3.1.1 Boiler 0&M Manual

~

~

80 -2350 kWHigh Efficiency, Welded Steel, Gas or Oil (Class D) Boiler

September 2000

INDEX

Page No.SECTION 1

Figure 1.1Table 1.1Table 1.2

-General Data & Dimensions-Boiler Dimensions (mm)-Combustion Chamber Data

CLEARANCES-Boiler Clearances-Boiler Base Dimensions-Technical Data

1.11.11.'21.21.21.21.3

4.34.3

Figure 1.2Table 1.3Table 1.4

4.44.4

BOILER & BURNER POWERSUPPLY

Table 4.2 -Minimum Burner Tube LengthFigure 4.6 -Boiler & Burner Power

SupplyFigure 4.7 -Burner Cable Conduit FixingFigure 4.8 -Boiler Control Panel Wiring

ConnectionsBOILER CONTROL PANEL

Figure 4.9 -Control Panel LayoutFigure 4.10 -ControlPane.l AssemblyFigure 4.11 -Hours Run Meter AssemblyFigure 4.12 -Installation of ControllerFigure 4.13 -installation of Heat Exchanger

Insulation Blanket

SECTION 2

GENERAL 2.1STANDARD SUPPLY 2.1INSTALLATION 2.1BOilER SITING & BASE 2.2SYSTEM WATER QUALITY 2.2

4.7

(SECTION 5SECTION 3

BOILER COMMISSIONINGFAULT FINDINGBOILER MAINTENANCE

5.15..25.3

3.13.13.13.2

SECTION 63.33,4 6.1

Table 3.1a

3.6 6.26.3

Table 3.1b

3..7Table 3.2

ELECTRICAL SUPPLYFUELSUPPLYVENTILATIONFLUEFLUE SIZECONSIDERATIONSFAN DILUTION SYSTEMS

-Flue Resistance LossesGuide

-Flue Resistance LossesGuide

-Flue Dilution Systems-Duct Sizes & Fan VolumesWATER CIRCULATIONSYSTEMSBOILER PROTECTION

-Saturated Steam Pressures-Cold Feed Pipe Sizes

CISTERN SIZING-Open Vent Pipe Sizes-Safety Valye Sizes

SEALED SYSTEMSNOISE LEVEL

6.33.8

Figure 6.1 -Boiler Wiring DiagramFigure 6.2 -Schematic Control Panel

Logic DiagramFigure 6.3 -Volt Free Contact ConnectionsFigure 6.4 -Optional LocalfRemote

Switch WilingFigure 6.5 -Pump Overrun Using

Changeover Pipe ThermostatFigure 6.6 -Bumer Connection Wiling

6.46.43.9

3.93.103.103.113.113.123.123.13

Table 3.3Table 3.4 SECTION 7

Table 3.5Table 3.6

Figure 7.1 -BoilerComponents 7.1BOilER PARTS LIST 7.2

Figure 7.2 -Control Panel Components 7.3CONTROL PANEL PARTS LIST 7.4

SECTION 4 COMMISSIONING SHEET

4.Figure 4.1

4.14.1Table 4.1

Figure 4.2

4.24.24.24.3

Figure 4.3Figure 4.4Figure 4.5

BOILER INSTALLATION-Inside View of Boiler

Combustion Chamber Door-Number Of Turbulators-Insta.lJation of Turbulators

and Location of BoilerControl Panel

-Control Panel Mounting-Phial Pocket Location-Burner Tube Installation

4.44.54.54.64.64.6

POTTERTON COMMERCIAL PRODUCTS DIVISIONINSTALLATION, OPERATING & MAINTENANCE MANUALARIZONA

Section 1Page 1.1

Fiaure 1.1 -General Data & Dimensions

RETURN FLOWL5 L1

I L3

r4 I

H11H2

~

H31

-----r -~ A1 ~ A1 ~~

I ! I I3/4" CONDENSATE DRAIN

Table 1.1 -Boiler Dimensions (mm)

-r~-A3 ~IL7~ L6 ~

1 1/4" BSP DRAIN

1-141

L1 L2 L3 l6L4* L5 L7 H1 H2 H3 H4 A1 A2 A3

1289 9981_]289

998

1.12891

~~ .I 810 I ~ 1 900 1101~1150 11025-1 950 I 500 -I 100 1 283~1 50 I 998-140

170

200

1289 I 250 , 810 I 900 , 900

11010I1Q1O"

150 I 1025 I 950 I 500 I 100 I 283 I 50 I 998

1289 I 250 I 810 , 900 ! 900 150 I 1025 I 950 I 500 I 100 I 283 I 50 I 998

250

290

350

405

465

157 129011~

1484

!

1~2 I 350 11200! 1100 11100 11500 I 200 11300 11150! 600 i 100 I 423 I 50 11484

!

1962 I 350 I 1200 I 1100 I 1100 11500 ! 200 I 1300 I 1150 I 600 1100 I 423 I 50 I 1484

1962 423

2240 423

50 .11484

50 11784

2240

2240

12240

350 11500 11250 11250 I 1800 I 200 I 1450 11300 I 675 I 100 I 423 I 50 I 1784

I 350 I 1 500 ~1250,

1250 I 1800 I 200 , 1450 1,1300 I 675 , 100 I 423 I 50 11784

I

350 I 1500 1250 11800 I 200 i 1450 11300 I 675 I 100 I 423 I 50 \ 1784t- I 2255 I 400 11500 I 1450 11450 I 1800 I 250 i 1650 11466 I 766 ( 100 I 523 50 11784

523

523

50 /1784

50 I 1784

2680' 450 I 1750 11750 , 1750 I 2150 I 250 I 1950 I 1800 I 925 , 100 I 673 50 .I 2130

2680 I 450 I 1750 11750 , 1750 I 2150 I 250 I 1950 11800' 925 I 100 I 673 I 50 ,I 2130 I

2900 I 450 I 2000 ! 1900 11900 I 2400 I 250 I 2125 11970 ! 1020 I 180 I 703 I 91

~

380 2380

2580

2900 I 450 ! 2000 i 1900 I 1900 .I 2400 I 250 I 2125 11970 j 1020 I 180 I 703 I 91

!

3100 91

See boiler clearances on page 1.2. The clearance required in front of theboiler is either L4 or P + 1000mm whichever is the greater.

Section 1Page 1.2

POTTERTON COMMERCIAL PRODUCTS DIVISIONINSTALLATION,. OPERATING & MAINTENANCE MANUAL

ARIZONA

Table 1.2 -Combustion Chamber Data

CLEARANCES

The minimum boiler room clearances for access, erection and maintenance are given in Figure 1.2 andTable 1.3. There is no minimum clearance above the boiler however, it is recommended that clearanceis left above the top of the instrument panel for access. "POI is the burner projection of the selectedburner. NOTE: The Arizona boiler combustion chamber door is hinged on the right hand sideand will open to the right hand side only.

";;

'1i~i~\'1

Fiaure 1.2 -Boiler Clearances

CLEARANCE IN FRONT OF BOILEREITHER L4 (SEE TABLE 1.1) ORP + 100(lv1M WHICHEVER IS THE GREATER

500mm MINIMUM

J:-a-ble 1.3 -Boiler Base Dimensions

Model

80100

140

170200

260

290

350

405

465-520

W

1000

1000

1000

1000

1000

1200

1200

1200

1200

1200

1300

Model

580

640

700

800

900

1100

1400

1650

1850

2100

2350

W

1300

1300

1300

1500

1500

1500

1800

1800

2000

2000

2200

L

1200

1200

1200

1200

1200

1300

1700

1700

1700

1700

2000

L

2000

2000

2000

2000

2000

2000

2240

2240

2500

2500

2800

I.- w ~


Section 1Page 1.3

Table 1.4 -Technical Data

See notes on page 1.5

Section 1Page 1 .4

POTTERTON COMMERCIAL PRODUCTS DIVISIONINSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

Table 1.4 -Technical Data

See notes on page 1.5


Section 1Page 1.5

1 FUEL CONSUMPTION

Gas fuel consumption is based on natural gas with a gross calorific value of 38.6 MJ/m3, refer torelevant burner data sheet for minimum and maximum fuel pressures. The g~s rate should becorrected for the meter supply pressure on high pressure supplies to prevent over-firing. Oil fuelconsumption is based on Class D (35 second) gas oil with a gross calorific value of 45.5 MJ/kg,refer to relevant burner data sheet for minimum and maximum fuel supply pressures.

2. (a) MAXIMUM OPERATING PRESSURE

The maximum operating pressure is 5 bar. As an optional extra the boiler can be supplied with amaximum operating pressure of 10 bar on request.

(b) MINIMUM OPERATING PRESSURE

This is the minimum operating pressure of the boiler with pumps operating (NOT static pressure).The requirements of the Health & Safety Executive guidance note PM5 regarding maximumoperating temperatures should be observed.

3. BOILER FLUE CONNECTION

This is the nominal flue size of the flue connection spigot. Actual flue size required to achieveevacuation of the products of combustion under all running conditions should be calculated andmay need to be increased.

4 FLUE GAS VOLUME

Flue gas volumes are given at STP (standard temperature and pressure, 15°C and 1013.25 mbarrespectively). Typical CO2 levels are, 9% -gas firing, and 12% -oil firing. Flue gastemperatures stated are at nominal output (kW) under the following conditions, Ambienttemperature 20°C, excess air 20%, flow temperature 80°C and return temperature 60°C.

5. NATURAL VENTILATION

The sizes indicated are free grille areas and are based on a single boiler installation,

6. MECHANICAL VENTILATION

The volume given is for a single boiler instal/ation.

7.

WATER CONNECTION SIZES

The boiler water connections are 2" BSP on models 80 to 250 and flanged (PN6 standard, PN16for higher operating pressure option), on all other models. Counter flanges are not provided.

8. WATER FLOW RATESWater flow rates are given for boiler flow and return temperature difference of 11°C.

9 COLD FEED/OPEN VENT/SAFETY VALVE SIZES

Sizes indicated are minimum sizes for single boiler installations. Safety valve sizes are for usewith open vented systems only. see BS 6644 for sealed system requirements.

10 MINIMUM RETURN TEMPERATUREThis is the minimum operating return temperature to prevent condensation within the boilersystem. See section 3 for further details on back end protection.

11 WEIGHTThe dry weight is exclusive of the burner and gas train, see burner manufacturers literature forrelevant burner weights.

Section 2Page 2.1

POTTERT'ON COMMERCIAL PRODUCTS DIVISIONINSTALlATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

'I ,; j

!;

7I[

1,w,

GENERAL

!

The standard boiler is factory tested to 7.5 bar with amaximum working pressure of 5 bar. Boilers can besupplied ~rith a maximum working pressure of 10bar (test pressure 15 bar) on request.

The Potterton Arizona is a high efficiency steelboiler in 22 sizes offering heat outputs from 80 to2350 kW

~

PackaainaThe Arizona is a one piece boiler has been speciallydeveloped for the public and commercial sectors.Compact dimensions mean it can ber easily andquickly installed in existing or new boiler houses.

Net efficiency of 92% is obtained through the largetwo pass reverse flame combustion chamber designwith high efficiency turbulators and a pressurisedcombustion chamber together with double layeredinsulation producing minimum case losses of lessthan 0.5% of boiler output.

The boiler is delivered in 4 packages as follows:-.Boiler heat exchanger complete (including 1 st

layer Iboiler insulation blanket)..Contrlol panel, fittings bumer mounting ceramic

fibre insulation -located inside the combustionchamber

.Casing pack (including 2nd layer boilerinsulation blanket).

.Bumer

DeliverYThe boiler is available for use with natural gas or 35second oil. Note that specialist lifting equipment may be

required to position the boiler on site, (especially forlarger models). Two lifting eyes are fitted to theboiler for this purpose.

A comprehensive control panel is provided to alloweasy control of the boiler with an option formonitoring via a BMS.

STANDARD SUPPLY INSTALLAI!QN

.

The installation should comply with relevant BritishStandard :Specifications, Codes of Practice andcurrent Building Regulations, together with anyspecial rE~gional requirements of the LocalAuthorities, Gas Undertaking and InsuranceCompany. All electrical wiring must comply withI.E.E. ReglLJlations for the Electrical Equipment of

Buildings.

.........

The installation of the boiler must be in accordancewith the rel~evant requirements of:-

Steel boiler shell (operating pressure 5 bar, testpressure 7.5 bar)High efficiency turbulatorsFlueway cleaning coversDouble insulation comprising 2 x 50mminsulation blanketsPainted chequer plate boiler topBoiler casingBurner adapter plate and gasketControl PanelMatched oil, gas or dual fuel burnerCasing colours Black-

Red - Health & Safety at Work Act 1974,

CP331:3 Low Pressure Installation Pipes.

BS 6644: 1991 Installation of Gas Fired Boilers.

BS 7074: 1989 Part 2 Application, Selection &Installation of Expansion Vessels & AncillaryEquipment for Sealed Water Systems.

PM5 Health & Safety Executive Guidance Note forAutomatically Controlled Steam & Hot WaterBoilers.

CP341 :300..307 Central Heating by Low PressureHot Water.

Control Panel.Thermometer.1 st Stage thermostat.2nd Stage thermostat.Overheat thermostat.Power on indicator light.Overheat indicator light.Burner on/off switch.Overheat thermostat test switch.6.3A fuse.1 st Stage run indicator light.2nd Stage run indicator light.Burner lockout indicator light.Pump on/off switch.On/off burner connection cable.High/low burner connection cable.1 st Stage hours run meter.2nd Stage hours run meter

CP342:2 C4~ntralised Hot Water Supply.


Section 2Page 2.2

Also for gas fired appliances the following BritishGas publications:- When preparing a site, reference should be made to

Local Authorities and Building Regulations 1992.Gas Safety (Installation & Use) Regulations 1984.

I

The Arizona boiler is not suitable for installation inkitchens or living areas.IM/11 Flues for Commercial and Industrial Gas

Fired Boilers and Air Heaters.

IM/2 PurgingInstallations.

Procedure for Non-Domestic SYSTEM WA IER QUALITY

To ensure the boiler heat exchanger remains ingood condition it is essential to condition andmonitor the system water to the following criteria:-

IM/S SoundnessInstallations.

Testing for Non-Domestic

In the event of a gas booster being necessary referto IM/16 'Guidance Notes on the Installation of GasPipework, Boosters and Compressors in CustomersPremises' and the Gas Act 1972, Schedule 4,Paragraph 18.

1 Water HardnessIf the system fill water has a hardness in excessof 250mg/1 (17.50 Clark) the water should besoftened prior to filling the system to ensure thatexcessive scaling does not occur within the heat

exchanger.Manufacturers notes must not be taken in any wayas overriding statutory obligations. 2. Water Acidity

The system fill water should have a pH valuebetween 7 -8.5 to ensure corrosion of the heatexchanger does not occur.

In addition for oil fired appliances refer to thefollowing:-

BS 799: Oil Burning Equipment 3. Free OxygenThe free oxygen content of the system watershould be zero. (When testing for oxygencontent the sample should be testedimmediately it is drawn from the system toensure a true reading is obtained).

For boilers with a heat input rating greater than2MW the provisions of BS 6644 have been adoptedas the best practice.

BOILER SITING AND BASE

4.

Iron Ions/OxidesIron content of the system water should be lessthan 0.1 lng/I. Iron ions are colourless, if iron isa serious problem then iron oxides, FeZO3 andFe3O4' coloured red and black respectively maybe produced.

The boiler should be sited in accordance with BS6644: 1991 with respect to protecting the boiler fromdamage, air for combustion and ventilation,discharge of products of combustion, clearances forservice and access, temperatures, noise levels, thedisposal of boiler water and flooding of the boilerhouse or seepage from a roof top boiler house. Seefigure 1.2 for boiler clearances for service andaccess and table 1.3 for boiler base dimensions.

5. SulphatesSodium Sulphate is the principal component ofwater treatment. Inclusion in the water systemensures dissolved oxygen is removed and thesystem is protected against corrosion.

A level non-combustible floor capable of supportingthe weight of the boiler filled with water, see Table1.4, together with any additional weight bearingdown on the base from connections, burner, etc,must be provided.

6. Copper IonsThe copper content of the system water shouldbe less than O.OSmg/l. If large quantities ofcopper are present red and black copper oxideCu20 and CuO and, grey/green coppercarbonate, CuCO3 will be produced. Copper willcorrode iron and aluminium within the system.

The weight of the boiler is supported by two "C"section supports fitted to the bottom of the boiler,see figure 1.1 and table 1.1 for support dimensions.

For certain special installations a sound proof plinthmay be necessary and a metal plinth resting onanti-vibration pads is recommended in these!instances. i

IMPORTANT: llnder no circumstances shouldraw make-up water be allowed to be regularlyintroduced into the system.

Section 3Page 3.1

POTTER-IrON COMMERCIAL PRODUCTS DIVISIONINSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

ELECTRICAL SUPPLY On oil distribution systems with long pipe runs orwhen the oil tanks are mounted at a lower level thanthe burner, consideration should be given to the useof a pressurised ring main. The individual boilerconnections to the ring main should incorporatepressure regulating valves to maintain a constantpressure to the burner below the maximum inletpressure.

The Arizona is supplied with both single phase andthree phase burners. The boiler installation shouldbe connected via a fused isolator. For a threephase installation a separate 230V 50Hz singlephase electrical supply should be taken to the boilerinstrument panel. This is fused 6.3A in theinstrument panel. See figure 4.6, page 4.4.

~I!.UrnQNAll on site wiring shall conform to I.E.E. Regulations.

Safe, e'ffjcient and trouble free operation ofconventionally flued boilers is vitally dependentupon the provision of an adequate supply of freshair to thE! room in which the appliance is installed.Account must also be taken of any other fuelburning appliance existing or to be fitted whendesignin~1 the ventilation and combustion airsystems.

.B.!ELSUPPLY

NATURAL GAS

Where there is an existing primary gas meter, theappropriate gas supplier/undertaking must beconsulted to ensure that the service/meter supplycapacity is adequate for the proposed installation.

The air slupplied for boiler house ventilation shall besuch that the maximum temperatures within theboiler house shall not exceed 25°C at floor level,3~C at mid level (1.5m above floor level) and 40°Cat ceilin~J level (or 100mm below ceiling level).Refer to 135 6644: 1991 for further details.

For gas burner connection sizes refer to the burnercard or burner manufacturers instructions. Note thatelevated gas pressure may be required, particularlyfor the larger models, (a gas booster may berequired). Ensure that the required gas volume atthe correct pressure is available.

Air SUDDlv bv Natural VentilationThe gas supply pipe should be sized to allow theminimum operating pressure to be available at thebumer inlet under full running conditions. The pipeshould be sized to prevent excessive pressure dropsunder full running conditions.

Ventilation by grilles communicating directly with theoutside air is required at both high and low levels.

A minimum free area of the grilles for a single boilerare given in Table 1.4. Where plant is likely to usedat or near maximum capacity during the summermonths, additional ventilation may be required toprevent excess temperatures.

Where gas boosters are required attention is drawnto the Gas Act 1986, Schedule 5, Part II, paragraph8 (4). Guidance is given in IM/16 "Guidance Noteson the Installation of Gas Pipework, Boosters andCompressors in Customers Premises" published byBritish Gas Pic. The gas booster should beelectrically interlocked to the burner.

For boiler houses with multiple boiler installationsthe minimum ventilation should be sized inaccordam:e with BS 6644 as follows:-

GAS OIL (CLASS "0") Low Level (inlet) - 540 cm2 plus 4.5 cm2 per kW inexcess of 60 kW total ratedinput.Each burner is provided with an integral fuel pump.

For boilers up to 300kW output a single pipe systemwith a positive head is adequate. For boilers inexcess of this output the burner manufacturershould be consulted.

Hiah Level (outlet) -270 cm2 plus 2.25 cm2 per kWin excess of 60 kW total rated

input.

Each burner is provided with a fuel filter forinstallation local to the burner. Refer to burnermanufacturers information pack supplied with eachburner for connection details for one and two pipe

operation.

The abov'e calculated areas are "free" grille areas.Grilles should be designed to minimise high velocityair strearns within the boiler house. Typical freearea of a standard louvre is a~.proximately 50%.

For boilers installed in a basement boiler house orsimilar, it is recommended that the inlet air beducted to low level in ducting not less than equal tothe free grille area. Should the inlet duct length be

Oil distribution pipes should be sized to maintainpositive pressure at the burner inlet where possible.


Section 3Page 3.2

excessive then mechanical ventilation should beused.

isolate the boiler from the area by situating it in aseparate area where fresh air can be introduced.

Position ventilation grilles to avoid accidentalobstruction by blockage or flooding.

Care should be taken in positioning extract ductsIfrom contaminated areas in relation to boiler housegrilles to ensure that cross contamination will notoccur.Fur1her guidance on ventilation for gas appliances is

provided by BS 6644: 1991.

E!::Y5Air Supply by Mechanical Ventilation

To ensure safe and satisfactory operation thechimney system, which may be individual orcommon in the case of modular boiler installations,shall be capable of the complete evacuation ofcombustion products at all times. The effectiveI height of the chimney terminal(s) above the boiler(s)flue outlet(s) shall ensure sufficient buoyancy toovercome the resistance of the bends, tees and runsof the flue pipe involved and shall terminate in aIdown draught free zone. The number of bends usedshould be kept to a minimum and runs of flue pipeless than 450 to the horizontal should be avoided inorder to comply with the recommendations made inBS 6644: 1991, British Gas publication IM/11 "Fluesfor Commercial and Industrial Gas Fired Boilers andAir Heaters". The third edition of the 1956 Clean AirAct Memorandum and the Building Regulationsshould be strictly observed and approval obtainedIwhere applicable, combustion chamber details aregiven in Section 1, Table 1.2.

The supply of air to a space housing the boiler bymechanical means should be by mechanical inletwith natural or mechanical extraction. Mechanicalventilation with natural inlet must not be used. SeeTable 1.4 for mechanical inlet ventilation rates forsingle boiler applications

For multiple boiler installations the ventilation rate isbased on a 0.9 m3/sec flow rate per 1000 kW totalrated input. The design extract rate should bebased on 0.6 m3/sec flow rate per 1000 kW totalrated input.

For mechanical ventilation systems, an automaticcontrol should be provided to cut off the supply offuel to the boiler(s) in the event of failure of air flowin either inlet or extraction fans.

IMPORTANT: The use of an extractor fan in thesame room as the boiler (or in an adjacent roomin communication) can, in certain conditions,adversely affect the safe operation of the boilerand th£:refore must be avoided.

The chimney design should avoid the formation ofcondensate which may be achieved by insulatingthe flue. Typical flue gas temperatures for theArizona boiler are given in Table 1.4.

Tests for spillage of products from the flue systemwhen the extractor fan is running and all doors anawindows are shut should be carried out duringcommissioning. If spillage is detected, the area ofpermanent ventilation must be increased.

In the case of flue systems which are exposed andhave an overall height of 12m or more thenconsideration should be given to lining the flue.

In the case of brick or similar structures a stainlesssteel rigid or flexible flue liner (Grade 304/316) maybe used backed up with a 50mm minimum thicklayer of vermiculite or perlite granules between theinner skin and the chimney body. Cavities aroundthe liner should be sealed at both top and bottom.

Contaminated Combustion Air

It is essential that fresh and uncontaminated air isintroduced to the boiler for combustion.

A flue system should be no nearer than 50mm tocombustible material except where it passes throughit enclosed in a sleeve of non-combustible materialwith an annular (air) space of 25mm.

Air contaminated with chlorine vapours and CFCgases must not be allowed to enter boilercombustion chambers or formation of chlorine gasand hydrochloric acid will create severe and rapidboiler corrosion. There is also a danger that toxicchlorine gas will be emitted from the boiler flue. The flue termination should be at least 1 m above

the roof surface and away from any wind pressureareas where the flue products could re-enter thebuilding, ego near an openable window, mechanicalair inlet, etc. Flues should not be terminated inI areas where down draught may occur.

In areas where such products are used, and theseinclude degreasants, dry cleaning fluids, refrigerantsand aerosol propellants, steps must be taken to

..

Section 3Page 3.3

POTTERTON COMMERCIAL PRODUCTS DIVISIONINSTALlATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

iMPORTANT: 900 square bends must not beused on the flue system, including the boilerflue spigot, a straight length followed by an"easy sweep" or lobster back bend should beused.

Where the flue draught is inadequate to meet the

minimum boiler flue draught requirements or

excessive horizontal runs of flue have been utilised

that may prevent satisfactory start-up of the boilerand flue system, then mechanical assistance should

be considered. The buoyancy force is directlyproportional to the flue gas temperature of theexhaust gas. The flue system should be designed,and insulated where necessary, to maintain a

temperature drop of less than 17°C between the fluegas entry and flue gas exit.

On multiple boiler installations where a common flueheader is utilised. boiler connections to the flue

header and connection of the flue header to the

chimney stack should utilise 1350 swept "T"connections.

For flue calculation purposes the mean flue gasI temperature is equated from flue gas temperatureI (net) + ambient temperature -17°C/2 (this assumesI a maximum temperature drop of 17°C across the

flue system and represents the mean temperature).

For example the Arizona Model 140 has a typicalflue gas temperature of 170°C (net). Assuming anambient temperature of 20°C a typical mean fluegas temperature for this boiler would be:-

Drainage points positioned at the bottom of all

vertical chimney sections should be provided. Drain

pipes should be no less than 25mm 1.0. and should

be manufactured from acid condensate resistantmaterial such as high temperature polypropelene or

stainless steel and positioned so that pipe runs anddischarge points are not subject to the effects offrost. Copper pipe is not suitable due to the mildlyacidic properties of the condensate. Condensatepipe runs should fall with a gradient of at least 3%and at no point must the drain pipe rise above thelevel of the drainage point connection.

170 + 20 -11 = 181.5°C

2

~: Net flue gas temperature = gross flue gastemperature -ambient

A draught of 0-4mm.w.g. (0-0.16 in.w.g.) should beprovided at the flue socket under full load runningconditions. The flue system should be designed toevacuate the products of combustion when allboilers are firing. The Local Authority should beconsulted with regard to Clean Air Act approval.

The buoyancy force available due to the verticalheight of the flue can be calculated as follows:-

[ 1 -L JB = 353 x H x t"+2=t3 -tz+273FLUE SIZE CONSIDERATIONS

Nominal boiler flue connection sizes are given inTable 1.4 these sizes refer to the boiler flueconnection spigot.

The actual size of the flue system will depend onindividual site applications. Detailed below aregeneral considerations on sizing flue systems.These notes are for guidance only and PottertonCommercial Division cannot accept responsibility forflue system design.

where: B = Buoyancy force in mmwgH = Stack height in mt1 = Ambient temperature °Ct2 = Mean flue gas temperature °C

For an Arizona boiler buoyancy force is typically 0.4mmwg (80 model), 0.41 mmwg (100 -170 models)and 0.43 mmwg (180 -2350 models) per metrestack height measured vertically from the flue

I connection on the boiler to the chimney exit point.

Natural Drauaht Flue Systems

Flue System LossesBuoyancy Force

Losses in flue systems are attributed to frictionlosses due to flue gas velocities, plus pressurelosses due to fittings and the chimney exit point.Table 3.1 (page 3.6) gives the pressure loss foreach metre of flue pipe and the pressure drop forIeach flue fitting. The flue system pressure dropsshould be totalled including all horizontal flue runsand the chimney exit loss.

Natural draught flue systems are designed so thatthe buoyancy force due to the hot flue gases createa draught (suction) that, after overcoming resistancelosses, is adequate for the flue draughtrequirements at the boiler connection spigot given inTable 1.4.


Section 3Page 3.4

Excessive Buoyancy ForceSubtraction of the total loss from the buoyancyavailable will give the flue draught available at theboiler flue outlet spigot. The flue system should besized so that the draught available is within theoperating range of the boiler as given in Table 1.4.

To reduce a high flue draught to an acceptableoperating level, consideration should be given to theinstallation of a flue draught stabiliser.

Horizontal Flue Runs Common Flue Systems

Horizontal flue runs are not recommended!particularly over 3m in length, where these areunavoidable advice should be sought from a flue I

system specialist. I

Where multiple boilers are installed on a commonflue system then the flue system should be designedto ensure the correct operation of the flue on varyingload conditions. In particular that the appliance fluedraught is within the operating parameter under fullload and partial load conditions. For safe andreliable operation of the boiler plant it isrecommended that the variance in flue draught

I available at each appliance under full and part loadoperation is designed to a minimum.

Cold Start Considerations

When the boiler starts up from cold no flue draughtIis available due to buoyancy and therefore the

burner has to overcome the total resistance lossresulting in a positive pressure at the base of theflue equal to the total resistance loss as calculatedfrom Table 3.1. Following start up of the boiler aflue draught, as calculated above, is available at theboiler flue connection spigot. This start upsequence results in the burner operating with a fluedraught that can vary between P1 (positive fluepressure) and P2 (flue draught), ego for a systemwith a total resistance of 5mm and a hot fluedraught of 3 mm (-3 mm pressure), the burner wouldbe subject to a variance in flue draught on start upof 8 mm.

(It is recommended that the services of aspecialist flue system manufacturer are soughtfor the design of common flue systems).

Mechanical Assisted Flue Systems

Where mechanical assisted flue systems are beingconsidered it is recommended that the advice of aflue system specialist is sought to ensure the dutyand suitability of the fan. On mechanically assistedflues the boilers must be interlocked to prevent

I operation unless the fan is operating and air flow is

proved.(P2) (P1)

Flue Draught Flue Resistance-3mmwg 5mmwg

I 9 I

~ Total variance 8mmwg~

FAN DILUTION SYSTEMS

Potter1on Commercial gas fired boilers are suitablefor fan dilution systems for low level discharge ofproducts of combustion in accordance with BS 6644.

The fan dilution system should be designed toreduce the CO2 concentration of the ventedcombustion products to 1 % (volumetric) or less.For reliable operation of boiler plant and in particular

Ion oil fired appliances, to prevent premature sootingof the boiler the variance in resistance on boiler startup should be kept to a minimum and is not Irecommended to exceed 6 mm. For example on a i

long, thin, tall flue system the cold start resistance ishigh but, due to the height, the flue draughtavailable under full running conditions is also highresulting in an unacceptable variance in flue gasconditions. To reduce the cold start resistanceconsideration should be given to increasing the fluesizes or soft starting of the boiler plant and fluesystem by operating boilers on low fire only for a

pre-determined period.

The discharge velocity from the fan dilution systemshould be a minimum of 7.5 m/sec and should be atleast 2m above ground level for systems up to 1 MW

input.

The outlet grille should diffuse the products ofcombustion upwards and be located so thatre-circulation of combustion products is avoided, inparticular the positioning of fan dilution systems intotally enclosed wells or courtyards should beavoided. The inlet and outlet grilles must be locatedon the same face of the building.

Section 3Page 3.5

POTTERTON CO~'MERCIAL PRODUCTS DIVISIONINSTALLATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

Fan dilution systems must be interlocked to preventoperation of the boilers unless adequate air flow isproved.

EXAMPL~

.-I :ii;

~-300mm DiaIn accordance with BS 6644: 1991 the position of

the outlet grille should comply with the following:- --.Eco

1. The outlet grille shall not be less than 2 x 'U'mfrom any fan assisted intake, where 'U' is theun-corrected chimney height in metres, asdefined in the Clean Air Act and is calculatedfrom:-

(\, TT I! -

c;:::~

Arizona Model 520'U' = 1.3 QO.6

2 x 45' bends toform easy sweepbend(where '0' is the heat input in MW)

2. The outlet shall not be within 2 x 'U' of anopenable window or 6 x 'U' from an adjacentbuilding.

An Arizona Model 520 boiler connected to a 300mmdiameter flue 6 metres high, net flue gastemperature 180°C. The flue draught is calculatedas follows from table 3.1:-3. The fan dilution system should be designed to

provide a flue draught at each boiler of 1-2m.m.w.g. 0.7874 mmwg

0.3150 mmwg0.3792 mmwg

Flue exit loss450 bend loss (2 x 0.1575)Straight flue loss (6 x 0.0632)Typical duct sizes, fan volumes and values of 'U'

are given in Table 3.2.Total flue pressure loss (P1) 1.4816 mmwg

It is important that adequate ventilation is providedinto the boiler house especially as a proportion ofthe dilution air is drawn through the draughtdiverters on atmospheric appliances. Ventilationrequirements must take this into account and mayrequire larger louvres.

The buoyancy available, dP, is:-

6 x 0.43 = 2.58 mmwg

Subtracting the loss from the buoyancy force:-

P2 = dP -P1= 2.58 -1.4816= 1.0984 mmwg draught

THE ABOVE RECOMMENDATIONS ARE FORGENERAL GUIDANCE ONLY. POTTERTONCOMMERCIAL DIVISION CANNOT ACCEPTRESPONSIBILITY FOR FLUE SYSTEM DESIGNSBASED ON THE ABOVE RECOMMENDATIONS.

P2 is within the range 0 -4 mmwg and therefore isan acceptable draught.

Note: P2 is a negative pressure, ie. suction at theflue exit.

Difference between hot and cold running (p1 + P2):-

2.58 + 1.4816 = 4.0616 mmwg

This is less than 6 mmwg and therefore should givereliable cold start operation.

POTTERTON COMMERCIAL PRODUCTS DIVISIONINSTALlATION, OPERATING & MAINTENANCE MANUALARIZONA

Section 3Page 3.6

Table 3.1a -Flue Resistance Losses Guide

FLUE DIAMETER (mm)

ArizonaModel

200mm 250mm

Flue 45 deg Straight Flue Flue 45 deg Straight FlueExit Bend Loss Flue Loss Gas Exit Bend Loss Flue Loss Gas

Loss per m Velocity Loss per m Velocity

mmwg mmwg mmwg m/s mmwg mmwg mmwg m/s

0.0909 0.0182 0.0152 1.5042

0.1431 0.0286 0.0228 1.8977

0.2823 0.0565 0.0413 2.6652 0.1156 0.0231 0.0144 1.7057

0.4165 0.0833 0.058 3.2373 0.1706 0.0341 0.0203 2.0718

0.5893 0.1179 0.0802 3.8932 0.2414 0.0483 0.028 2.4916

0.3766 0.0753 0.0414 3.1123

0.5079 0.1016 0.0537 3.6142

0.74 0.148 0.0747 4.3626

0.9905 0.1981 0.0964 5.0471

ArizonaModel

80

100

140

170

200

250

290

350

405

80

100

140

170

200

250

290

350

405

FLUE DIAMETER (mm)

ArizonaModel

ArizonaModel

300mm 350mm

Flue 45 deg Straight Flue Flue 45 deg Straight FlueExit Bend Loss Flue Loss Gas Exit Bend Loss Flue Loss GasLoss per m Velocity Loss per m Velocity


0.1164 0.0233 0.0119 1.73031

0.1816 0.0363 0.0175 2.1613 0.098 0.0196 0.0085 1.5879

0.2449 0.049 0.0228 2.5099 0.1322 0.0264 0.011 1.844

0.3569 0.0714 0.0316 3.0296 0.1926 0.0385 0.0153 2.2258

0.4777 0.0955 0.0408 3.505 0.2578 0.0516 0.0198 2.5751

0.6298 0.126 0.052 4.0247 0.34 0.068 0.0252 2.9569

0.7874 0.1575 0.0632 4.5 0.425 0.085 0.0306 3.3062

0.9798 0.196 0.0766 5.0198 0.5289 0.1058 0.037 3.688

1.1904 0.2381 0.0908 5.5332 0.6426 0.1285 0.0439 4.0652

0.7689 0.1538 0.0514 4.447

1.0054 0.2011 0.065 5.085

200

250

290

350

405

465

520

580

640

700

800

200

250

290

350

405

465

520580

640

700800

Section 3Page 3.7


ARIZONA

Table 3.1 b -Flue Resistance Losses Guide

FLUE DIAMETER (mm)

ArizonaModel

ArizonaModel

350

405

465

520

580

640

700

800

900

1100

1400

350

405

465

520

580

640

700

800

900

1100

1400

400mm 450mm

Flue 45 deg Straight Flue Flue 45 deg Straight FlueExit Bend Loss Flue Loss Gas Exit Bend Loss Flue Loss GasLoss per m Velocity Loss per m Velocity


0.1129 0.0226 0.0082 1.70421

0.1511 0.0302 0.0105 1.9715 0.0944 0.0189 0.006 1.5578

0.1993 0.0399 0.0134 2.2639 0.1244 0.0249 0.0077 1.7887

0.2491 0.0498 0.0163 2.5313 0.1555 0.0311 0.0094 2

0.31 0.062 0.0198 2.8236 0.1935 0.0387 0.0113 2.231

0.3767 0.0753 0.0234 3.1124 0.2351 0.047 0.0134 2.4592

0.4507 0.0901 0.0274 3.4047 0.2814 0.0563 0.0157 2.6902

0.5893 0.1179 0.0347 3.8932 0.3679 0.0736 0.0199 3.0761

0.7453 0.1491 0.0426 4.378 0.4653 0.0931 0.0244 3.4592

1.1135 0.2227 0.0605 5.3513 0.6951 0.139 0.0347 4.2282i 1.1268 0.2254 0.053 5.3832

FLUE DIAMETER (mm)

ArizonaModel

ArizonaModel

500mm

45 degBend Loss

mmwg

FlueExitLoss

mmwg

FlueGas

Velocity

m/s

FlueExitLoss

mmwp

FlueGas

Velocitym/s

600mm

45 deg StraightBend Loss Flue Loss

perm

mmwg mmwg 0520

580

640

700

800

900

1100

1400

1650

1850

2100

2350

0.0204

0.0254

0.0309

0.0369

0.0483

0.0611

0.0912

0.1479

0.2053

0.0057

0.0069

0.0082

0.0096

0.0121

0.0149

0.0211

0.0323

0.043

0.102

0.127

0.1543

0.1846

0.2414

0.3053

0.4561

0.7393

1.0266

520

580

640

700

800

900

1100

1400

1650

1850

2100

2350

1.62

1.8071

1.9919

2.179

2.4916

2.8019

3.4248

4.3604

5.1384

0.0178

0.0233

0.0294

0.044

0.0713

0.099

0.1245

0.1604

0.2008

0.0041

0.0051

0.0063

0.009

0.0137

0.0182

0.0223

0.0278

0.0338

1.5132

1.7303

1.9458

2.3784

3.028

3.5683

4.0009

4.5412

5.0816

u

StraightFlue Loss

perm

mmwQ

0.089

0.1164

0.1472

0.2199

0.3565

0.4951

0.6224

0.8019

1.0041


Section 3Page 3.8

Table 3.2 -Flue Dilution Systems -Duct Sizes & Fan Volumes

Gross InputkW

Input Gasm3/h

I

Flue Volume

@ 1% CO2m3/s

DuctDiameter

mm

Velocity "'U""

m/s8.587

10.733

9.617

8.11

9.5418.762

7.782

9.392

8.587

7.986

8.93

8.232

7.633

8.348

8.129

7.886

8.396

9.392

8.746

7.943

9.016

8.338

97

121

169

205

241

302

350

422

489

561

627

700

772

844

965

1,086

1,327

1,689

1,991

2,232

2,533

2,835

0.27

0.337

0.472

0.573

0.674

0.843

0.978

1.18

1.366

1.568

1.753

1.956

2.158

2.36

2.698

3.035

3.709

4.721

5.564

6.238

7.081

7.924

200

200

250

300

300

350

400

400

450

500

500

550

600

600

650

700

750

800

900

1,0001,0001,100

m

0.32

0.365

0.447

0.5020.554

0.633

0.692

0.775

0.846

0.919

0.983

1.049

1.113

1.175

1.273

1.366

1.541

1.78

1.965

2.104

2.271

2.429

9

11

16

19

23

28

33

39

46

52

59

65

72

79

90

101

124

158

186

208

236

264

~

odel Output

kW

80

100

140

170

200

250

290

350

405

465--~~80 640

700

800

900

~~~~~1,650

1,850

2,100

2,350

Flue gas volume at 1013.25 mbars and 15°C. Typical diluted flue gas temperature is 14OCabove ambient.

Un-corrected chimney height from the Clean Air Act.

Section 3Page 3.9


ARIZONA

.

WATER CIRCULATION SYSTEM§ The maximum and minimum design pressures are8 bar (272 ft.w.g.) and 2 bar (68 ft.w.g.). Care isneeded in siting the pump relative to the cold feedand open vent connections. (NOTE: The above arenot static pressures).

The water circulation systems should be indirectand installed in accordance with the relevant partsof British Standards Codes of Practice CP342 andBS 6644: 1991.

The boiler flow and return connection sizes aregiven in Table 1.4.The maximum and minimum design temperature

differential across the boiler should be 20°C and10°C and the boiler should be prevented fromoperating with flow rates giving a temperaturedifference across the boiler greater than 25°C basedon the full boiler output. Boilers operating underconstant flow conditions can be more accuratelycontrolled and are not subject to excessivetemperature stresses. The boiler must not be firedwith less than the minimum flow.

It is recommended that the system is designed togive a constant boiler flow rate. For ful1herinformation on water circulation systems seePottel1on Publication Technical Bulletin Number 1Issue 2. a

Boiler Condensation

If the system water content is large, and the start upperiod before which the water return temperatureattains the minimum operating temperatureexceeds 20 minutes then consideration should begiven to the fitting of a shunt pump or by-pass valvecontrolled by a pipe thermostat to raise the returnwater temperature to prevent formation ofcondensation within the boiler and flue system. Itshould be noted that shunt pumps should not beused to boost low water flow rates. See PottertonPublication Technical Bulletin Number 1 Issue 2 forfurther information.

On systems with variable flow rates due to flowreducing devices, ie. TRVs, zone valves, etc., orwhere the minimum heat demand, ie. summerdomestic hot water load, does not achieve theminimum boiler flow rate then consideration shall begiven to incorporating a primary loop system. Forfurther information see Potterton PublicationTechnical Bulletin Number 1 Issue 2.

The flow rate and hydraulic resistance for an 11°Cboiler temperature rise are given in Table 1.4,alternatively, flow rates through boilers can becalculated from:- §Q!bER PROTECTION

FLOW (Iit/sec) = kW (Boiler Cutout)4.2 x Boiler Temp Rise °C

The provision of pump overrun by a time delayrelay or a thermostat situated in the flow pipe closeto the boiler is essential to remove residual heatfrom the boiler, see Figure 6.4, page 6.4.The minimum design flow rate relates to a 20°C

boiler temperature rise and should not bemisinterpreted as the system design temperaturedrop particularly where systems have beendesigned with stand-by capacity.

The boiler and system should be protected bysuitable frost thermostats.

Unions and isolating valves should be fitted to theflow and return manifolds so that the boiler can beisolated from the system if the need arises.

The hydraulic resistance of the boiler is proportionalfor flow rates equating to a boiler temperature riseof between 10°C and 20°C. The hydraulicresistance at 11°C AT is given in Table 1.4,hydraulic resistance at alternative flow rates can becalculated from:-

Strainers

Migrating sludge and debris will have a detrimentaleffect on the life and operation of the boiler and thismust not occur. If all debris cannot be removed,strainers and/or other devices should be fitted.Consideration should be given to water treatmentand inhibitors to maintain water quality. Migrationof system debris or scaling of the waterways willimpair the life expectancy of the boiler sections.

.~112AT2J~

R =2 R, X

System Fillina

where:- R1 = Boiler Resistance with temp rise ~ T 1R2 = Boiler Resistance with temp rise ~ T 2~T = 11°C1AT 2 = Alternative Boiler Temperature Rise

When filling the boiler system with water careshould be taken that the water does not backwash


Section 3Page 3.10

system debris into the boiler via the flow connectionby-passing any strainers that may have been fitted.

It is essential that all systems are thoroughly flushedthrough with a flushing agent to remove all debrisand scale prior to fitting the boilers. Cleaningsystems with acidic de-scaling agents is notgenerally recommended as, if incorrectly used, thescale and deposits may continue to break up afterthe system has been flushed and the boilerinstalled.

NOTE: These are absolute pressures notgauge pressures. For gauge pressure1 bar must be subtracted.

It:Xample

: A boiler system with a maximumoperating temperature of 93°C and allowing for asafety margin of 17°C the temperature would be93°C+17°C=110°C.

From the above the minimumQauge pressure within the system should be 1.43Dar -1 bar = 0.43 bar

Where the boiler is being installed as a replacementfor an existing boiler it is recommended that wherepossible sections of the removed boiler are cutopen and internally examined to determine thepresence of scale or system debris to foresee andrectify any potential problems for the new boilers.

COLD FEED SUPPL Y

The fitting of strainers is strongly recommended.A cold feed pipe should be provided and takendirectly from a feed and expansion cistern whichshall not supply water for any other purpose. It shallnot be smaller than as specified in Table 1.4 andshall be connected to the boiler or boiler side of anyvalve on the return pipe.

The system should be checked to ensure that thereis no raw water make-up. It is stronglyrecommended that a suitable water meter is fitted tothe cold feed supply of the boiler system to monitorfor unregulated water make-up.

The cold feed pipe shall be situated within thebuilding and shall be insulated along those parts ofit's length where freezing conditions orcondensation may be expected to occur.

The quality of the water in both the heating systemand the water supply should be checked to ensurethat the hardness and salinity are not excessive. Inthe case of systems containing aluminiumcomponents the pH should be monitored to preventcorrosion. For multiple and modular boiler installations the

cold feed connection shall be either to the commonreturn pipe upstream of the individual boilerisolating valves or to each individual boiler returnpipe downstream of the isolating valve.

On systems where unregulated raw water make-upor system debris is known to exist but remedialaction cannot be implemented then considerationshould be given to installing a heat exchanger toisolate the boiler from the water system to protectthe boiler otherwise premature failure may occur. Aspecialist water treatment company should beconsulted if in doubt.

The cold feed to a multiple or modular boilerinstallation shall be provided with a lockableisolating valve and sized in accordance with Table3.4.

Open Vented Systems

Maximum Operatina Temperature

The maximum operating temperature of a system isdependent on the operating pressure. Theminimum design operating pressure (not static) atany point of a system should be sufficient to preventboiling within any part of the heating system and theboiler control thermostat should be set to provide a17°C safety margin below the saturated steamabsolute pressure given in Table 3.3 correspondingto the minimum design operating pressure.

For fur1her details see BS 6644: 1991

Section 3Page 3.11


ARIZONA

CISTERN SIZING venting point. The open vent pipe shall dischargeinto the feed and expansion cistern above theoverflow level and for a single boiler installation thepipe shall not be fitted with valves (apart from a3-way type such that when closed the boiler is opento atmosphere through the third port and shallincorporate means of indicating the position of theopen port. The nominal bore of the valve shall benot less than that of the open vent pipe in which it isfitted). Nor shall there be any obstruction whichcould prevent safe venting of the boiler. The ventpipe shall be insulated along those parts of it'slength where freezing may be expected and shall besituated as far as is practicab1e inside the buildingto reduce freezing problems.

The cistern should be sized to accommodate thewater expansion in the system from QoC to themaximum operating temperature. Where thevolume of the system is not known then it can beestimated at 12 litres per kW of design load.

For systems with a maximum operatingtemperatures of up to 100°C the water can expandby 4% (for systems up to 140°C the expansion is8%). Therefore assuming a system loading of 1000kW, the approximate system volume is 1000 x 12litres = 12000 litres and the expansion of water in a

system with a maximum design temperature of100°C is 4% x 12000 = 480 lit res.

Boiler Safety ValvesIn this instance the cistern should have anexpansion capacity between the cold fill level andthe overflow pipe of 480 litres (minimum), (overflowshould be 80mm above the highest expansion

level).

Each boiler, whether in single or multipleinstallations, shall be fitted with an individual safetyvalve complying with BS 6759 Part 1.

IMPORTANT: The water level in the cistern orexpansion tank should be minimal on coldcharge to allow expansion without dischargefrom the overflow between cold and hotoperating conditions.

In the case of modular boiler installations each bankof boilers shall be provided with a common safetyvalve sized in accordance Table 3.6 to suit the totalrated output of the boiler bank. Any boiler in amodular installation that can be isolated from thewater supply shall be fitted with an individual safetyvalve.

The safety valve shall be sized to suit the total ratedoutput of the boiler and shall be located betweenthe boiler and the water isolating valve. See Table3.6 for safety valve sizes on open vented systems.Refer to notes on sealed systems for safety valvesizes on sealed systems.

The safety valves shall be fitted in the flowpipework between the boiler and the next valve inline and the safety valves shall not be more than1 m from the boiler measured along the flow pipe.

Boiler safety valves shall be of the direct springloaded type or dead weight type and the maximumsetting shall not exceed the following equation:-

MAXIMUM VALVE = 0.1 + MAX BOILER DESIGNSETTING (IN BAR) PRESSURE (IN BAR)

Multiple or modular boiler installations shall have anopen vent pipe or pipes of the size stated in Table3.5 as appropriate. Individual open vent pipes shallbe either routed independently to the venting pointor be connected to a common open vent pipe ofappropriate size for the total rated heat input of theinstallation (see Table 1.4 for individual boiler openvent sizes). The open vent pipe shall risecontinuously by the shortest practical route to the

NB: 1 Bar = 33.5 ft head or 14.5 Ib/in2

On systems containing components with lowermaximum operating pressures than the boiler, therating of the safety valve should be reducedaccordingly or additional safety valves provided toprotect these items.


Section 3Page 3.12

without exceeding the maximum design pressure ofthe boiler.

The position of the expansion vessel(s) should besuch that the manufacturers maximum operatingtemperature is not exceeded and the provision of ananti gravity tank may be required for systemsoperating above 100°C.

In addition, the position of the expansion vessel(s)should prevent inadvertent isolation of the boilersystem from the expansion vessel, where isolatingdevices, ie, valves, etc., are incorporated betweenthe boiler(s) and the expansion vessel these shouldbe capable of being locked in the open positionduring normal operation. See BS 6880 Part 2 forfurther details.

Alternatively "A" can be calculated from:-A= R

0.659 x P1 x I!cdrwhere R = boiler output in kW, P1 = 7.6Kdr = The de-rated coefficient of discharge,

(available from the safety valve manufacturer)and A = flow area in mm2

System Fillina & Water Make-Uo

The sealed system should incorporate suitablemeans for initial filling, ie. pressure boost pump,which shall comply with the local water authoritybye laws and the cold feed supply to the systemshould incorporate a non-return valve and anisolating valve with the capability of being locked inthe open position during normal operation.

Spring loaded valves are recommended where thestatic head exceeds 2.5 bar and/or where the boilermay be affected by external vibrations.

The size of the connecting pipe from the safetyvalve shall terminate in a visible position wheredischarge will not result in hazard to the user orplant. The size of the discharge pipe shall be notless than the nominal size of the valve outlet.

An automatic air vent should be provided betweenthe isolating valve and the non-return valve andprovision should be made within the sealed systemto allow automatic replacement of water lost fromthe system. This may include a pressure boostpump and associated controls or an independentprimary feed cistern. However, it is recommendedthat a suitable device such as a water meter isinstalled to detect unregulated raw water make-up.

For fur1her guidance on safety valve sizes see BS6644: 1991.

See BS 6644: 1991 for further details on provisionfor filling and make-up on sealed systems.SEALED SYSTEMS

Maximum ODeratino TemceratureGeneral

The maximum operating temperature of a sealedsystem is dependent on the operating pressure.The minimum design operating pressure (not static)at any point of a sealed system should be sufficientto prevent boiling within the any part of the heatingsystem and the boiler control thennostat should beset to provide a 17°C safety margin below theabsolute saturated steam pressure given in Table3.3 corresponding to the minimum design operating

pressure.

Potterton Commercial boilers are suitable for use onsealed systems designed in accordance with BS6644: 1991 and BS 6880 Part 2. In addition,reference should be made to the Health & SafetyExecutive guidance note PM5 "AutomaticallyControlled Steam & Hot Water Boilers".

Expansion Vessels

The sealed system should incorporate an expansionvessel complying with BS 4814 sized toaccommodate the volumetric hydraulic expansionof the heating system between ooG and thetemperature setting of the overheat thermostat

The boiler overheat thermostat should provide asafety margin of at least 6°C below the absolutesaturated steam pressure.

~

Section 3Page 3.13


ARIZONA

Minimum Operating Pressure

The minimum operating pressure (not static) or coldfill pressure should be sufficient to maintain apositive pressure within the heating system toprevent boiling as detailed above. Care should betaken in positioning of the circulating pump(s)relative to the expansion vessel (zero or null point)particularly on systems where a high hydraulicresistance is present to ensure that operation of thepump does not cause a reduction in operatingpressure at any point in the system below theminimum operating pressure.

A low water pressure cut off device shall beincorporated to prevent operation of the boiler planton low water pressure. The pressure cut off deviceshould be set at a pressure to prevent boiling inany part of the heating system while operating atthe design working temperature.

Consideration should be given to the positioning ofsafety valves, low level cut off devices andautomatic air vents relative to the minimumoperating pressure to ensure that the influence ofpump operation does not cause or preventoperation of these devices.

Maximum Ooeratina Pressure

The boiler plant should be prevented from operatingwhen the system pressure rises to within 0.35 bar ofthe safety valve setting. .

Safetv Valves

The safety valve on a sealed system should besized in accordance with the following equation.

R2.5 x Kdr

A =

where R =Kdr=

Boiler output in kWthe de-rated coefficient of discharge(available from the safety valve

manufacturer).flow area in mm2A =

NOISE LEVEL

Detailed figures are available on request for alltypes of burner specified with the Arizona boiler.Additionally gas boosters may be required for someburners, especially with the larger Arizona boilers.


Section 4Page 4.1

BOilER INSTALLATIONTable 4.1 -Number of Turbulators

Boiler assembly and installation should be carriedout by a competent person. , Model No. of

Flueway tubesNo. of

TurbulatorsThe boiler shell is supplied complete with thecombustion chamber door fitted. Once placed init's final position, (for site and base requirementssee page 2.2), complete the installation of theArizona boiler as follows.

80

100

140

170

200

250

290

350

405

465

520

580

640

700

800

900

1,1001,400

1,650

1,850

2,1002,350

1212

1818

212122

22

26

26

25

25

28

28

32

46

56

64

84

88

65

70

0

4

12

32*

21

21

16

22

26

30*

19

25

28

32*

32

32

56

45

59

61

92

100

Ensure that the boiler is installed level andstable.

2. Open the combustion chamber door andremove the boiler control panel and fittingspack from within the combustion chamber.

3. Ensure that nothing is left in the combustionchamber then close the combustion chamberdoor, (note that the combustion chamber doorneeds to be re-opened -see below).

4. Fix the burner adapter plate to the combustionchamber door, using the gasket supplied.

5 Fit the burner gasket and mount the burner onto the boiler and secure.

6. Re-open the combustion chamber door and fillthe gap between the burner blast tube and thecombustion chamber door insulation with theceramic fibre roll provided. Push it into place50 that it is flush with the combustion chamberdoor insulation.

Two turbulators installed in each flueway tube.Figure 4.1 -Boiler combustion chamber door

Turbulators

Turbulators are fitted to all boiler models to improveefficiency. Turbulators will be fitted to between 70%and 100% of boiler flueway tubes depending on themodel of boiler, see table 4.1 for details of thenumber of turbulators.

Turbulators should be installed evenly from the top ofthe boiler. Where boilers have flueways withoutturbulators these flueways should be at the bottom ofthe boiler.

8. Ensure that the combustion chamber door sealis intact and correctly located then close thecombustion chamber door and secure.7. Check that the correct number of turbulators

are fitled into the flue way tubes, see table 4.1and that they are located correctly, see figure4.2. Ensure the turbulators are pushed fullyinto the flue way tubes as far as they will go.

Fit the loose supplied blanket insulation aroundthe front of the cylindrical boiler heat exchanger,

9.

Section 4Page 4.2


ARIZONA

tucking the edges underneath to secure, seefigure 4.13. .

16. Connect the burner via the 2 Weiland plugconnectors provided. (Note: If a 3 phaseburner is fitted a separate 3 phase electricalsupply must be provided via a fused isolator tothe burner motor contactor). See wiringdiagram section 6 page 6. 1.

10. Fit the control panel support bracket, seefigure 4.3.

11 Remove the rear cover from the control paneland fit the control panel to the control panelsupport bracket. see figure 4.3. (Seeadditional information on control panel page4.5).

17. Locate the side casing panel in the lower casingsupport rail. Lift the top chequer plate slightly toallow the side panel to be positioned underneaththe lip of the chequer plate thus holding it inplace. Repeat with the other side casing panel.

12. Thread the thermostat and thermometercapillaries through the access hole in theboiler top and fit phials into the phial pocket atthe base of the flow outlet pipe. See figure4.4.

Fiaure 4.3 -Control Panel Mounting

13. Fit the burner cable support brackets to thefront vertical casing support rail, see figure 4.7

14. Fit the burner cable conduit to the controlpanel and wire to the control panel tenninalblock, see wiring diagram page 6.1.

15. Secure the burner cable conduit to the frontcasing support rail, see figure 4.7. Fiaure 4.4 -Phial Pocket Location

F~~r~ 4,6 -Installation of Turbulators and Locationof Boiler Control Panel

0BURNER REQUIREMENTS

The Arizona boiler supplied with a matched oil or gasburner to Potterton Commercial specification.

If any other burner equipment is to be used ensurethat it is suitably matched to operate with the boiler.

Also ensure that the burner tube is of the correctlength as per figure 4.5 and table 4.2. Note that theArizona has a reverse flame combustion chamberand the products of combustion may short circuit ifthe minimum burner tube lengths are not adhered to.


Section 4Page 4.3

Fiaure 4.5 -Burner tube installation Table 4.2 -Minimum burner tube lenath

BoilerModel

Combustionchamber doorburner orifice

diameter D mm

Burner tubeminimum

lengthLmm

80

100

140

170200

250

290

350

405

465

520

580

640

700

800

900

1,100

1,4001,650

1,850

2,1002,350

220

220

220

220

220

270

270

270

270

270

270

270

270

270

270

270

270

270

270

350

350

420

180

180

180

180

180

180

250

250

250

250

250

250

250

250

310

310

310

310

310

8)

Burner Adapter Plate

A burner adapter plate is supplied with each boilerspecific to the burner to be used.

If a burner other than a Potterton specified burner isto be used a blank burner adaptor plate will beprovided for drilling by others. .

WATER CONNECTIONS

Connect the boiler to the circulating system.Connection sizes are given in table 1.4. Theorientation of the connections, flow and return, isgiven in figure 1.1. A drain connection is providedat the rear of boiler.

BOilER & BURNER POWER SUPPLYBurner Cables

The Arizona boiler is supplied with either a singlephase or a three phase burners. Check the burnerdata plate to identify the power requirements.

The Arizona boiler is supplied as standard fitted withtwo burner control cables, a 7-pin Weiland plug and a4-pin Weiland plug, from the boiler control panel forconnection to the burner. In addition for gas burnersthe burner controller must be connected to the gastrain -See the burner manufacturers instructions fordetails.

General ReQuirements

All electrical connections to the boiler and burnershould be made via a fused isolator which shouldbe positioned adjacent to the boiler. The isolatorshould isolate all power supplies to the boilerincluding control signals if applicable. See figure4.6.

Hiah/Low BurnerThe 7-pin and 4-pin Weiland plugs should beconnected to the respective sockets provided on theburner.

The control panel incorporates a 6.3A fuseOn/Off BurnerThe 7-pin Weiland plug should be connected to therespective socket provided on the burner. The 4-pinplug should be disconnected from the control paneland discarded, see wiring diagram page 6.1.

Section 4Page 4.4


ARIZONA

(FiQure 4.6 -Boiler & Burner Power SUDDlv

«SinQle Phase Installation

3 -Phase InstallationApplicable to the smaller boilers in the range,typically Models 80 to 290. , Applicable to the larger boilers in the range, typically

Model 290 and above.Install a 230V 50Hz single phase electrical supplyto the boiler control panel. No separate electricalsupply to the burner is required. The burner ispowered from the control panel lead.

Install a 400V 50Hz 3-phase electrical supply to theburner motor contactor as per the burnermanufacturers instructions and, install a single phase230V 50Hz electrical supply derived from the3-phase supply to the boiler control panel.Burners requiring start or run current exceeding

6.3A should not be used.

FiQure 4.7 -Burner Cable Conduit FixinQ Fiaure 4.8 -Boiler Control Panel Wilina Connections

BlankplaJe

~

u

Section 4Page 4.5


.~~;L~TROL

PANEL ~The Arizona has a comprehensive control panelwith the following functions:- ."..v

1.2.3.4.5.6.78.7b8.9.108.10b.118.11b.12.13.

Overheat thermostatLow fire thermostat (2nd stage)High fire thermostat (1st stage)1 st stage hours run meter2nd stage hours run meterBoiler thermometerIndicator lights

Plus, as an optional extra, facility for remotesignalling of boiler fault, overheat and burnerlockout and, boiler run 1st and 2nd stage.

Power on light (Orange)Pump on/off switchBurner on/off switchOverheat thermostat test switch6.3A fuseBoiler thermometer1 st stage hours run meter2nd stage hours run meterBurner lockout indication light (Red)Blank cover -optional controller fixing point1 st stage control thermostat2nd stage control thermostat1 st stage run indicator light (Green)2nd stage run indicator light (Green)Overheat indicator light (red)Overheat thermostat re-set button

1.2 8. Position the control panel on the control panel

mounting plate and fix the control panel to theboiler.

9. Connect the earth wire onto mounting nut toearth the control panel to the boiler body.

10. Thread the capillary tubes through the hole in theboiler chequer plate top and locate them in thephial pocket on the flow pipe header. Ensurethey are pushed fully home.

11. Connect the control panel to the power supply asshown in figure 4.6.

12. Make any control connections as required.13. Refit the control panel top and transparent dust

cover.14. Connect burner cable plugs to the sockets

provided on the burner.

3

4

5.

6

Open the wired control panel package.Remove the transparent plastic instrumentpanel dust cover from the control panel bodylifting it horizontally.Remove the control panel top cover, see figure4.10.Turn the control panel over to provide access tothe cable outlet.Insert the capillaries and earth wire into therectangular cut-out in the front top and thenbelow the front cross bar.Fit the burner cable conduit elbow into the holeprovided on the control panel.Wire the burner cables to the control panelterminal block as per figure 6.4.

7

Section 4Page 4.6


ARIZONA

Fiaure 4.10 -Control Panel Assemblv

I .

..

c

110.

Front

Fiaure 4.11 -Hours Run Meter AssemblY OPTIONAL CONTROLLERS

Optional controllers are available for the Arizonaboiler to provide a complete system control package.Refer to Potterton Commercial Technical departmentfor controller availability and function.

Wann°=//ighl rng

/Black wires Blue wiresController Installation to the Control Panel

~Controllers are delivered mounted on a printed circuitboard. To install the controller to the Arizonainstrument panel proceed as follows:-

~

"'"HOlrS run meter

Remove the spade connector covers from theboiler run indicator lights and connect the hours runmeter in parallel to the light.

Fiaure 4.12 -Installation of Controller

1. Unclip and remove the instrument panel fasciacover.

2. Remove the top cover of the instrument panel

(three screws).3. Undo two screws holding the instrument panel

fascia in place and drop the instrument fasciaforward.

4. Remove the blank plate in the fascia coveringcontroller position.

5. Fit the controller into the prepared fixings (fiveoff) in the instrument panel and bolt tight tosecure, see figure 4. .

6. Feed any capillaries through the instrument panelgrommet to the sensor pockets.

7. Connect all sensor and control system wiring.IMPORTANT: Do not install sensor cable and230V cable in the same conduit.

8. Disconnect the twelve way connector, (boilercontrol wires), and connect to then controllerprinted circuit board.

9. Replace instrument fascia panel, top and fasciacover.

u


Section 4Page 4.7

.,

Fiaure4.1 ;:allation :;:at Exchanaer Blanket

1 Cut the insulation blanket to the correct length and ensure it is not pinched tight whentightening the blanket in place. Ensure that the blanket butts up to the front and rearof the heat exchanger.

INCORRECT CORRECT

2. Do not overlap the insulation blankets. For a correct fit the blankets should butt together.

CORRECTINCORRECT

3. When fitting the insulation blanket ensure that the blankets fit togther in the correct way tominimise heat loss from the heat exchanger.

CORRECTINCORRECT

I

Section 5Page 5.1


ARIZONA 1t ;c. "-

Before commencing commissioning the burner "check the following:- ~

BOilER COMMISSIONING

Water Quality

It is important for the longevity of the boiler shellthat water of the appropriate quality is used in thesystem to avoid the formation of limescale in the

boiler.

Note the fill water requirements stated in Section 2page 2.2.

Where the water volume of the heating system islarge and the water is very hard the fill water shouldbe softened.

WARNING: After initial filling under nocircumstances should unregulated make up water beintroduced into the system. If a water leak isdetected in the system it should be repairedimmediately.

In the event of limescale or water corrosion causingthe failure of the boiler shell the boiler warranty isinvalidated.

It is recommended that a water meter is fitted to andthe amount of raw make up water monitored.

Safety Interlocks

The operation of safety interlocks such as water flowproving, gas boosters, mechanical ventilation,mechanical flue systems should be checked toensure that operation of the boiler is inhibited ontheir failure.

1. Electrical supply is of the correct voltage andpolarity and earthing is available.

2. The fuel supply is of the correct type for theburner fitted, tested for soundness, purged of airand correctly connected to the burner.

3. Boiler and system are fully flooded with waterand the water system operating pressure iswithin the boiler range.

4. Pumps are operational and any flow provinginterlocks are functional. The operation of thepump should be checked, particularly on sealedsystems, to ensure that the operation does notcause a reduction in pressure within the systembelow the minimum operating pressure.

5. ventilation is adequate and in the case ofmechanical ventilation systems, operation of the . ~boiler is inhibited unless the ventilation fan is

vproved. "6. On mechanically assisted flue systems the

operation of the boiler plant should be inhibitedunless the mechanical flue system is operationaland flow proved.

7. The safety valve should be checked to ensurethat it is of the correct size and pressure. Seesection 3 for further details.

8. The cold feed and open vent sizes should bechecked. See section 3 for further details.

9. Ensure the burner fitted to the boiler is of thecorrect specification and size for the boiler andsuitable for the fuel supply available.

10. The burner blast tube has been sealed to thedoor refractory and the boiler door seal iscorrect. See section 4 for further details.

BURNER COMMISSIONtNG

Comoetency

Following completion of the above checks theburner should be commissioned in accordance with Ii;the manufacturers hand book provided with the.burner. The commissioning form provided at theback of this manual must be completed andreturned to Potterton Commercial at the address onthe back page.

IMPORTANT: The boiler must be commissionedfollowing completion of installation. Operation of anun-commissioned appliance is a criminal offence. Itmay cause injury to personnel and damage to theboiler and will invalidate the boiler warranty.

Typical combustion figures are:-CO2 Gas 9-10% OilCO 0-20 ppmOil Firing Smoke No. 0-1 (Bacharah Scale)

12-13%

Commissioning should only be carried out bypersonnel approved and competent to do so. Thisfacility is available from Pottel1on CommercialService Offices at the addresses listed on the backof this manual.

Flue Gas Temperature ~ see Technical data in

section 1 page 1.3.

IMPORTANT: A condition of the supply of theappliance for compliance with the PottertonCommercial Quality Assurance, (registered to meetthe requirements of BS5750 Part 2), plan is thereturn of the appliance commissioning report,enclosed at the back of this manual.

Commissioning of the burner should be carried outin accordance with the burner manufacturersinstructions provided.

u

Section 5Page 5.2


Following/during commissioning of the burner unitthe following additional checks should be carriedout.

Where overheat operation is reported the followingshould be checked.

1. Operation of the overheat thermostat. This canbe tested using the overheat thermostat testbutton on the boiler control panel.

2. Operation of the control and high/low (if fitted).thermostats. (1 st and 2nd stage thermostats).should be checked.

3. The flue draught available at the appliance flueoutlet should be checked under all operatingconditions (hot and cold) and should be withinthe boiler operating parameters, see table 1.4.

4. The fuel supply to the appliance should beisolated and the burner operated to ensuresafety shutdown and lockout of the bumer onflame failure.

5. Shutdown of the boiler plant by external controlsdoes not cause a hazardous condition and pumpoverrun is provided to remove residual heatfrom the boiler.

6. Following commissioning the boiler overheatand control thermostats should be set to therequired operating setting. See section 3 formaximum operating temperatures.

7. Following completion of commissioning thesoundness of all automatic fuel valves shouldbe checked for leakage.

I

(a) The boiler/system pump is adequate for the

duty.(b) Operation of flow reducing devices, i.e.

thermostatic radiator valves, compensatedmixing valves, etc., do not reduce the water flowrate through the boiler below the minimum flowrate. See Water Circulation Systems, section 3for water flow rates.

(c) Pump overrun is incorporated to dissipateresidual heat from the boiler on system shutdown.

(d) The operation of boiler back-end valvesincorporate a time delay to allow for removal ofresidual heat from the boiler.

(e) The boiler is operating at the correct rate and isnot over-fired.

The use of as primary loop system is highlyrecommended to provide constant boiler flow rateunder all operating conditions. For furtherinformation refer to Potterton publication TechnicalBulletin No.1, Issue Water Circulation Systems.

Burner Lockout

The package burners supplied with the boiler unithave an integral safety system to allow the safe andreliable operation of the burner. Failure of theburner to operate correctly will cause the burnercontrol box to "lockout", the lockout button on theburner will illuminate to indicate this.

Additional Checks

Where possible the system should be checked toensure that following purging of air there us no rawwater make-up. In particular, when the system usoperated in the hot condition, there should be nodischarge of water from the safety valve, open ventor cold feed tank overflow that would otherwise leadto unregulated raw water make-up when the systemcools down.

The lockout condition can be manually reset bypushing the reset button and the control box shouldrestart it's control sequence in an attempt to light theburner. If the control box lockout will not reset orgoes to lockout after being reset then the services ofa boiler repaor/maintenance company should besought. This service is available from PottertonCommercial Division Service at the addresses onthe back page of this manual.

FAULT FINDING

General fault finding for burner failure should be inaccordance with the burner manufacturers handbook. Set out below are general guidance notes onsystem fault finding.

WARNING: The lockout reset button should notbe repeatedly operated otherwise a hazardoussituation may occur.

Overheat Operation

The boiler control panel has an built in overheatindicator lamp. Operation of the boiler overheatthermostat is associated with a reduction in boilerwater flow. The overheat thermostat can be testedby pressing the test button on the boiler controlpanel. Note that the boiler temperature will rise to110°C.

Should the boiler go to lockout, check the followingbefore attempting to re-light the burner.1. Fuel is available at the burner.2. The electrical supply to the appliance is of the

correct voltage and polarity.

The boiler control boxes in some instances haveindicator dials as an aid to fault finding on boilerlockout. In these instances refer to the control boxmanufacturers data sheet for fault finding details.

Section 5Page 5.3

POTTERTON COMMERCIAL PRODUCTS DIVISIONINSTALlATION, OPERATING & MAINTENANCE MANUAL

ARIZONA

BOILER MAINTENANCE

It is essential for efficient and trouble free operationthat the boiler plant is regularly maintained. Thismust be carried out by qualified and experiencedengineers and in the case of gas fired appliancesattention is drawn to the requirement that ACOPScertified engineers only undertake this work.

2. Brush out the flueway tubes ensuring any soot isremoved.

3. Re-commission the burner as per the burnermanufacturers instructions and instructionsgiven on page 5.1.

Lenathv Shutdown

If the boiler is left shut down for a long period oftime consideration should be given to placing a boxcontaining quicklime in the combustion chamber toprevent moisture building up in the boiler.

Potterton Commercial Service Division provides afull maintenance service -see the back of thisinstallation manual for the telephone number of yourlocal service depot.

Boiler Checks -Combustion ChamberService Interval

In addition to the checks on the water system thecombustion side of the boiler should be maintainedas follows.

The Arizona boiler and burner should be servicedand the burner re-commissioned once per year.

WARNING: Isolate the electricity and fuelsupplies to the boiler before commencing anymaintenance work.

Natural Gas & LPG Fired Boilers

The combustion chamber and flueways should bebrushed out and any debris removed from the boilerbi-annually.Boiler Checks -Water System

Class "0" Fuel OilWeekl~ -Check the amount of raw water make up.If raw water make up is occurring IMMEDIATELYidentify and rectify any leaks on the system. The boilers should be brushed out thoroughly at

least bi-monthly during the heating season but morefrequent attention may be necessary dependent onthe operating conditions to prevent the formation ofhard adherent scale on the tube surfaces.

Monthl~ -Check to make sure there is no sludge inthe boiler by isolating the boiler and draining down.

Quarterly -Shut down the boiler, open thecombustion chamber door and check that therefractory is in good condition and that the fluewaysare not blocked, (i.e. clogged with soot). Withdrawand visually check the turbulators for soot and

deterioration.

It is essential to ensure that cleaning is carried outthroughout the full length of the flue tube passes andthat the rear clean out covers are taken off to allowfor the removal of deposits brushed through into theflue box.

Should heavy or tough adherent deposit becomeformed, which is too hard for the standard brush toremove, it may be necessary to :-

Take a sample of system water and analyse for:-pH value HardnessOxygen Steel contentCopper content

If the water analysis exceeds the maximumrecommended concentration levels then remedialaction should be taken to treat the water see section2 page 2.2 for details.

Wash out the tubes with water followed by athorough brushing -this may have to be repeatedseveral timesor,.Use a flexible drive rotary descaling machine.

The Arizona boiler should not be fuelled by mediumor heavy fuel oil.

Annual Service

At the annual service carry out all the operations forweekly, monthly and quarterly maintenance and inaddition:-

Comoletion of Maintenance

On completion of annual maintenance and when theboiler combustion chamber door has been openedthe boiler should be re-commissioned as describedon page 5.1 above.

1 Open the combustion chamber door. Check thecondition of the turbulators by removing themfrom the flueway tubes.

Wirina Diagram

""" 6

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Section 6Page 6.3

Control Panel Wirina

The Arizona boiler can be connected to a Building Management System

The following remote signal options are available.

12

Burner lockout alann signal1 st stage boiler run indication

3,

4.2nd stage boiler run indicationBoiler overheat alarm signal

Fiaure 6.3 -Volt Free Contact Connections

IG~IEINIJ I~I~L I Control Panel

terminal block

,<,\(

'}

vsc

CH2

~

R21

~

[ r: r;! r:;! r:;! [I ~ t;;T, ~VOLT FREE CONTACTSR1 -BURNER LOCKOUT INDICATIONR2 -1ST STAGE RUN INDICATIONR3 -2ND STAGE RUN INDICATIONR4 -OVERHEAT INDICATION

.

It is also possible to fit a local/remote switch. This is fitted by utilising the heating pump switch fitted to thecontrol panel. The local/remote overrides the boiler external on/off control, (X1) and external high/lowcontrol (X5).

Fiaure 6.4 -Octional Local/Remote Switch Wirina

Section 6Page 6.4


ARIZONA

Fiaure 6.5 -Pumc Overrun Usina Chanaeover Pice Thermostat

INCOMING SUPPLYFROM FUSEDISOLATOR

RELAY

NC

PIPETHERMOSTATSET <55 DEG CPUMP

Pump overrun equipment is not supplied by Potterton

Fiaure 6.6 -Burner Connection Wirina

7 -PIN PLUG ON/OFF OPERATIONL -PERMANENT LIVE TO BURNER

N -NEUTRALE -EARTHT1 -CONTROL CIRCUIT TO

BOILER CONTROL PANELT2 -ON/OFF CONTROL CIRCUIT

TO BURNERS3 -LOCKOUT SIGNAL84 -BOILER RUN SIGNAL

4-PIN PLUG HIGH/LOW OPERATION

B5 -HIGH FIRE RUNS-IGNAL- T6 -HIGH FIRE CONTROL SIGNAL;

FROM BURNER

T7 -NOT USED

T8 -HIGH FIRE CONTROL SIGNAL

TO BURNER

7 -P1N W~llANQ P,LUG 4-PIN WEILAND PLUG

Section 7Page 7.2


ARIZONA

Boiler Component Parts List

~ DESCRIPTION PART No

010203

04050607080910111213141516

()

17181920

21

FRONT SIDE PANEL (2-0FF PER BOILER)REAR SIDE PANEL (2-0FF PER BOILER)INSULATION BLANKET (2-0FF PER BOILER)

(Not shown)CONTROL PANEL MOUNTING BRACKETCONTROL PANEL MOUNTING PLATE FIXINGSSTEEL CHEQUER PLATE TOP (LEFT HAND SIDE)STEEL CHEQUER PLATE TOP (RIGHT HAND SIDE)COMBUSTION CHAMBER DOORCOMBUSTION CHAMBER DOOR HINGECOMBUSTION CHAMBER DOOR HINGE PINCOMBUSTION CHAMBER DOOR HINGE PIN NUTCOMBUSTION CHAMBER DOOR INSULATIONCOMBUSTION CHAMBER DOOR SEALEYE GLASS ASSEMBLYCOMBUSTION CHAMBER DOOR FIXING BOLTSBURNER ADAPTOR PLATE (SOLID)(requires drilling to suit burner specification)BURNER ADAPTOR PLATE GASKETBURNER ADAPTOR PLATE FIXINGSCOMBUSTION CHAMBER DOOR SEALTURBULATOR(See page 4.1 for No required per boiler)CERAMIC FIBRE BURNER TUBE INSULATION

(Not shown)SMOKE BOX CLEAN OUT ACCESS PLATE (Not shown)SMOKE BOX CLEAN OUT ACCESS PLATE FIXINGS

(Not shown)TWO PART BOILER FLUE CLEANING BRUSH

(Not shown)

2223

24

Section 7Page 7.3

Fiaure 7.2 -Control Panel Comoonents

,

133117

101

114-",.

~

'~,0,"-;./l~~ I "

f " "I ~", "t'..J ~ ,~ '~<

, ~ ~, '~-, .'J ~ ", ~. ~ '°", ,,~~/ 'J"

~~';.<~. ~ ~~ ':--~? ~"ti}) ',~ ~ ~ "

~--<, "'" ~ I~- '""" I'- I,

111 ',j;i

/'10I<"'-,..~

~"

.

119'-- :

Section 7Page 7.4


ARIZONA

Control Panel Parts List

1IgM Qfj3CRIPTIOtj PART No

100101102103104105106107108109110111112113114115116117118119120

17202471170038541700559115838260158382621583826115803999158035251580402015804082170069941700473917006940170022681700706117002281

TRANSPARENT INSTRUMENT SCREENCONTROLLER BACK PLATE (BLACK)ALARM INDICATOR LIGHT (RED)RUN INDICATOR LIGHT (GREEN) 0=12POWER ON INDICATOR LIGHT (ORANGE) LS 5A B5 0=12FUSE HOUSING6.3A FUSEPUMP ON/OFF SWITCH ~~oo B5 NNTWIN SWITCH (BURNER ON/OFF / OVERHEAT TEST)CONTROL THERMOSTAT RAK 51.41.71THE:RMOSTAT KNOB (MOD 91)OVI::RHEAT THERMOSTAT SECU. RAK 67.44.71BLANK PLATE (BLACK) NXR1THERMOMETER RECT 200C -120°CTHE:RMOMETER BLANK PLATE

HOIJRS RUN METERBURNER CABLE 1ST STAGE (7 PIN WEILAND PLUG)BURNER CABLE 2ND STAGE (4 PIN WEILAND PLUG)COrllNECTOR T/BCOrllNECTOR G15 & G25SIDE PANEL RIGHTSIDE PANEL LEFTMISC. FIXING PACK L PANEL

1700121317077185170771861707075817070759170022871700228917880347

133

134

Brooks House. Coventry Road, 'fIarwickWarwickshire CV34 4LL.

Tel: (08706) 050607 Fax: (08706) 001516

4.9 I PR -

4.1J Is the boiler house ventilation as per manual?

4.~J..ElectriC supp~sed, isolated & earth wire connected?

RHI LHj Centre I 4..~.1 Check external controls allow o~~~_tion

4.4 Check boiler/system flooded & pumps operational and anyisolation valves open

I Class 0 I i N/Gasl LPG!i4,~.j Check gas available at burnerCoco6UBN~R

Type4..51J) Check oil available at burner

4.6~1 Check gas meter sizing adequateSerial No

4.1 j Check flues~stem clear2.3

2.9"

I

Spec No

Control Box Type '5.0 t.CQ~ay§tIONPilot I Low I High I Unit

Electrical Supply

Gas Train Type & Size

Gas Train Serial No

Gas Booster Type & Size

Gas Booster Serial No

m3/hr

mmwg

uA

5.1.* 1 Gas rate

5,2" 1 Burner head pressure

5..$* j lonisation probe/UVcell current

5..41 Air shutter position

5.511 I Oil pump pressure

~

1%~5,f} .! CO2 or 0,3;1 mm

mm

mm

mm

5.~J co5.81/ I Smoke Number

5.9) Gross flue gas te~~~~

5..10i Ambient temperature

5,11 J Flue draught

~

c'C

mmwg

mmwg

3.5.1

Side No of Holes

Diameter

No of Holes

Di

Si

TySi

Ty

5.12* Inlet gas pressure (high fire). If multi boilerinstallation, inlet gas pressure all boilers high fire

Imm

EndI .1..5...131 Combustion chamber resistance mmwg

mmwgImm

5.14J Burner fan static pressure3.51' Oil Nozzles: High Fire

MQI.E: Normally 5.13 and 5.14 only recorded when tappings provided.Position of measurement to be in accordance with boiler I burnermanufacturers instructions.

Low Fire

3.6 Electrode Settings?(to burner card/manufacturers instructions) .

11

GAS FIRED INSTALLATIONS ONLYOil FIRED INSTALLATIONS ONLY

13.7

Burner to Spec?I (to burner card/manufacturers instructions)

~

~O

YES I NO17.17~Vidence of condensate formation?

7.18 Any evidence of water leakage? YES I NO~~7.19 Any evidence of flue gas leakage? YES I NO

1.20 Has boiler been built and cased correctly'? YES I NO

7.21*

7.2 Is oil filter fitted? YES I NO

s fire valve fitted? YES I NO

il Supply: Single pipe

J

I Document ID Ref: PCF/O29~

.:.

3412 Btu/hr0.0009478 Btu/hr3.968 Btu/hr

-

CONVERSION TABL-~- IMPERIAL TO METRIC I~ METRIC TO IMPERIA, I

I tlMI 1 Therm = 100.000 Btu/hr1 Btu/hr = 0.2931 W1 Btu/hr = 1055 J1 Btu/hr = 0.252 kcal

1 kW1 J1 kcal

1 dm3 = 1 LITRE 1,000 dm3 = 1m328.317 dm30.02832 m34.546 litre1.2 U.S. Gallon

!VOLUME

1 ft3 =1 ft3 =I 1 Imp. Gall =1 Imp. Gall =

1

1 m31 litre1 litre

- 35.3147 ft30.2199 Imp. Gallon0.03531 ft3

1

1 kPa = 100~Pa 1 bar = 1000 mbar = 100 kPa

1 bar -33.45 fl w.g.1 kPa = 0.3345 ft. w.g.1 bar = 14.5 ib/in21 Pa = 0.3858 in.w.g.1 mm.w.g. = 0.0394 in.w.g.11 mm.w.g. = 9.8 Pa.w.g.

PRESSURE 1 PSI = 2.307 FT1 Ib/in2 = 6895 Pa11 ~b/in2 = 68.95 mbar I1 In.w.g. = 249.1 Pa1 in.w.g. = 2.491 mbar1 in.w.g = 25.4 mm.w.g.

Ii1m

= 1000mm1mm =1 m =1

1 m =1 km =

25.4mm0.3048 m0.9144 m1.609 km

-

!LENGTH

1 inch1 ft1 yard1 mile

0.03937 in3.281 ft1.094 yard0.6214 mile

I~

1 in21 in21 ft2i1

ft2

1 mm21 cm211

m2,1

m2

645.2 mm26.452 cm2929 cm20.0929 m2

0.00155 in20.155 in21550 in210.76 ft2

- -

'FLOW RATE1 gall/min =1 ft3/min =1 ft3/min =

1 kg/sec = 1 litlsec @

0.07577 liUsec0.4719 liUsec0.02832 m3/sec

OOC reference1 liUsec =1 liUsec =1 m3/sec =I

1°c

to ofI11°C

= 1°K"X" °C x 1.8 =

TEMPERATUREIDF to DC = ("X"DF -32) x 0.5556 ("X"OC x 1.8) + 32=

'TEMPERATURE

DIFFERENCE"X"DF x 0.5556 = DC OF

WEIGHTI Ib

cwtton

2.205 Ib0.9842 ton2204.6 Ib

0.4536 kg50.8 kg

1016kg

1 kg1

1 tonne1 tonne

--

J.

temperature13.2 gall/min2.119 ft3/min2119 ft3/min

For furtherdetajlson Potterton Commercial boiler products contactthe following:-

fIPottertonCommercial Products DtvisionBrooks HouseCoventry RoadWARWICKCV34 4LL

Tel: (08706) 050607Fax: (08706) 001516Sales Direct Lihe:(08706) 001991Technical Djrect Line: (08706} 002322e-matl: [email protected]: www.potterton.co.uk/commercral

COMMERCIAL SERVICE OFFICES

Our serv!ce organisation covers the whole of the U.K, to look after your needs for all PottertonCommerciafProducts.. We are alsoabfe to offer our services for other manufacturers products.

SOUTHERN REGIONPotterton Commercial Service Dept

,

Un!t 2... Borehamwood Enterprise CentreTheobald StreetBOREHAMWOODHerts WD6 4RQ!el:{O8702) 412759Fax: (02082)072466

I"::cic.

NORTHERN REGIONPottertbn Commercial Service Dept.Unit 102" Batley EnterpriseCehtre513 Bradford RoadBATLEY, -"WestYorksh.rreWF178JYTel: (08702} 412759Fax: (01924 )420276

Our service offices offer a wide range ofspeciaJised servtcesincludjng:-

.....

Boi.ler.SlteAss~mblyBurner Commiss1oningfor all Fuels

Breakdown & Repair ServicesBo11erDismantling & Re-Joint.ing

Burne r&BoiJ erRepJace mem

Oil/GasConversjonsSystem Condttioni ngWater Treatment & DescalingPackaged Units

Potte~oriCommercial )hroughthe Potterton Myson..lnterpart Divisiont 'a:,.

OR Curzon ComponentsNationa1 Spares Hotline0990 10 30 30c

BaxlParisBrooks House, Coventry RoadWARWICKWarwickshire CV34 4LLTel: (08706) 000454

-Fax: (08706)000545

'AJldescrfptionsand..illustrationscontafned

inthi$ leaflet have been carefully prepared but we reserve the fight to make changes andimprovements in our proquct which may affect theact~racyofthe information contained..in this leaflet"

BaxiHeating Ltd. Reg;Office: Sceptre Way, Bamber Bridge, Preston ~ Registered in England, No.3879156

3.1.1 Boiler 0&M Manual

Documents

Transcript of 3.1.1 Boiler 0&M Manual