term wn~rr~ri covers the olectr icnl or electro.
- d
mechanical devices mounted on the boiler or
furnished loose For field installation. The*
devices work in harmony with the burner
controls, discussed in the bumer
operatinghaintenance manual. Turn refers to
mechanical items such as valves, pressure or
temperature indicating devices, and piped items
responding to the boiler's pressure or
temperature functions. Regardless of the
component, the authorized boiler operator must
b hiliar with all mounted and if furnishad,
*mote mounted items that will affect the
cpmtioa ofthe boiler.
Spceific controls fitrnishod for the project will
be denoted on the General hangement
drawing and on the Bill of Materids list.
PI- refer to Figure 1-5 for cmfrol Iocations.
A
1.
. .
- This device
starts and stops the bmer based on the
sy&m hand for ditiod heat or
when the demand is satisfied,
2. Wieh_Lmlt CQnfml
. .
- This device,
ats0 hown as an Excess Temperature
Control, stops the burner when the
normal operating temperature set-point
has been exceeded. Normally the device
is a mechanical manual reset type,
but may be wired to affect a manual
reset via the combustion flame safeguard
control .
3, khhhug Ca - For burners
which oprate on the full modulation
principle, this device positions the
burner from low fire to high fire in
L
response to system demand. When a .>

Universal Boiler Works, Inc,
- C- 1 General Description of Hot Water Boiler
-,
.+. full load is required, this control will
signal the burner to drive to the
maximum firing position and as the
load is satisfied, positions the burner to
less input, eventually driving the burner
to low fire for safe shutdown upon
demand ~tisfhction. Smaller units, 1-
than 80 horsepow, wilt b standidy
equippod with a control that positions
the burner
either at full fire or low fire
and is referred to or hown as a
ow Fire Canb.al. While it is
design4 to respond to the system
demand, it is not designed to position
the bunttr at any pint in betwen high
or low firt.
4. LmwW - A probe sensing
device below a safe operating level. In a
hot water boiler, this device should be a
back up to a system water sensing
I-
device, as a low Wr level in a hot
water boiler is very serious and will
L,
affect the longevity of tbe tubs.
. *
5, mw W-CuW- (Optional)
This device, when required by p-
ject specifications, can be of the in-
probe sensing type or an exkmd float
actuated device. Its purpose is to shut
the burner should the primary low
water cutoff fail.
bile r Trim
I. Wer Water Pressure Gwgg -
Mechanical indicating device for visual
indication of the internal pressure of the
boiler (waterside).
2. ~emperarureu-
Mechanical device to indicate the
relative water temperature at the outlet
connection to the system,
\,
3. Brlief Valve(s\ - Dependiny upon the
six of the
boiler. one or more water
pressure relief valves are furnished.
These valves are shipped loose and
should be piped to a safe point ofdis-
charge by the installing contractor. The
set point is genera1 ly iess than the system
operating pressure, to relieve water pnti
sure within the bailer when the set
point has been exceeded. Under no cir-
cumstances should the setpoint be
altered above the system design nor
above the boiler design pressure. Vdve
sizing and quantity are determined
in accordance with the
Code. Additional valves
be added in accordance with the
project specifications.
4. --
(Optional) When fumishd, this 6
vice is shipped l~ose for instaktion by
the contractor. This device indicates the
outlet gas temperature of the boiler. It
is normatly laxted in the vertid rise of
the stack to the boiler connection;
approximateIy three feet above the
boiler connection. Provides indication of
the fireside cleanliness of the boiler.
5. p- Valve -
(Optional) When finished, this valve
is shipped loose for contractor piping
( rear drum connection) and is used
to drain the boiler for waterside inspec-
tion or when the unit is to be stored, for
any lengthy period.
6. J nw Watd2mhiu - (Optional)
When an optional float actuated
control is furnished in lieu of the
standard prok control, a drain valve
is furnished. This valve is factory piped
to the bottom of the float housing to

Universal Boi let Works. Inc.
-
Chaw I General Oescription of Hot Water Boiler
perm it periodic draining of the hwsing
to remove any accumulated sludge.
E, Burner Controb
The Model BF boiler is design4 Fbt operation
with a forced draft bmer for natural gas, LP
gas, or light oil. A separate burner mmmt fram
the specific burner manufacturer is included. In
that manual are the descriptions of the various
controls provided in acco~ with the
requirmenl of the Undetwfitds IAmratory
W.L) and any specific requirements of the
project, in acco~ with the project
specifications.
Within the bucner manual, one
will find the Burner hhmgment Combwtiun
Safeguard Conml along with Sm-up
instructions and combustion settings.
For fuel supply connections, refer to the &nerd
hangement drawing and the burner manual.
As a brief aver-view, the package wiI1 contain:
1. Cantrol-hcatedootkebmeron
smaller units or on the boiler b
extension at the front of the boiler.
The
electrical supply for the burner and
contsoIs are to tre made in this panel,
hy interface connections to system
contmls or shipped loose controls will
be lmted within this panel.
2. -
Located in the Control Panel to provide
safe start procedure for burner start-up,
burner operation, and safety shutdown.
Flame supervision is via a flame
scan-
ner which monitots pilot ignition,
main
flame ignition, and flame strength
during operation,
It is programmed to
shut the burner fuel supply off in the
event of an unsafe condition.
3. - Locared on the
burncr. provides purge air of the bile<
prior to ignition and following a safe
shutdown. Provides the air required for
combustion.
4. Folced - Located in the
Control Pmel. This device al1ows
current flow to the fan motor upon
energization of the coil. Overloads are
installed within the starter to prevent
damage to the motor in the event of
voltage or current spikes.
5, 5
*.
- For W-
latiom opcnting on a 3 phase powcr
supply, this device is located in the
controI panel for stepdown. voltage of
120 volt single phase supply to the
bwer and boiler controls.
6.
- Located on the burner
to position the fuel input valve ad the i-'E
det
air damper in accordance with -L ' . ,i
demand requirements. .
7. Gas TTraia - Standardly located on
the left side of the bailer, when Each
the front of ?he unit. The train for
units operating on gas, as a minimum,
will have a main gas pressure regulator,
shutoff cocks, safety shutdown
valves, and fuel input valve. Please refer
to the burner manual for specific gas
train components.
8. P? - A separate pilot regulator
and pilot safeg shutoff valvc are
hished on the bmer for gas pilot:
ignition.
NOTE: Some units operating on oil may
be equipped with direct spark ignition.
Refertotheburnermanualforspecifics.

Universal Boiler Works, Ine.
Cm I Omed -ription of Hot Water Boiler
9. Pi1 Fuel -- Locatcdonthcbumer
u
and as a minimum will include oil
metering valve, oil pressure regulator.
oil strainer, safety shutoff valves, and oil
pressure gauges. Standard atomization
of oil is via mechanical pssurization.
Air atomization is optional. Pleast refer
to the burner manual for spific oil
components furnished.
F. Other Controis
Specific project requirements may have
included controls not mentioned in this Ocneral
Description section. These items csln include
Ieadflag systems, indoor/outdoor energy
management interface systems, system pump
interlock, etc. For specific items furnished by
UBW, refer to the Bill of Materials and the
Burner Manual for additional infomation.
2* is important to un- the operation of
..='
,.jr device, which will hterhcc with the
boilerhumer, so that all components oprstc as
they have been selected and designed. Do not
attempt to by-pass any control or device during
start-up or during operation in order to explite
start-up or continue operation.
Each device on
the package has been firmished for a specific
reason of dety or infodonal purposes. If a
component is not operatiod, coatact your Id
service agency or UB W.

Chapter 2
Unloading and Installation
Model BF Hot Water Boiler
A. Unloading
Before any attempt to unload the boiler
from the transport company is made,
perform a visual inspection of the boiler.
Ascertain if any damage has been
incurred during transit. The equipment
has been loaded by UBW and accepted
by the transport company as undamaged.
Once the equipment has been lifted hm
the trailer, my damage that is not filed
against the Transport Company, will be
the responsibility of the rigger or
purchaser.
NOTE
If the boiler will mt be zm~aiied for
me perid of time qfter ddivery, #he
mit sbuId be protected adequately
again# fallen debris, the weather, etc.
extended storage will be neceswty,
proper @-up uf the unit shd be
provided to prevent own pi- of the
tubes. Make certain thst all shim
loose or separate& boxed componenb
ar~d conirob me stored with rite Boiler
or proper& marked arad located, so that
whet1 the items me reyiired they can
easily be reaimed Check that all items
have beet1 received. Report tzry missing
items. Ifems not noted us missing, within
48 kvrrrs of receipt, will twt be replaced
of charge, as we will mmme thai
/he shipment h beet^ received
complete.
The Model BF boiler is equipped with
lifting lugs located on each side of the
boiler base frame. (Please refer to figure
2- I) These lugs have been located for
the specific purpose of lifting the unit
with the use of a spreader bar. A
spreader is needed to prevent damage to
the outside casing.
Refer to figure 2-2 for the correct
placement of the spreader bar and
cables.
Smaller units, depending upon the
available equipment, may be unloaded
via a forklift. If a forklift is used,
ascertain its lifiing capabilities and the
use of extended forks.
X)o not attach slings around the boik
or to the burner in an attempt to pd
or drag the unit!
If the unit must be dragged or pulled,
attach cables to the lifting lugs only.
UB W does not recommend &aaaraaarnp the
unit for awv wed Gisfmre, If the unit
must be placed into a location other than
lifting into place, we recommend the use
of rollers.
DO WOT ALLOW THE UNIT TO BE
SET DOWN UNEVIENLY. IF A
FRONT BASE EXTENSION HAS
BEEN PROVIDED, MAKE
CERTAIN THAT IT DOES NOT
MAKE CONTACT M SUCH A WAY
AS TO SUPPORT THE WEIGHT OF
THE BOLLER THIS COULD
DISTORT THE FRAME AT THAT
PDLNT OF CONTACT.

t:rlrr crs;~l IJullcr Works. Ir~c. -. L'11;bpcr 1 - UntuJiny 2k l~~slallrrtwn ol' kldol 131: 1 lot Wa1c.r t3oilcr
The Mode! BF boiler must be installed
on a level surface. Ir is recommended
that the unit be placed on a
housekeeping pad to prevent water
splashing during routine floor cleaning.
Although the Model BF boiler is
adequately insulated and has an enciosed
combustion chamber, do not instal1 tie
boiler on a combustible surface!
Ascertain what the local code
requirement dictates and as well, the
project specifications, for the type of
surface upon which the boiler is to
rest.
Tf the unit is to be installed on a trailer,
as a portable piece of equipment, make
certain that the trailer floor is adequately
insulated if the floor is wood. We
recommend that the .floor be covered
with sheet steel or some type of heat
resistant covering.
Project specification will dictate the
location and ' orientation of the boiler
within the boiler room. The boiler
should be located in a well-lighted area
and boiler room air supply ducts should
not be positioned near the rear of the
boiler. Cold air hitting directly on the
unit can have an adverse eff'ect on the
unit.
D. Air Su~~iv
Adequate air supply into the boiier room
tbr combustion must be provided.
Ij'ndcr no circumsiancc should the boiler
be operated when a negative pressure
{~acuurn) cxists. We recommend a
siiyntiy positive condition at all times.
As a rule of thumb. we recommend that
a quantity of 10 ctin per boiler
horsepower airflow be available,
whcncver the burner is operating. The
location of bailer room air supply
dampers should provide cross flaw
ventilation. The recommended size of
the openings shouId be in accordance
with TabIe 2- I.
Make-up air openings may be fixed or
may include a motorized drive for
opedclose operation. Tf the openings are
furnished with an electrical drive, check
the burner electrical wiring diagram ibr
interface connections. The burner must
be started if the air dampers are closed.
. .I
When placing the boiler, ensure
adequate service and maintenance space
is provided. As a minimum, a 30-inch
space should be allowed at the rear of
the boiler, a minimum of 30-inches at
rhe front of the boiler for burner
sewicing and for each side. Refer to the
General Arrangement drawing far aisle
space requirements; project
specifications may require more room.
(See Figure 2-3)
NOTE: Project specifications andlor
local codes may require more service
clearance space than noted above.
To ensure rase uf access to the t itbes,
11ot it~stnli the unit against a wall or
other su~norting structures. This wili
prevent access panel removal. The outer
and inner casings are removable to
provide access lo the tubes from each
sidc of thc boilur. Therc is an access
cioor at the back of the boiler for access
to ~hc combustion chambcr, Kecp this in

mind when placing piping, etc. at the
back ofthc unit and alony thc sidcs.
As an option. access panels located at
the rear of the unit fir cleaning and
inspecting the convection passes, may
have been Mshed. Check the general
arrangement drawing if these have been
furnished to ascertain if clearance at the
rear will be adequate for tube surface
brushing.
F. Connections
Local cdes and project specifications
wilt dictate the requirements for all
interface connections of fuel watts
exhaust and eIdcal. Those
requirements must be adhered to and
inspected by the authority having
jurisdiction for the installation. UBW is
only noting the location of the
connections fbr reference, along with
other recommendations not con£lichg
with code or specification requirkmmts.
Wfer to the gd arrangement
drawing for connection locations, sizes
and types.)
1. Stack or Breacbinq - This
connection is located on the top
centerline of the boiler at the rear.
The specific size and dimensioned
location are noted on the General
Arrangement drawing. If a vertical
stack is furnished, do not allow the
boiler to be the support for the stack.
The stack should be supported 60m
the roof trusses or another means of
stack support should be provided.
Do not permit the stack to slide
pl~st the boiIer connection so
that it rests on the umer drum.
This will create n backaressure
a~id seriously affect co tn bus don
gnd lcakaee of combustible
products.
The stack outlet should be fitted with
some means of preventing ingress of rain
as shown in Figure 2-4.
2. U~gl~IReturn - The hot
water supply connection to the
system is located on the upper drum
at the front, and the system return
comction is located at the rear of
the lower drum. For multi~ie boiler
mshlhtions, it is recommended that
balancing valves be indied in the
return line, to 9insure equal flow to
each boiler, ai the required flow rate.
(See Table 2-2)
3. Air Vent - To ensure that entrained
air is not ailowed to accumulate, aa
air vent tapping is located on the top
drum centerline at the front. This
connection should be piped to the
expansion tank San auto air vent
valve can be used, but is not
recommended in Iieu of expansion
tank piping.
4. Boiler Drain - For draining the
boiler, a tapping is locatmi on the
bottom drum wntdhe at the rear.
Connect an approved vdve to this
opening and pipe to a safe and
approved discharse point.
NOTE: For Section I hiyh pressure
boilers or as Iocal codes or
specifications may dictate, one quick
opening and one slow opening valve
shall be installed to the boaom drum
drain connection. The valve closest
to the drum shall be the quick open
type, directly into the boiler. For
nlost effecfiveness, we recommend
that the chemicals be introduced into

Unnvrsal hlcr Works. Inc, - Chilpicr 2 - Uni-ng R insr;l~k~Il~ll ol' kldcl B1: I.Ioc Water Uoilcr
the fucd lank, prior tu boi1cr
introduction.
5. Relief Valvds) - Thest. items are
shipped separate and must be
inounted direct to the boiler withuut
any interveniny shutoff devices. The
connections are located in the rear
top dnrm. Discharge piping shdI
foIlow local code requirements.
WAhYIXG!
Improper handling or instabtionof a
relief valve may adverseIy affect the
valve's operatian, multing in serious
damage to property and life.
Observe the following precautions when
installing relief valves.
P Use only flat jawed wrenches
an the flats of the valve.
+ Do not use a pipe threaded
into the outlet wnnectiorl of
the valve to turn the valve.
"r Avoid over tightening, which
can distort the valve's seating
ability.
> Apply only a moderate
amount of pipe compomd to
mate threads only.
9 l3ischrrrse pipins rn~~st be
used if the discharge is
iocated where workers might
be scalded.
3 Ciscl~arge pipe dian~eter ii1~5t
be at least equal EO the size of
the safety valve.
> If' discharge pipiiig extends
greater than 17 feet, use a VZ"
diamctcr larsur hr tach 12
feet length.
Avoid all 96' bcnds if
possible.
r If discharge terminates
outdoors wherc it can be
subjected to freezing, ensure
appropri atc measures prevent
the discharze pipe from
fr'reezing shut.
i Each discharge pipe should
have 36" Or X" Open drain at
its lowest point.
Refk to Figure 2-5 for a recommeraded
method of safety valve dischaqe piping.
6. Electrical - Foliow lucal cdtv and
the National Electric Code wC) for
cmnection of the mh power supply
and my external interfaces
connect mns. Power connection
points are provided in the burner
control pami. Mer to the burner-
wiring diagram for details.
7, Gas Fuel - If the burner is equipped
to burn gas? the gas trz?in is located
on the left side of the boiler when
facing the burner. (Note: project
specifications may locate the train on
the opposite side, or i~ may have
been shipped not mounted for a
specific ~ocation). Locd codes wiil
govern the supply line connection to
-
the bdler hit shdd inchide a drip
e and strainer prior to the
connection a~ the boiler. Refer to the
hcrner Sas tmir. dzwing fgr vent !i~e
dctai4 of the individual, componcnts.
(NOTE: Do not run the supply line
tli~sh tn the side nf the boiler, which
will hamper casins removal)

8. Oil Fucl - Rcfcr. to the burner
manual tbr specific controls and
componellis. It' an integral oil pump
is furnished, this will be Iocated ,at
the burner to which the suction and
return lines are to be connected. If a
remote pump is furnished, project
specifications will note the location
and piping.
Follow local s~ecificat ion aud
gpverning code middines for fd
pi~in~.
G. Water Treatment
The following layout, marked Hot
Water Generator Room Plan shows
two hat water boilers feeding two
heat i vg zones.
A stand-by pump is shown to pump
either of the two zones. This is possiile
only if the water flow and pipe Friction is
practically the same for each zone.
The expansion tanks are shown
connected to the top of the low water
cutoff (if a float operated control is used,
otherwise connect to the vent connection
on the upper drum) to prevent air
binding in the control or drum. The cold
water make-up line is connected to the
expansion tank header, and make-up
should be treated and softened.
An isometric view is given to show the
piping for Rot water operation in the
180' to 7-40" F ranges. The system
shown describes the popular pump-out
system, with the pumps installed on the
hot water line leaving the boilers. This
system offers the advantages of constant
water pressure in the boilers with the
espansion tank connected to the boilers.
Also, on high friction head systems. the
pump discharge is not imposcd an the
bailers and standard Section IV boiler
units can be used, provided extreme
static head pressure does not exist.
The return water enters the bottom rear
drum of each unit and the hot water
supply take-off is from the top front
drum. The run-out should include an
elbow that moves the shut-off valves off
the boiler centerline. allowing the valves
to be accessed without climbing onto the
boiler.
A balance cock is shown for each boiler
and must be utilized. It is impossible to
perfectly balance the flow of water
through each boiler simply by piping
design or via the use of gate valves.
Unequal flow will impact the proper
response and load demand on each
boiler.
Zone threeway valves should be
designed for proper pressure drop to
prevent huntins and they should be of
the slow open md slow close type.
Never allow the vaIves to fully close so
that the flow my be established thugh
each boiler. Should the heating demand
not require the use of more than one unit
for my lengthy period, it is
recommended that the boilers not used
be properly valved out. System pumps
should be interlocked with the burners to
prevent burner operation unless the
pump(s) is operating.
NOTE
Pressure vesset warranty is subject to
proper water treatment. 1f wwtcr
treatment is not undertaken, pressure
vessel wilrrantv is voided.

I.:i~ncrwl Boikr Wurka. Inc. - C'hapcr 2 - Unlouding dk l~~sltlllario~~ ol' Mudcl 13F Hot W;llcr btlcr
The safety of a gas-tired boiler
instd!ation is cantrolled 'by the care
taken in the application of gas
accessories to the combustion equipment
on the hoiler. Fi,m_lres A. B and C
describe some of the various
appiications of gas se~.vices as weii as
some of the details that should be taken
care of, to ensure that a saik and efficient
installation is secured.
Figure A shows an incorrect methad of
connecting gas service to a boiIer. As
show, it is impossible to ch9cl; the piiot
on the boiler without the
electrical head to the main gas valve. It
is not recommended that the pilot line be
down-stream fmm the main manual
shut-off vatve,
Fi~ure 3 shows the correct method of
connection of the pilot line to the main
gzs Fine. With this hook-up, it is possible
to shut-off the main gas valve and run
the burner on pilot only, so that an
eficient, stable flame can be secured by
proper adjustment, After the pilot is
properly adjusted, the operator or server
technician can then open the main gas
vatve and be assured that the boiler will
I:.- llshr properiy. Szlme gas cozpanies may
I-eyuire ail additional gu valve ahead of
the pilot connection.
it is exrremcly important that vent piping
from sas regulators. solenoid vent valves
fir check ~rh be instalied correctly to
prevent the escape of gas into the boiler
room, in the: event oi improper operation
or by failure of a _pas regulator
diaphragm. The gas vents from the
hiler should be ample sire and not less
then w. Ooequaner inch copper
piping. that is seen often in boiler
installations should be avoided. as it is
easy to plug up such small vent piping,
leading to an unsafe operation of the gas
accessories. 'I'he gas vents shouid be
tminated outside of the building wall
and be equipped with a bug screen type
venl cap. As shown in Figure _C, vents
htom test cocks or vent valves should not
k combined with vents from as
pressre reglators.
As shown in aH three figures, it is
preferable to run the gas drop (drip or
dirt leg) itII the way to the floor, thus
providing support of the gas piping as
we11 as a dirt pocket, to catch welding
spatter or scale, before it enters into the
gas train components. (@Tote: keep rhe
gas drops behind and away from the side
of boiler to permit removal of side
casing and tube pull from the Sailer)
Note
Keep the gas drop behiad and away kern
the side of the boiler to permit removal
of side casing and tube pull from the
boiler.
The manual shut-off valve should be of
the lubricated plug type or baII type, nd
a cone type brass cock. A Iubricatd plug
valve will not freeze and become
biEcilt to ttiri;. This ~alvc shculd be
equipped with a per-nmlelltly attached
handle that indicated whether the valve
is opened or closed.
The requirements of local gas utilities,
!I?CL~ and figtima! xdes shou!d be
checked carehlly, Sefm making .the
ti.nai connections ul' the gas service to
the boiler. As a minimum. the gas train

Ilt11i cml f3wlcr Works. lac. - Ctwplcr L - Unloadmy & Irisultation ol' Mo&l UF Hot Wil~ct Bvilcr
components should be in accordance
with L~C laicst 111. standards li)r gas lird
equipment.
I. I,iel~t Oil Circulating Purrlp
Oil pipiny requirements vary with
different types of burners and the
specific burner manufacturers' data
should be consulted. to determine
specific pumping requirements Burners
that operate with mechanical pressure
atomization of oil for combustion must
be known, so that line size is proper fbr
adequate oil supply at high fire.
Mechanical oil atomization generally
utilizes the burner pump to increase the
oil pressure at the oil nozzle, for proper
atomization. Consequently, the oil flow
to the suction side of the pump must be
at least twice the fir in^ rate capacitv
at hiph fire.
The illustration shows the installation of
a light oil transfer pump for a multiple
boiler installation. The drawing depicts
the preferred method over pressurized
supply lines or sdl storage tsnks in the
boiler rmm.
The suction tine between the tank and
the circulating pump should be tested for
24 hours under 100-psig-air pmure; to
insure that it is tight before it is covered.
One oil pump is shown as only one
piimp is usually installed, if oil is a
stand-by fuel. If oil is the primary fuel,
tw*o pumps should be installed in
parallel. If two pumps ate used or if gate
valves are installed in the discharge line,
the pumps should be equipped with
safety relief valves.
The uil loop rovrtl the pump to the
boilers and hack to the tank should be
located in a trench, if possibte IF it is
necessary to locate the loop over the
boilers, a check should bc made to insure
that the pumps on the boilers cortld with
stand the suctiurl pressure imposed by
the height of the loop,
NOTE:
Per NFPA standards, the pressure
imposed on the suction side of the
boi ter-mounted pump may not exceed 3
Therefore, a pressure-reducing vaive
may be required.
By raising the end of the Imp up one
foot, a positive supply of oil is available
at all times on the suctions of the pumps
at the boilers. If the oil bop is located in
a trench, the end of the loop should be
raised at least one foot above the
elevation of the pumps on the boilers.
This system has a number of advantages
over pressured supply lines or d
storage tanks. These are:
I. Minimum of pressure required in the
oil supply line.
2. Minimum amount of oil storage is
required in the boiler room.
3. No floats switches, pressure
rewlators or relief valves required,
other than noted above.
4. Oil cannot spill out of vents or
ove:tlows that are required on other
svsterns.
J. Electrical
Power Supply to the boiler must be
protected with dual element fbses or
circt~~t breakers Similar fhes should be
used in branch circuits. Standard one-
shot ti~ses are not recommended.

tfnlrrml &~rlcr Works, Inc. - Chaplet 1 -Unloading& Irmlldon of M&l BP HOI Wuw BoiLr
foR>rmtion in Table 24 is inuiudcd as r
widel ine of fuse protection requirements
-
and thcsc shouici bc confirmed with
project speci Acacions. burner provided.
and shouid bc in accordancc with the
latest NEC (National Electric Code)
requirements and local governing codes.
It is recommended that Emergency
Power Disconnect switches be located at
each entry ~nto the boibr room. These
switches should be interlacked with the
boilerburner control circuit.
hfakc sure that all external wiring to stnd
from the control pel is properly
identified and marked. This is to ensue
that if burner power is disconnected,
oiher power sources are known and
marked, which may remain active within
the panel, even fhough the burner power
has been disconnected.
Check that the wiring diagrams for the
burner and boiler controls are contained
in tam wnhl panei print pocket at dl
times. Reference thae drawings for
external cunnections that rnsy require
inledace wiring with other controls. If
these drawings am not nvaiiable, check
with your local UB W Representative.

Chapter 3
Model BF Boiler
initial Start-Up md Opera tion - Hot Water
A. General Preparation for
start-up
Before initial burner fwhg is undertaken,
be certain that dl conndons have been
completed and secured. Make certain
that the vent, water, firel, elemid
services are complete and that
interruptions will not occur during the
start-up procedure.
NOTE: IF THE WTT IS INTENDED
FOR TEMPORARY SERVICE,
CHECK WITH UBW FOR
WARRANTY ~LICATIONS!
J Electrical
conndpmtected?
J Motors pro@y connected fbr
rot don?
4 Fuel-supply piped and fUel
avail able?
J Exhaust ventlbreeching connected
and he of obstructions?
J Combustion Air Make-up available?
J hterfkce wiring completed to
external controls or devices?
J Water supply piped?
J Drain and Relief Valves piped?
J Inspection cumple4ed?
J Sufficient Load demands available
for setting combustion and controls?
During fabrication of the boiler, heating
surfaces are subjected to cutting oils,
grease, etc. These must be removed
prior to full operation of the boiler. To
accomplish this, a boil-out of the unit is
recommended. This procedure can be
Med out dong with the cleaning the
system, and can be accomplished during
the time period to cure the fiont and rear
wall rehctories.
The & system should be cleaned
including the boiler, befbre full
operation of the boiler is penmd.
Piping connected to the
boiler may
contain oil, grease, or other materials
detrimental to pumps and the boiler.
These irnpwitieq if not removed, will
adversely affect the hdng dces of
the boiler. Chemical cleaning of the
system piping is necessary and the entire
system drained after cleaning. If the
boiler is replacing an existing unit within
m existing system, boil-out of the
system modifications, impurities may be
introduced and it is recommended that
an existing system be reviewed for
cldiness.
C. Refractow Curing
The front and rear walls for the BF unit
are constructed of high temperature
refractory. Before initid firing of the
unit, these should be checked for any
damage that may have occurred during

Universal Boiler Works, Ine. - Chpt. 3 - Start-Up & Opemion of the Model BF HW Blr.
shipment of the boiler.
hy hairline
cracks should be wash mated with a
lightweight cement mixture.
To provide longer life of the rehctory,
it is recommended that the refractory be
cured properly prior to full fim
operation. During Eabricaiion and while
the unit was under instdlatioq the
refractory absorbed a goodly amount of
moisture. This contained moisture must
be driven off slowly to prevent rapid
expansion of the material that could lead
to large uacb and eventual overheating
of the extdor st4 surfaces. Please
refa to the separate pnxedtm coming
refractory curing.
Boil-out - Refer to the water content of
the Wed boiler shown on Table 3-1.
If the boiler will be dad with the
system note the &od amount of
water dative to the required chemicals.
An Wine solution sbould be used
during the --out period.
PROCEDURAL STEPS FOR BOIL
OUT:
Chemicals used for bohut nre
injurious to eym and skin. Refer to
the Matdl Safety Dab Sheet for
proper safety equipment and
protection, and required precamtions.
Always wear eye protection and
rubber gloves when handling boil-out
chernicltls.
1. Remove upper and lower drum
handhole covers and inspect dl
internal surfaces. Remove any
debris and wash with a water hose.
Close bwer handhole cover.
e sure that the relief valvds)
valve seatt
2,
If the boilelm onlp is to be boiled
out, connect an overflow pipe to
one of the relief valve connection
openings, This pipe should have a
tee connection fbr adding
chemicals as needed during the
boil-out period.
a. Fill the boils with clean water
jua below the upper dnrm
handhole opening, Water
tmw must be at l&
70°F.
b. Add the cleaning chemicat
wing a pump. Never add the
chemical into the boiler before
adding water.
c. Close the upper hmdhole cowr
and add mom water udl water
begins to flow out the overflow
pipe.
d. Recheck all bum controls and
fight the burner. Me sure the
burner is in the manual firing
position and at low fue. Fire
the boiler intermittent Iy until
the water reaches the boiling
point.
IPO NOT IPIRQDUCIG,
PRESSURE!
em When boiling temperature has
been established, hold at this
point for at least five hours. If

Universal Boiler Works, [nc, - Chpt. 3 - Star-Up & Operation of the Model BF HVV Btr.
the rehctory is being cured,
keep the curing process in mind
during the boil-out period.
f. During the boil-out period,
open the bottom drain wive
once every hour. Allow this to
remain open for a count of 5,
then close, Add more water
until overflows. Check the
alkalinity periodically. When
the alkalinity Mb below 3000
ppm, add more chemical
solution,
g. Intermittently, add more water
to dow an overflow of witer
to cay off surface impurities.
Continue this process until the
water clears.
h. The time Wod for boil-out
wit1 vary in &tion to ttae size
if the boiler, and as well, if the
dactory is being 4.
Generally, a boil-out should
take no more than 24 hours for
the largest units (300 hp to 800
hp) and las than 12 hours fbr
sder units. Cleanliness of
the waterside is cdhmd by
water clarity.
i. Upon completion, shut the
burner off and allow the water
temperature to drop to
approximately 120' F. Drain
the boiler.
j,
Remove the handhole covers in
both drums and wash the
waterside surfaces. Inspect the
surfaces and if not clean, repeat
the boil-out procedure.
k. Replace the handhole covers
with new gaskets and attach the
relief valve(s).
1. If the boiler will be placed into
operation shortly after boil-out,
fill the unit with clean treated
water and fire the unit to reach
at least 180°F, If the unit will
not be used right away, prepare
the unit for lay-up storage.
3.
If the boiler and system will be
cleaned jointly, an overflow pipe
may be used, with a shut-off cock,
to check the cleanliness of h
system water. However, the
addition of the cleaning chemicafs
should be introduced via a shot
fdw or via the expansion tank.
a, Make sure the boiler relief
valve@) is removed duriug
systedboiler cleaning
b.
Follow the burner firing and
rehctory curing ndom as
desai'bed for boiler only bil-
out.
E. Refractory
The reeactory used in the construction
of the Model SF watertube boiler has
beam chosen for the intrinsically good
insulating properties and longevity and
reduces maintenance andlor repair
substantially.
To avoid rapid expansion of moisture
contained in the refractory, caused by
immediate full load f~ng the following
refractory curing schedule should be
accomplished. Once the curing process
has been accomplished, normal-
operating procedures can be permitted.

Universal Boiler Work, Inc. - Chpt. 3 - Start-Up & Operation of the Mudel BE W Blr.
Set the burner to the low fire position.
The curing proccss will follow a period
of low fire operation with an increase in
firing rate throughout the curing period.
Hour Q
Hour 2%
Hour 4:
Hour 6;
Fire for 5 minutes,
stop for 10
minutes
dtmatively. (5
on, 10, off, etc.)
Fire for 5 minutes,
offhrsminutes
ahmatidy.
Fire for 10
minutes, stop for 5
minut=
dtdvel y.
hcmme fuhg
rate between low
md mid range;
fite for 15
minutes, ad off
for 5 minutes
ahnative1 y.
Continue firing at
the rate noted in
hour 4.
Position fig
rates at mid-point
and continue
firing as noted in
Hour 4.
Increase firing
rates to 75% and
continue fig.
Increase firing
fate to 10% and
continue for
approximately 314
of an hour then
slowly turn down
to low fire. If
boil-out is being
accomplished,
continue with the
boilat
pdure.
Note: On units below 150 horsepower,
-
the cuing time can be reduced by 50%.
This means that during hour 4, the firing
rate may be increased proportionately
throughout the hour.
Note: One the curing process has
begun, it should not be intmpted,
Note: Before boil- or rehctory
curing is undertaken, the bumex should
Ix properly adjusted for proper fuel
input and keYair ratio. Tmproper
fuel/& ratio can cause incomplete
mbustion and sooting of the fieside
sudiaces. Refer to the burner mantlaI for
prop lwlmr adjustments.
Refer to the burnerhoiler-wiring
diagram, the combustion safeguard
control manual, and the burner marmd
fbr specific refereace to the combustion
safeguard control furnished. A more
detailed discussion is contained in the
technical information booklet covering
the specific combustion safeguard
control. However, the folIowing is an
overview of the burnerhoiler sequence
of operation
The burner and control system are in
starting condition when the following
conditions exist.

Universal Boiler Works, Inc. - Chpt. 3 - --Up t!k Operation of the Model BF HW Blr.
Boiler and system are filled with water
and the low water control probes or float
control confirm correct water level.
The
aperating limit temperature control and
high limit temperature arc below their
respective cut-off settings, All entrance
switches are closed and power is present
at the line termids of the forced draft
fan starter. Powa must be ptem
to the oil pump starter fbr remote oil
pumps far burners operating on oil fuel.
The sequence of operation does not
attempt to corrdate the don of the fuel
supply system, system pump inhx1odq
combustion air damper interlack$ atld
pedn specifically to the action of the
combustion sdegwd -1.
1. Ciit and Interlock Co&
The burner control circuit is a *wire
system designed fm
120 volt, single
phase, 60 hertz, altemahg current.
Control circuit power is extended to the
combustion dbguad terminals Ll and
LZ and simultaneously, to the burner air
inlet damper motor.
The controls used in the inlet circuit vary
depending upon the fud - oil or gas -
and the specific requhments of
appliwble regulatory budies. Refer to
the wiring diagram to determine the
controls provided- The controls
normally used are:
-Control Power On-Off Switch
-Gas-Oil Switch (Combination
Fuel Units)
-Operating Limit Temperature
ControI
-High Limit Temperature Control
-Low Water Cutoff Control
-Low Gas Pressure Switch
-High Qas Pressure Switch
-Proof or Closure Valve End
Switch
Controls used in the running interlock
circuit
are:
Blower (Forced Draft Fan) Motor
S tarn
Combustion Air Proving Switch
With the programmer energized, the
following sequence occurs
automatically:
f *Purged Period
When the burner control switch is placed
in the on position, power is routed
through the limit controls and the limit
proving circuit, intend to the
combustion safeguard control is proven,
provided that dl limits are made- With
the limits proven mi if supplied, the gw
fuel valve md switch proves that the gas
valve is cIosed (M valve hrlock
circuit), the fbrced draft -fan is
energized.
Internal circuitry provides power to the
burner air inlet damper motor and the air
damper drives to high airfIow position.
Depending upon code requirement$ the
damper will go to the fill open position
and if n high fire position switch on the
damper has been furnish4 the switch
must be made before the combustion
control will allow the damper to return
low fire position for sid for ignition.
Provided that the damper has proved fiIl
airflow and the running interlocks have
been proven closed (combustion air
interlock closed) the combustion
safkguard must sense that the damper
has returned to the low fire start position,