York-Shipley 400 Series Guide

400 SERIES BOILERS
500 SERIES BOILERS
WITH
FV-20A&B
AUTOMATIC BURNERS
'l~n ~ .. ....,_,....,~~~
Se'Wiee ad Pa~tU ?It~
YORK-SHIPLEY, INC.
YORK. PA 1 7· +0 ~
A TOTAL ENERGY COMPAN~
Ill 1111 ~ \ • III I ~ NI ~\ •111 1\ l I I IIIII II IW, • Ill 1\ I ' VINI J, \( • ~~ IIIII IIIII \Y\IIM~
I D-78-578R4 884
PRINTED IN U 5 A

TABLE OF CONTENTS
Preliminary Information
Protection
Of Equipment Before And During Installation
Check All Components Immediately Upon Arrival
Removal & Installation of Burner Assembly
Breeching, Stack and Draft Controls
Fuel Connections and Sizes
Gas Train Controls
Gas Fuel Systems
Sizing
Gas Header from Meter to Burner
Sizing
Gas Header from Meter to Boiler
Gas Pressure Regulator Requirements
Gas Line Feeder Sizes
Oil Fuel Systems
Suggested Fuel
Oil Piping Arrangement
Light Oil
Fuel Oil Tank
Suggested Procedure for Installing Fuel Oil Tanks
Boiler Room Ventilation
Service, Maintenance
and Starting Instructions for Burner
Oil Nozzle
Lubrication Procedure
and Requirements for Motors
Starting Instructions
Parts List and Reference Drawings
FV-20 A &B Light Oil Full Modulation
FV-20 A & BLight Oil-Gas Combination
FV-20 A & BLight Oil Spark Ignition
FV-20 A Gas Fired Gas Ignition (141809)
FV-20 B Gas Fired Gas Ignition (141794)
Nozzle Pipe Assem~ly (131550)
Nozzle Pipe Assem b ly (127515)
Nozzle Pipe Assembly (131210)
Nozzle Pipe Assembly (131553)
Ignitor Assembly (138643)
Ignitor Assembly (131554)
Page
3
3
3
4
5
5
5
8
9
9
10
11
11
12
12
12
13
13
14
17
23
24
25
26
27
28
29
30
31
32
33

PRELIMIMARY INFORMATION
The most important single point in the successful operation of a York-Shipley, Inc.
Burner
is proper installation. Please read these instructions carefully before
starting the installation. For special components and arrangements, refer to
factory. Failure to follow these instructions and precautions could result in
voiding the York-Shipley, Inc. warranty on this product.
PROTECTION OF EQUIPMENT BEFORE AND DURING INSTALLATION
If the unit is exposed to the elements, dust, cement , mortar and so forth, it should
be covered with a tarpaulin or protected in any manner that will prevent damage to
the burner, controls and other components. If there is a possibility of flooding
the boiler room, it is suggested that the necessary steps be taken to install
cellar drainage or sump pumps.
CHECK ALL COMPONENTS IMMEDIATELY UPON ARRIVAL
l. If unit is damaged, make claim to the carrier .
2. Check specifications of electrical service to make sure that they correspond
with the
electrical characteristics stamped on the unit.
3. Check total ampere rating of the motors, control system, to make sure that the
electrical service is adequate.
4.
Check the unit controls for type and pressure to make sure that they correspond
to the system.
5.
Investigate the gas pressure required for maximum capacity of unit on gas or
gas/oil burners.
The burner will arrive complete ready to conn e ct t o fuel and electrical service.
~
OIL LI N ES tl
SIIC TION ---j
/
/
i4- - - MAIN GAS LI N[
L-- --f'll 0 T ( ;1\ S L IN[

REMOVAL & INSTALLATION OF BURNER ASSEMBLY
ThE entire burner can be removed as a unit as follows:
l. Turn off all power &fuel supply lines.
2. Remove and tag any wiring which would restrict the removal of the burner.
3. Disconnect all fuel lines (unions and/or flare fittings).
4. Remove the nuts holding the burner mounting plate to boiler.
5. Place a rope sling around the neck of the blower to support and balance the unit
during removal. The sling should be attached to a suitable hoist or lift truck.
6. Be careful to remove the burner unit from the boiler in a straight line to pre-
vent
damage to the refractory.
7. Replace all gaskets before replacing the burner unit. Insert in a straight line
line to prevent refractory damage.
8. Coat all studs with grease or anti-seize lubricant.
9. Tighten the nuts evenly to assure proper alignment and a tight seal.
10. Replace power and fuel lines.
4

BREECHING, STACK AND DRAFT CONTROLS
FV Series burners are designed for forced draft operation, with the burner
blower providing all the air necessary for proper combustion. A simple vent
to the atmosphere, run as directly as possible (in compliance with local
requirements) is satisfactory. York-Shipley strongly recommends use of round
breechings (to avoid excessive noise and vibration) with gaskets and flanged
joints.
Multiple boiler installations may be connected to a common breeching and/or
stack, but other appliances should be connected to separate breeching and
stacks. All directional changes should use wide sweeps, and connections from
each boiler should enter the main breeching with a wide sweep elbow or 450
connection in the direction of gas flow.
The following chart suggests minimum breeching and stack sizes for various
boiler sizes. Variations may be necessary to suit specific conditions.
Vent/Breeching and Stack
Sizes for Number of Boilers
Boiler Horsepower {diameter in inches)
1 2 3 4
40
and 50
10
14 16
20
60
thru 80 12
16
20 24
When high stacks or other conditions on such installations, result in a draft
condition of the boiler in excess of 0.3" w.c. Negative, dampers and sequence
draft controls are usually recommended.
FUEL CONNECTIONS AND SIZES REQUIRED FOR STANDARD BURNERS
OIL:
Pipe size of fuel pump (#2, oil)-
Supply - 1/4" Pipe
Return -1/4•• Pipe
GAS TRAIN CONTROLS
All standard U/L gas trains for main flame include an upstream shut-off cock,
and electric gas valve, a down-stream shut-off cock with test connection, and
a gas volume control (butterfly) valve. A gas pressure regulator is not included.
For firing rates above 2,500 MBh, the gas train also includes high and low gas
pressure switches
and the electric valve is a proof of closure motorized valve.
Components vary, as necessary for FM or IRI insurance requirements, and pipe
sizes vary with burner
size and with available gas pressures.
The following schematic drawings show component arrangements for U/L, FM &IRI.
Pressure requirements, main pressure regulator selection, and varaiations in pipe
size are
detailed in price sheets and on page 9 in this manual.
All gas burners are assumed to fire natural gas, 1000 btu/cu. ft., 0.6 specific
gravity. For other fuels, consult the factory.
5

B U ~NER
BUtNU
SUGGESTED GAS PIPING
S.O. COCK
~
BUTTERFLY TEST MOTORIZED
PRESSURE STRAINER q
REGULATOR I
I ~cr
~ MAINGA$.
/"" ; ~ONN/'"' )CO"
-~-----1
BUTTERFL Y
VALVE
SOLENOID
VALVE
\
PRESSURE
REGULATOR 5.0 .
COCK
FV20A BURNERS--U/L
MOTORIZED VALVE (I'V-20A)
MOTORIZED VALVE-
PROOF OF CLOSURE (I'V - 208 )
HIGH GAS LOW GAS
PRESSURE PRESSURE
· SWITCH SWITCH
/
•o <oi I I ,
0
,~,
,~!~. I I
SOLENOID
VA LVE
PRESSURE
REGULATOR S.O. COCK
FV20A BURNERS--fM
FV20B BURNERS--U 1L& FM
6
PILOT GAS
S.O. COCK
r
I
I
I
I
I
-I
~
PRESSURE
REGULATOR
~
""'"" i
~cf-
I
MAIN GAS
----~
I
I
I
I
I
. I
PILOT GAS
---- - -i
~

BURNEt
SUGGESTED GAS PIPING
MOTORIZED VAlVE (UNDU 5,000 Mlh)
MOTORIZED VALVE-
PlOOF Of ClOSURE (OVU 5,DDD Mlh)
lOW GAS
HIGH GAS
PRESSURE
SWITCH
VENT PHSSUIE
BUTTERfly t I
VAlVE 5.0 . COCK/
I I
V/AlVE MOTORIZED /SWITCH
VAlVE
I
SOlENOID
PIESSUH
FV20A & B- IR I
7
S.O. COCIC
~
STIAINfl ~
~I
L}
PIESSUIE
MAIN GAS
--- ----i
I
I
I
I
l
~0~~----~

GAS FUEL SYSTEMS
SIZING GAS HEADER FROM METER TO BURNER
Sizing the gas line from the utility service at the meter to the gas pressure
regulator
at the burner can be important in cases where the gas pressure
available limits the pressure drop to a low value. The following sizing method
will prove helpful in sizing this line for single or multiple burner
installations.
Step #1. Determine the gas flow rate (CFH) by adding the CFH inputs of all
units being supplied by the header line. (Note factor for gas with BTU/cu.ft.
other than 1000.)
Step #2. Determine the highest pressure required at any one unit being
supplied
by the header line. (Note pressure requirements will change if IRI or
FM controls are desired and also BTU/cu. ft. less than 1000, note factor).
Step #3. Determine the gas pressure required at the entrance of the unit gas
regulator. This would be the inlet pressure shown on the gas pressure
regulator
chart.
Step #4. Determine available pressure drop through the header to supply the
quantity of gas by subtracting pressure found in Step #3 from the gas pressure
available at the utility meter. (This information will be supplied by the
utility).
Step #5. Determine the estimated equivalent length of header piping to the
most distant unit by adding 25% to the actual length of straight pipe involved
to allow for all fittings and valves in the line.
Step #6. Divide (Step #5) answer by 100.
Step 17. Calculate the pressure drop
available in the header per 100ft. of
pipe
by dividing (Step #4) by (Step #6).
Step #8. Refer to (Fig. I) . Locate the gas flow rate (Step #1) on the left
side of the ch a rt and draw a horizonta1 1i ne to the right. Locate the
available pressure drop per 100ft. (Step #7) along the bottom of the chart and
draw a line vertically upward. The location of the intersection of the lines
will determine the pipe size of the header line (where the intersection falls
between pipe sizes use the larger size).
Step #9. Step #5 may now be repeated using from (Fig. II) the actual straight
pipe equivalent for the pipe size fittings as determined in (Step #8) in place
of the
25% estimate. Steps #6, 7, 8, 9 can then be repeated to check the
original estimated condition.
PIPE SIZE REQUIRED FOR GAS FlOW & PRESSURE DROP/100 EO. FT.
100. 000
- SO . OOO
-
:> 10.000
v
10 ooc
?
-
g 10 000
0
~
z
X
v
I 000
)00
100
..........
V i
/l)--1
v v I
v
......
....- ,
·/
)-- I
v
v
;,
vv
, J
B~
':f)
~
4
f!)
/ B
L/'
/ 10
v / v
.....
~
/ / .
......
,.
rtl'f Silt
/ v
/ 7
y v v v EQUIVALENT
lENGTH FOR FITTINGS IN FEET
PIPE SIZE (IPS) I I 'h 11 /, 2 2 'h 3 4 6 8 10 12
s TO TEE lhru . SlOE 5.5 7.5 9.0 12.0 14.0 17 .0 22.0 33 .0 43.0 55.0 65 .0
......
s
4
G
:~ :~~ 2.7 3.7 ~ : ~ - - ~~ -- 6 ~ ~ - B :. ~ --.-! l : ~ · 0 _ _2 _0 _:_ 0 _ . !.~ . 0 __ __3 _ 1_: . ~
:-::-c":-'--- ____ __: 1 _:.:. 2 ~ 1.6 2.0 2.5 3.0 3.7 5.0 7.5 10 .0 12.0 15.0
LOBE VALVE 27.0 40 .0 43 .0 45.0 65 .0 82.0 120.0 170 .0 240.0 290.0 340 .0
G ATE VALVE 0.6 0.8 0.9 1.2 1.4 1.6
2.2 3.5 4.5 5.5 7.0
p
16 .0 27.0 39 .0 51.0 65 .0
_L_U_G_ C_O_C_K_ __ __: 3c.:.: .0 :____.: 4:_: . 0:___=5 .5 7.5 9.0 12.0
I 0 : 0 J 0 S 0 10 0 10 lO SO
100
PlfSSUif DIOP" • •
INCHES W ( .I I 00 fT.
Figure I 8 Figures II

NOTES:
GAS
SIZING GAS HEADER FROM METER TO BOILER
FIG. I II
MAX.
SIZE
FIRING REQ'D PRESS. AT UNIT
SERIES &
RATE
(See Notes)
HP
CFH STD. FM
542-40
1675
5.0 5.0
-50 2095
7.0 7.0
-60
2520 6.5 6.5
548-60 2520
4.5 4.5
-70
2935 6.0 6.0
-80
3350 8.0 8.0
UNIT FIRING RATES (CFH 1000 BTU/CU FT
.55 to .65 SPG GAS)
APPROXIMATE CONVERSION
13.9" W.C. = 8 OZ/SQ IN = .5 PSI
IRI
5.5
8.0
7.5
5.5
7.0
9.0
40 & 50 H.P. FV20A Burner
60 To 80 H.P. FV20B Burner
1.
FOR GAS WITH BTU/CU. FT. OTHER THAN 1000, DETERMINE CFH BY MULTIPLYING CFH SHOWN IN (FIG. Ill) BY
THE RATIO OF (1000/ACTUAL BTU/CU. FT.)
2.
WHEN BTU/CU. FT. IS LESS THAN 1000, MULTfPLY THE REQUIRED PRESSURE AT THE UNIT SHOWN IN (FIG. Ill)
BY THE RATIO OF (1000/ACTUAL BTU/CU. FT) . IF TOTAL PRESSURE REQUIRED IS NOT AVAILABLE CONSULT THE
FACTORY FOR INCREASED GAS TRAIN SIZES AVAILABLE.
3. FOR GAS OR SP.G. OTHER THAN .55 TO .65, DIVIDE THE ALLOWABLE LINE PRESSURE DROP/100 EQ. FT. BY THE
RATIO OF (ACTUAL SP.G./.6).
GAS PRESSURE REGULATOR REQUIREMENTS
CFH
U/L STANDARD & FM APPROVAL IRI APPROVAL
Boiler Size Firing Press. Req'd Reg. Size Press. Req d Reg. SHe
Series &
HP Rate
Inlet Outlet & Model Inlet Outlet &
Model
Std 6.5 5.0 1-1/2"
RV-81 Std 7.0 5.5 1-1/2"
RV-81
542-40 1675
Low 3.5 3.0 2-1/2"
RV-91
Low 3.5 3.0 2-1/2" RV-91
High 11.0 6.5 l"
RV-60
High 12.0 7.0
1" RV-60
Std 9.0 7.0 1-1/2"
RV-81
Std 10.0 8.0 1-1/2"
RV-81
-50
2095
Low
5.0 4.0 2-1/2"
RV-91 Low 5.5 4.5 2-1/2"
RV-91
High
16.0 9.5
1" RV-60 High 17.0 10.5
1" RV-60
-60 Std 7.5 6.5
2" RV-91 Std 8.5 7.5 2" Rv-91
2520
Low 6.5 5. 5 2-1/2"
RV-91
Low 7.0 6.0 2-1/2"
RV-91
High 13.0 10.1 1-1/2" RV-81 High 15.0 11.5 1-1/2" RV-81
548-60 Std 5.5 4.5
2" RV-91
Std 6.5 5.5
2" RV-91
2520 .
Low 4.5 3.5 2-1/2"
RV-91
Low 5.0 4.0
2-l/2" RV-91
High 11.0 8.0
1-1 /2" RV-81 High 13.0 9.5 1-1/2" RV-81
-70 Std 7.5 6.0
2" RV-91 Std 9.0 7.0 2" RV-91
2935
Low 5.0 4.5
3" RV-110 Low
5.5 5.5
3" RV-110
High 14.5 11.0 1-1/2"
RV-81 High 17.5 13.0 1-1/2" RV-81
-80 Std 10.0 8.0
2" RV-91 Std 11.0 9.0 2" RV-91
3350 Low 6.0 5.5
3" RV-110
Low 7.0 6.5
3" RV-110
High
18.0 13.5 1-1/2"
RV-81 High
22.0 16.5 1-1/2"
RV-81
9

GAS LINE FEEDER SIZES
The size of the p1p1ng from the gas header piping to each unit gas regulator in
a mu
ltip le unit installation should be sized using the max. gas flow for the
i
ndi vidual unit and the pressure drop per 100 ft. found in (Step #6 - in no
case should the pipe size be smaller than the unit gas pressure regulator pipe
si
ze -see gas pressure regulator requirements.
SA.MPLE PROBLEM
What size gas header should be run to handle two 50 HP hot water boilers and a
single
80 HP high pressure steam boiler? The boilers are to be furnished to
meet UL requirements. The gas is natural, .6 SPG and 1000 BTU/cu.ft.
Step #1. Determine the maximum gas flow rate of all units using 2 x 2095 +
3350 = 7540 CFH.
Step #2. Determine that the highest pressure required at any one unit for UL
requirements is 10.0" W.C .
Step #3.
The gas company indicates that gas pressure of up to 1 psi will be
ava ilable after their meter. The available pressure drop to push the quantity
of
gas through the header is then 1 psi = 27 .8" -10.0" W.C. (Step #2) = 17 .8"
w.c.
Step #4. From the plans it is determined that the length of straight pipe in
the header
to the most distant boiler is 200 ft. The allowance for fittings
etc. would then be 200 ft. x .25% = 50 ft. or a total length straight pipe
distance of
200 ft. + 50 ft . = 250 ft.
Step #5. Divide 250ft. (Step # 4) by 100 = 2.5.
Step #6. The pressure drop available in the header per 100 ft. of pipe is then
17.8"
W.C . (Step #3) divided by 2.5 (Step # 5) = 7. 12" W.C./100 ft.
Step #7. Referring to (Fig. I) and locating the intersection of 7540 CFH
(Step # 1) and 7. 12" W.C./100 ft . (Step #6) we find that a 2-1/2" IPS pipe
might
be satisfactory .
Step #8. Now that a good est i mate of the pipe size required has been made, go
back to Step #4. It has been established that the header will contain - 2
tees, 3 standard elbows and a gate valve. For 2-1/2'"' pipe (Step #7) the
equivalent length of these
is (2 x 14) + (3 x 6.5) + 1.4 = 48.9 ft.
Step 4A. The new equivalent length of pipe is 200 + 48.9 = 248.9 ft.
Step 5A. Divide 248 .9 ft . (Step #4A) by 100 = 2.489 ft.
Step 6A. The new pressure drop available in the header per 100 ft. of pipe is
now 17.8"" W.C . (Step # 3) divided by 2.489 (Step #5A) = 7.15" W.C./100 ft.
Step 7A. Referring to (Fig. I) and locating the intersection of 7540) CFH
(Step # 1) and 7.15" W.C./100 ft . (Step # 6A) we find that a 2-1/2" IPS pipe is
the actual requirement.
10

SUGGESTED FUEL OIL PIPING ARRANGEMENT
I
J
NOT£ ., 1
NOTE #1-FOR SUCTION AND RETURN LINE SIZE AND ALLOWABLE LENGTH OF
RUN SEE "LIGHT OIL" LINE SIZING INFORMATION.
LI GHT OIL
40 SSU MAX. @ 100 ° F-.85 SPG
Maximum allowable run and suction return line sizing
for :# 2 Oil Burning Units.
LINE SIZING
For oil light oil burners, use individual lines of 1f2"
O.D. tubing or
1
/
2" pipe for both suction and return
lines.
MAXIMUM ALLOWABLE PIPE RUN
To determine the maximum allowable pipe or tubing
run from the pump suction connection to the bottom of
the fuel oil tank for various lifts and for all size units
use the chart below.
TOTAL ALLOWABLE
LIFT (FT .) •
RUN (FT. l • •
0
91
--
1
87
2 84
!--- -3
81
4
77
5 74
----
6
70
--
7
67
8 63
--
9
60
10 58
11
53
12
50
13 46
14 43
15
39
• To determine "Total Lift" for all units add 4 ft. to
the vertical dis t ance from t he boiler room floor to the
bottom t:Jf the fuel oil tank .
• • If the actual run exceeds the maximum allowable
run, an auxiliary pump set must be used.
11

/Fill
FUEL OIL TANK PIPING
#2 OIL
· --
~-c v SUCTION
·:J
~
r-
..
PIPING SHOWN FOR
I
TWO BOilERS ONlY
~
1
_. RETURN
..
I L __
l
CHECK
~
r :=:=:J sue
I
VAlVE j
..
I
I
-J'--
i
r:±.J-
--
--
-
~
PROVIDE
I FOR DRAIN
l'j
/OF MANHOLE
..
ll
~
/1
·~
< c
\ .)
0
~
u
j
~
:)
<
"'
::;
0 0
v z
<
TION
I r··
.. l
·.· ·. ·. ·.·;
FUEl Oil
:.:<<~ : .. ..... ·
TANK
I
CONSUlT lOCAl
I
AND STATE CODE
6"
_f
CA BLE_/ 1 + . .
..
.· <CcoNCRETE ANCHOR SlAB R
..
. . . . TANK ANCHO
FUEL OIL TANK
The fuel oil tonk should be located os per local and
State Regulatio ns. Prop er size depends on the number
of go/Ions consum-:d per hour, and the availability of
de liv ery. When possible, the tank should be buried
beneath the ground. If it is not possibl e, it should be
well protected by masonry construction . Sufficient top-
pi ngs should be furnished to accommodate a large fill
I ne, remote oil gauge, vent line , suction line and return
! ne.
SUGGESTED PROCEDURE FOR INSTALLING
FUEL OIL TANKS
Tes• suct ion and return lines by sealing o ff tank and
bo,ler piping end subiecting closed svst em to l 25
lbs . ire rt gas pressur e. Remove source of gas. Allow
sysrem to re-noin ful l for a pe r iod of no less tha n
8 hrs Pr
essure gouge should be installed in close d
systerr b efore subiecting to pressure. If pressure re-
ma ins at 12 5 PSI for test period it is assumed syste m
is tig h ~.
2. PO SITIVELY DO NOT use cast iron fittings in fue l oil
pip i ng . Check all pipe thr eads fo r over cutting.
3 Ru n outside lines well below frost lin e.
4. Prot ect outs ide lines below driv eways with reinforced
con crete slab. Be carefu l with heavy machinery used
dur i ng constru c tion and in vicinity of pipe runs .
5 Ins tall tank vent high enough to eliminate source of
obj ectiona ble odors. Term inate tonk vent within sight
of t onk fill . Use full sized tonk fill pipe .
6 Use as
few elbows and other fittings as po ssible-
straight run preferab l e.
7. Pitch lines up from tonk to burn er or r em ot e pump
set.
8. Run
suction and return lines full siz ed to within 2-
feet of burn er pump connection . '
9. To size lines and locate pump set see "Fuel Pumr-
Locoti on and Suction and Return L ine Sizing" in-
format i on .
12
!
BOILER ROOM VENTILATION
Each boiler requires sufficient fresh air to assist the
combustion process . Insufficient air will result in smoky
fires and large deposits of soot and carbon inside the
boiler which will lower the boiler operating efficiency.
There are times when incoming air is not desirable.
These will be periods of normal shutdown of the equip-
ment. When the boilers are shut off the air supply
damper automatically positions the fresh air louver to a
closed position preventing the chilling of any piping
into the boiler room.
Switch on the motor should prevent burner from start -
ing if louvers fail to open.
Prop er screening sho uld be provided.
If automati c louv er is not required, stationary louvers
ore satisfactory.
Sufficient amount of ventilation should be fu r nished
into the upper section of boiler room to keep the am-
bient tempera tur e below 90 ° F.
BOILER
Equivo lent Free
Area Opening
HORSEPOWER
1--- - - - ~ -
40 and
50
18" X 25"
60 thru So
25'' X
29"
The area oroiX'Id the unit and it s c omponents must
be maintained and serviced . Check dimensions of th e
burner and components so that ample space is avail -
able to perform these functions and meet local codes .

SERVICE, MAINTENANCE AND STARTING INSTRUCTIONS FOR BURNER.
The starting and O f?e rotion of the burner is just as
important as the instol l otion. If a good installation is
mode and the unit is not properly started and the oper-
ator not properly instruct e d, maximum operating effi-
ciency cannot be obta i ned . For the proper procedures
of starting and maintaining the equipment. these in-
structions ore provided by York-Shipley, Inc.
TIP
DISC lOCKNUT STRAINER
The Oil Burning Nozzle prepares the oil for burning
by properly atomizing the fuel. Therefore, this assembly
should be properly adjusted and cleaned . When assem-
bly is removed, careful note should be mode of the
dimensions and returned as per drawing provided. A
detail of the nozzle is provided above.
NEW NOZZLES
If a new nozzle does not spray properly, polish the
orifice with o round sharpened toothpick . This will re-
move any test oil which may not have been flushed out
completely and, later, congealed in the orifice.
HANDLING
Always handle a nozzle as carefully as you would
a fine watch . It is a precision piece of equipment, easily
damaged by careless or rough treatment. NEVER clean
orifices with needles , pins, wires or ANY sharp metal as
the least scratch will ruin the spray and damage the
nozzle permanently. Keep your stock nozzles in indi-
vidual containers as supplied from the factory-DON'T
place them loosely in your toolbox or a bag and expect
them to be usable .
CLEANING
Remove strainer, locknut and disc from tip . Brush
parts thoroughly , particularly the slots of the disc and
the inside of the tip . Usc a Monarch brass wire nozzle
brush. Soak in carbon tetrachlor i de or any good carbon
solvent, and then rinse thoroughly with hot water.
Polish orifice lightly , front and rear, with a round sharp-
ened toothpick .
CAUTION: Be sure hands and tools are clean before
re-assembling. Re-assemble disc and locknut in tip and
tighten firmly with screw driver, holding tip in socket
or box wrench or a vise. Re-assemble strainer, first mak-
ing sure that ports ore free of any loose wires, lint,
sludge, etc., then screw it into the tip, finger tight.
STRAINERS
Strainers should always be used with nozzles up to
about 5. 00 GPH and may be used for as Iorge as 12.50
GPH if desired . They will not fit sizes over 12.50 GPH.
To clean nozzle ma~e sure the main disconnect switch
is open . Drain fuel oil from nozzle lines. Disconnect
electrode cables and fuel lines; loosen allen set screw
between mounting plate and holder, withdraw nozzle
and electrode assembly. When returning assembly,
make sure holder is flush to mounting plate.
NOTE : Extreme care should be taken to adjust elec-
trode as per d:mensions.
13

LUBRICATION PROCEDURE & REQUIREMENTS ~OR 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 to little.
Housing should be at least 1/3 full but never more than 2/3 full.
b. When greasing use only a hand operated pressure gun.
c. Wipe clean the plugged hole and the regions around hole and relief
plug. (G.E. motors use pressure fitting.)
d. Remove both filler plug and relief plug to prevent a pressure build
up.
e. Free
relief hole of hardened grease.
f. Add grease with motor running until it is expelled through the
relief hole.
g.
Run motor for several minutes with relief plug removed to expel
excess grease
and relieve pressure which may have been built up.
h. Clean
and replace relief plug.
2.
To Clean and Re-Grease:
a. Bearings should
be cleaned and regreased once a year.
b. Follow through on Section 1, items c, d and e.
c. Replace relief plug and fill housing with solvent, with motor
running. After
10 minutes drain off solvent. Repeat this process
until solvent comes out clear. If carbon tetrachloride is used for
flushing, rinse housing with small amounts of light mineral oil.
d. Follow through on Section 1, items f, g and h.
3. Motors with special
characterisitcs:
a. High speed motors (3450 RPM) should be greased every six months.
b. Motors
7-l/2 HP or greater should use at least one ounce of grease
every
six months.
c. Westinghouse pre-lubricated ball bearings provide adequate
lubrication for at least five years. At the end of five years the
shield on the outer end of the bearing should be removed a~d the
grease examined. If grease is discolored and has a bad odor,
bearings should
be cleaned and re-packed with grease. If not,
shield may be replaced and the bearings put back into service for
several years.
B. Sleeve Bearings (Usually identified by spring capped oil fill)
l. Periodic Oiling:
a. Check oil on sleeve bearing once a month.
b.
To add oil, motor should be stationary. A false oil level is shown
when motor is running. It may be high or low, depending on
direction of rotation. Always fill to near the top of housing.
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:
14

a. Bearings should be cleaned andre-oiled every six months.
However, if oil is dirty and emulsified before this time, clean
more often.
b. To clean bearings, flush through filler cap with drain plug
removed.
c. After draining, seal threads of drain plug with an oil sealing
compound and refill the oil reservoir.
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.
Integral Horsepower Motor Bearings: Relubricate with Non-Fluid
Oil Corp G-60 or Chevron SRI #2 grease unless otherwise stamped on
the nameplate.
2.
G. E. Motors:
a.
G. E. Grease Specification D6A2C5- General Electric Co.,
Schenectady, N.Y.
b. A grease with following characteristics:
1. ASTM worked consistency 270-290 with minimum change over range
of operating temperatures.
2. Melting point
preferably above 150°C.
3. Freedom from separation of oil and soap.
4.
Freedom from abrasive matter and acidity.
3. Westinghouse Motors:
a.
Use Westinghouse 53701RY grease unless a special grease is ·
specified on the nameplate. Some equivalent greases are:
Chevron SRI - 2- Standard Oil of California
Premium RB -Texaco, Inc.
Unirex
N2 - Exxon
Dolium R - Shell Oil Company
Rykon Premium- American Oil
b. Lubricate approximately every two years - 1800 RPM &every year
- 3600 RPM.
4. Marathon Motors:
a.
Frame 56 Motor Bearings: Sealed lubricated bearings require no
attention.
b. All Other Frame Sizes: Alvania #2, Shell Oil Company or
equivalent. Relubricate approximately every two and one-half
years.
5. Reuland Motors:
a. Reuland Motors
feature lifetime lubricated, Sealed Ball Bearings,
grease packed
and sealed by the Bearing Manufacturer.
15

6. Baldor Motors:
a.
For motors 1/8 to 7-1/2 HP, relube every five years. For motors 10
to 40 HP, relube every three years.
b. Frame 21ST and smaller motor bearings: Alvania #2, Shell Oil
Company or equivalent.
c. Frame 254 and larger motor bearings: Dolium R, Shell Oil Company
or equivalent.
D. LUBRICANT FOR SLEAVE 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. SAE 10 viscosity for motors up to 1/2 HP.
c. SAE 20 viscosity for motors 1/2 HP and larger.
3. Marathon Motors:
a. Reoil with SAE No. 10 oil for every 2000 hours of motor operation.
NOTE: NEVER LUBRICATE COMMUTATORS.
NEVER OVERLUBRICATE.
16

STARTING THE OIL BURNER MODEL FV-20-2
After all pipe lines have been tested and all electrical connections have been
made, the fuses should be fastened in their proper places, the automatic
controls adjusted to operate the burner, and the burner motor oiled with SAE
No. 20 Motor Oil. ·
There should be sufficient oil in the tank. The oil lines and pump should be
freed of air by running the burner and bleeding the air through the gauge port
of
the fuel unit until oil runs free of bubbles. An oil pressure gauge should
be used when adjusting the pump pressure. Set pump pressure at 100 PSI.
When the burner is fired for the first time, loosen the air damper locking
screw
and set air damper to allow about one-half of the total opening of the
shutter. A finer adjustment may be made after the flame has been maintained in
a hot combustion chamber.
Metering of
the air for combustion is accomplished by the air damper. An
upward position of the lever allows more air to enter the combustion chamber
while
downward position of the lever allows less air to enter the combustion
chamber.
After setting the air damper to the desired position it should be
locked in place by tightening the linkage.
To obtain the best burner operation three adjustments are usually necessary.
l. The air damper that regulates the volume of air should be set to produce
the proper flame color. Increasing the volume of air will produce a flame
changing
from yellow toward white. Too much air usually produces a fire
having sparklers and can be detected by a strong odor. Decreasing the
volume of air will produce a flame changing from white through yellow into
an orange color with dark smokey tips at the end of the flames. The best
setting should yeild a flame between yellow and orange color with no smokey
tips.
2. The oil pressure at the pump should be adjusted between 90 and 120 PSI. To
get the best setting vary the pressure between these two settings until
needle on pressure gauge remains stationary or has the least movement. If
gauge is not available do not alter this setting more than 1-1/2 turns from
the original setting. Changing this setting may reduce flicker in flame
due to variable pressure.
3. Lengthwise movement of the nozzle pipe assembly forward or back to give the
best mixture of oil and air at the air nose. To make this adjustment,
loosen
the nut holding the assembly in position. Lock securely when
finished and check bus bars to be sure they are in position.
GENERAL SERVICE
A. If Oil Fails To Ignite
1. Make certain there is oil in the tank.
2. Check oil pressure- standard setting 100 PSI. If no pressure is
developed, bleed air from pump through gauge port opening.
3.
Remove nozzle pipe assembly. Check electrode setting both as to spark
gap and position of tips in relation to nozzle check tightness of nozzle.
4.
If electrode setting is correct, clean nozzle as follows:
a.
Remove nozzle from nozzle adapter.
b. Screw out nozzle strainer and insert.
17

GENERAL SERVICE CONT'D
c. Wash all nozzle parts in very hot water or in carbon tetrachloride,
making certain there are no dirt particles in the slots or nozzle
orifice. UNDER NO CIRCUMSTANCES, USE A PIN OR A NEEDLE TO CLEAN
SLOTS AND ORIFICE. Use the edge of a piece of hard paper to clean
slots. Use clean rags and keep hands free from grit and dirt while
working with nozzle
parts. IT MAY SAVE YOU A REPEAT SERVICE CALL.
d. Assemble nozzle and install in nozzle adapter.
5. Check transformer for proper spark as follows:
a.
Remove motor lead from tranformer terminal.
b. Remove nozzle pipe assembly from burner and connect buss bars to
transformer clips. WARNING: BUSS BARS CARRY HIGH VOLTAGE - KEEP
CLEAR OF THEM WHEN BURNER IS ON.
c. Turn burner on -spark should be strong enough that you cannot blow
spark from electrode tips.
B. If Fire Is One Sided
l. Follow steps A-3 and A-4 and if fire is still one sided, install a new
nozzle.
C. If Fire Is Well Centered But Rough
l. Check oil pressure- standard setting 100 PSI.
2. Clean nozzle as described under A-4
3. Adjust nozzle pipe assembly to the rear position (toward burner cover
plate) .
4. Adjust
pump pressure between 90 and 125 PSI. and set at point which gives
best
operation.
5. Check for fluctuating pump pressure - this may be corrected by step C-4.
6. Check for oil leaks in suction line or on suction side of fuel unit -
check
particularly at oil line filter and fuel unit end plate. An air
leak will generally be indicated by an intermittent hissing sound at the
fuel unit or by unsteady pump pressure. Air leaks MUST be eliminated.
7. Increase
air by rotating air damper slightly.
D. If After Fire or "Bump" Occurs on Shut-Down
1. Adjust nozzle pipe assembly to rear position (toward burner cover plate).
2. Make certain air is purged from fuel unit and nozzle pipe assembly.
3.
In crease pump pressure 5 to 10 PSI.
4. Che ck for air leaks in suction line and suction side of fuel unit (See
c -6).
5. Check for excessive vacuum on pump by inserting vacuum gauge in unused
suction opening in fuel
unit . Vacuum should not be over 7" . High vacuum
may be caused by kinked suction line, dirty oil line filter or dirty
strainer in pump .
6.
Rem o ve cut-off valve piston (under hex nut on fuel unit) and remove any
dirt particles on neoprene seat in the end piston.
E. If Fi re Puffs on Start
l. Follow step A-3
2. Check for air leaks in suction line on suction side of fuel unit (See
C-6).
3. On a two-pipe system, check for leaking check valve in suction line by
pu tting pressure on suction lin e be tween fuel unit and check valve with a
18