Bryan Boilers BE Series Service-Handbuch

Form 2055 Revision Date 5/1/2015



InstallationandOperating

ServiceManual

ELECTRICSTEAMBOILERS



BryanSteamLLC,783N.ChiliAvenue,Peru,IN46970,Phone765.473.6651,Fax765.473.3074

www.bryanboilers.com

Form 2055 i Revision Date 5/1/2015

Table of Contents

SECTION 1 –

INSTALLATION INSTRUCTIONS

1.1 Boiler Foundation ......................................................................................1

1.2 Clearances ................................................................................................1

1.3 Uncrating the Boiler...................................................................................1

1.4 Boiler Connections .................................................................................2-3

1.4.1 General

1.4.2 Steam Supply Connection

1.4.3 Feedwater Connection

1.4.4 Safety Relief Valve(s)

1.4.5 Blowdown Connection

1.5 Electrical Connection.................................................................................3

1.6 Boiler Accessory Equipment...................................................................4-5

1.6.1 Elements

1.6.2 Boiler Components – General

1.6.3 Power Panel Wiring

1.6.4 Control Circuit Wiring

1.6.5 Safety Relief Valves

1.6.6 Low Water Cut-Off

1.7 Procedures to be Followed Before Placing Boiler in Operation.................5

1.7.1 Hydrostatic Test of Boilers and System

SECTION 2 –

START-UP AND OPERATION

2.1 Limit Circuit Cut-Out Test .......................................................................6-7

2.1.1 Protective Devises

2.1.2 Steam Pressure Operating Control

2.1.3 High Limit Control

2.1.4 Low Water Cut-Off(s)

2.1.5 Combination Low Water Cut-Off & Feeder

2.1.6 Other Controls

2.1.7 Boiler Feed System

2.1.8 Chemical Feed System & Softener

2.2 Operating Controller..................................................................................8

2.2.1 PLC Step Control

2.3 Operating Instructions ...............................................................................8

2.3.1 Familiarization with Manual(s)

2.4 Maintenance Schedule..............................................................................8

2.4.1 Posting Schedule

Form 2055 ii Revision Date 5/1/2015

Table of Contents – cont.

SECTION 3 –

CARE AND MAINTENANCE

3.1 Required Precautions During Temporary Use......................................9-10

3.1.1 General

3.1.2 Operator Skills/Responsibilities

3.2 Cleaning the Boiler and System – New Systems ...............................10-11

3.2.1 Boil Out Procedure

3.3 System Clean Out...................................................................................12

3.3.1 System Cleaning Procedure

3.4 Replacement Boiler Installations -

Protection Against Corrosion & Sediment..........................................12-13

3.4.1 Clean or Replace All System Piping and Heating Units

3.5 Boiler Water Treatment......................................................................13-14

3.5.1 Purpose Of Water Treatment

3.5.2 Objectives

3.5.3 Water Softener

3.5.4 Continuous Monitoring Required

3.6 Suggested Maintenance Schedule.....................................................12-13

3.6.1 Daily

3.6.2 Weekly

3.6.3 Monthly

3.6.4 Annually

3.7 Float-Actuated Water Level Controls .......................................................15

3.8 Water Gauge Glasses.........................................................................15-16

3.8.1 Installation

3.8.2 Maintenance

3.8.3 Inspection

3.8.4 Replacement of Glass

3.9 Idle Boiler Care and Lay-Up...............................................................16-20

3.9.1 General

3.9.2 Pre-Operational Cleaning and Lay-Up

3.9.3 Taking Boilers Off Line

3.9.4 Pre-Shutdown Precautions

3.9.5 Washdown

3.9.6 Lay-Up Considerations

3.9.7 Wet Lay-Up of Steam Boilers – Short Term

3.9.8 Wet Lay-Up – Alternate Method

3.9.9 Dry Lay-Up of Steam Boilers – Long Term

3.9.10 Returning Idle Boiler to Service

Form 2055 1 Revision Date 5/1/2015

INSTALLATIOIN INSTRUCTIONS

ELECTRIC STEAM BOILERS

Note: Please read the entire instruction manual before attempting installation.

Insurance and local or state regulatory codes may contain additional or more stringent

requirements than those contained in this manual. Installation must conform to these codes and

any other authority having jurisdiction. Appropriate sections of NEC should be consulted and

followed.

1.1 BOILER FOUNDATION

Before uncrating, the boiler location should be prepared. The boiler should set upon a good level

concrete floor. If the boiler is not level or the floor is not in good condition, a concrete foundation

should be built, the dimensions being larger than the outside dimensions of the boiler base.

1.2 CLEARANCES

The front of the boiler should not be any closer than 36" from any obstruction for servicing the

electrical panels. The element end of the boiler should not have any obstruction to allow for the

same length as the boiler supplied for removal and servicing of elements. The back of the boiler

(as long as panels are not supplied in the rear) can be mounted next to an obstruction. Local

codes must be applied to specific installations and the minimum clearances established

accordingly. Provisions must also be made for service, accessibility, and clearance for piping

and electrical connections.

NOTE

ADHERE TO ALL APPLICABLE LOCAL CODES REGARDING BOILER INSTALLATION AND

CLEARANCES.

1.3 UNCRATING THE BOILER

Uncrate the boiler near its permanent location. Leave it on the bottom crating until ready to place it

permanently. Leave the plastic shroud on the boiler until all piping work is complete, cutting holes

in the plastic for access to connections.

Remove the bolts attaching the boiler to the crate at the underside of the bottom crating. Lift or

slide the boiler off of the bottom crating into position. Be careful not to tip the boiler up on one

corner or side, which could cause damage to jacket.

Sectio

Form 2055 2 Revision Date 5/1/2015

1.4 BOILER CONNECTIONS

1.4.1 GENERAL

Do not run any pipes along the element access and power panel side of the boiler. Maintain

clearances as shown on the dimensional drawing for servicing and as referenced in NEC. All

piping should be designed and installed to avoid any loadings on the boiler connections or piping.

1.4.2 STEAM SUPPLY CONNECTION

A steam shut-off valve must be installed between each boiler and the steam main. This valve

must be of the outside screw and yoke design to allow indication from a distance whether the

valve is open or closed.

1.4.3 FEEDWATER CONNECTION

Install a check valve and a globe valve between the feed pump and the boiler. It is also

recommended to install a globe valve between the feed pump and the receiver tank. This valve

can then be adjusted to bypass excess pump capacity to better control the boiler feed rate.

BOILER MUST CONTROL FEED WATER

The water feed to the boiler must be controlled by the boiler-mounted water level control. It is

unacceptable to use gravity return or to let the water feed be controlled by a

condensate/receiver/condensate pump system. The water feed to the boiler must be controlled:

by a feed pump control which is mounted on the boiler. This control is to activate the

feed pump on a boiler feed system. It will be necessary to supply such a system if not

already installed

by an automatic water feeder mounted on the boiler. This is used only on systems

requiring 100% make-up, such as humidification, steam process, etc.

NOTE

It is not recommended to provide the make-up for a closed steam heating system to the boiler by

means of a water feeder. It is preferred that system make-up be connected to the condensate

return tank of a boiler feed system. A boiler feed system may be used in conjunction with an

existing condensate receiver system by allowing the receiver system to pump condensate into the

boiler feed system tank.

Form 2055 3 Revision Date 5/1/2015

1.4.4 SAFETY RELIEF VALVE(S)

A connection is provided in the top of the boiler for the relief valve. The relief valve discharge

piping must be the same size as the relief valve discharge opening. Avoid over-tightening as this

can distort valve seats. All piping from relief valve must be independently supported with no

weight carried by the valve.

1.4.5 BLOWDOWN CONNECTION

Blowdown valve(s) must be full size of the connection on the boiler. Steam boilers 15 psig and

below require at least one blowdown valve. Higher pressure boilers require two blowdown valves

with one or both valves being slow opening type. Each water column and float type low water cut-

off must be equipped with a blowdown valve.

1.5 ELECTRICAL CONNECTION

IMPORTANT

All electrical connections must conform to the NEC and to all other applicable State and Local

Codes.

The heating elements supplied with Bryan electric boilers are of the resistance type with an

incoloy sheath and a watt density not exceeding 75 watts/square inch. These elements are

typically delta wired unless otherwise specified. Power supply voltage must be as shown on the

wiring diagram enclosed. A fused main disconnect switch must be supplied per NEC

requirements. Wiring to the main power terminals in the power panel by the contractor must have

current carrying capacity equal to at least 125% of the amperage rating of the boiler. The lugs

supplied are at the top of the power panel and the entrance can be recognized on the

dimensional.

EQUIPMENT GROUNDING: The boiler must be grounded in accordance with the NEC,

ANSI/NFPA #70

CAUTION

ALL CONTROL PANELS AND CONTROLS ARE SUBJECT TO SOME INTERNAL HEAT.

ADEQUATE BOILER ROOM VENTILATION MUST BE PROVIDED.

Form 2055 4 Revision Date 5/1/2015

1.6 BOILER ACCESSORY EQUIPMENT

1.6.1 ELEMENTS

The immersion type electric resistance heating elements are mounted in a standard 150# flange

(300# flange if required). These elements are held into this flange with brass fittings. Each

element hairpin is rated at 5 KW or 10 KW at the rated volts. The incoloy sheath is a nickel,

chrome and iron alloy, which provides good resistance to oxidation and has good strength

characteristics at elevated temperatures. By virtue of its very high nickel content, the material

does not have a tendency to become embrittled after prolonged exposure to temperatures.

Corrosion resistance of the incoloy is attributed to the chrome and nickel content of the alloy. This

type of material was chosen as a sheath material because of its resistance to corrosion oxidizing

conditions and attacks from impurities in the various water conditions. Each element is easily

replaced by using ordinary hand tools. This eliminates the necessity of having a complete element

bundle as spare parts and also eliminates the necessity of returning the element bundle to the

manufacturer for repair, although this service is available.

1.6.2 BOILER COMPONENTS - GENERAL

The boiler equipment list in this manual lists the components supplied with this boiler. A

description of the major components follows, however, detailed information can be found in each

manufacturer’s literature data

1.6.3 POWER PANEL WIRING

These circuits are broken down into branch circuits of no more than 50 amps per circuit. A

distribution lug in the BE Series and a copper bus bar in the BH Series is used to branch the

power to individual fuses and contactors in each branch circuit. Each leg in each circuit is

individually fused with fast acting fuses to interrupt power if required. The contactors are then

wired using high temperature wire to each element circuit and bundle located in the element

flange.

1.6.4 CONTROL CIRCUIT WIRING

The control circuit voltage is 120 V, single phase, and fed from a step down transformer (if

provided). The transformer’s primary side is connected to two fuses located in the power panel.

One side of the secondary is grounded and the other side feeds the control circuit through the

control circuit fuse. All of the safety controls are wired in series so that any one of the safety

controls will shut down the boiler if the limit is reached. Also, located in the control circuit a recycle

relay (in some cases the relay is built into the sequencer). In case of power failure, the function of

this relay is to eliminate a sudden power load on the distribution system. If a power failure occurs,

the recycle relay interrupts the control circuit power causing the magnetic contactors to drop out.

Form 2055 5 Revision Date 5/1/2015

Power is shut off to the elements until the modulating motor has driven the sequencer back to its

original starting position. The relay is then activated, and the sequencer will bring the steps back

on one at a time until the system is again balanced. There is also a limit supplied to be installed

with the shunt trip on the main circuit breaker in order to completely shut down all power to the

boiler. Refer to the electric wiring diagram supplied

1.6.5 SAFETY RELIEF VALVES

The safety relief valves are mounted on the top of the boiler. These are a final safety device in

case the operator and other safety devices fail. Such a failure will cause the pressure to rise in the

boiler to the set pressure of the relief valve. The relief valve will discharge, so that the boiler will

not be able to generate pressure beyond the set pressure of the relief valve.

1.6.6 LOW WATER CUT-OFF

The function of the low water cut-off is to shut down the boiler if for any reason the water level

should drop below the normal operating range

1.7 PROCEDURES TO BE FOLLOWED BEFORE PLACING

BOILER IN OPERATION

1.7.1 HYDROSTATIC TEST OF BOILERS AND

SYSTEM

After completing the boiler installation, the boiler connections, fittings, attachments and adjacent

piping must be inspected for leaks by filling the unit with water. The pressure should be gradually

increased to a pressure just below the setting of boiler safety relief valve(s).

Remove the boiler access panels (see dimensional drawing in this manual). Inspect all openings

and fittings for any leaks. Although the boiler is hydrostatically tested at the factory, minor leaks in

fittings and attachments can develop from shipping vibrations or from installation procedures. It is

often necessary to re-tighten such fittings after installation and after the boiler has been in

operation for some time. Replace panels before starting boiler.

Form 2055 6 Revision Date 5/1/2015

START-UP AND OPERATION

ELECTRIC STEAM BOILERS

WARNING

SERVICING AND START-UP MUST BE DONE ONLY BY FULLY TRAINED AND QUALIFIED

PERSONNEL.

CAUTION

BEFORE DISCONNECTING OR OPENING ANY BOILER ITEMS OR ACCESSORIES,

BEFORE CLEANING OR REPLACING PARTS OF ANY KIND, TAKE THE FOLLOWING

PRECAUTIONS:

1. TURN OFF AND LOCKOUT ALL ELECTRICAL DISCONNECTS TO THE BOILER AND

ANY OTHER EQUIPMENT OR SYSTEMS ELECTRICALLY INTERLOCKED WITH THE

BOILER.

2. ALL COVER PLATES, ENCLOSURES, AND GUARDS MUST BE IN PLACE AT ALL

TIMES EXCEPT DURING MAINTENANCE AND SERVICING.

2.1 LIMIT CIRCUIT CUT-OUT TEST

2.1.1 PROTECTIVE DEVICES

All operating and limit controls, and low water cutoffs must be tested for proper operation.

Sectio

Form 2055 7 Revision Date 5/1/2015

2.1.2 STEAM PRESSURE OPERATING CONTROL

The steam pressure in the boiler is regulated by the Boiler Operator. This is a pressure control

which senses the steam pressure and turns the boiler on and off accordingly. This control must be

operationally tested. Adjust the pressure setting on the control to a pressure less than the boiler

pressure (as shown on the boiler pressure gauge). The control should turn the boiler off. Restore

the control setting to normal. The boiler should cycle on.

2.1.3 HIGH LIMIT CONTROL

At least two additional pressure controllers are provided as high limit controls. They are set at a

pressure above the operator to act as a back-up should the operator fail. The high limit control

must be operationally tested. With the boiler operating, decrease the pressure setting of the limit

control below the current pressure of the boiler. The boiler should cycle off. Restore the high limit

control setting to normal (pushing the reset button if it is a manual reset type). The boiler should

now cycle on.

2.1.4 LOW WATER CUT-OFF(S)

Most boilers are supplied with at least one float or electric probe type control, designed to sense

the level of the water in the boiler. It operates to shut off the boiler if the water level drops below its

sensing level. The low water cut-off controls must be operationally tested by manually lowering

the boiler water level (by opening the drain valve). The boiler should cycle off when the water level

drops below the control point of the low water cut-off. When the water level is restored, the boiler

should cycle back on. Depress the manual reset button of devices which require manual reset in

order to restore the boiler to operation. Carefully read the enclosed literature on the low water cut-

off controls, particularly installing, operating and servicing.

2.1.5 COMBINATION LOW WATER CUT-OFF &

FEEDER

The low water cut-off/feeder supplied with some boilers serves as a low water cut-off (see above)

and also causes make-up water to be added to the boiler, should the water level drop below its

control point. This type of control must be operationally tested as described in Section 2.1.1 and

also to assure that the make-up water is introduced as needed. Carefully read the enclosed

literature on the Low Water Cut-off controls, particularly installing, operating and servicing.

2.1.6 OTHER CONTROLS

Additional controls, as required for the particular installation, may also be provided. Refer to the

literature on these devices included in the Boiler Manual. All such devices must be operationally

tested to assure reliable operation of the boiler and system.

2.1.7 BOILER FEED SYSTEM

The boiler feed pump must be operationally tested to assure that it can provide boiler feedwater at

the pressure and in the amount needed for safe and reliable boiler operation.

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