HomeMy WebLinkAboutManley's Boiler 2017-10-05SHORT FORM CONSTRUCTION CONTRACT ##1718127
This Agreement is made and entered on October 5, 2017, in Ukiah,
California, by and between Manley's Boiler's Inc., a CA Corporation
("Contractor") and the City of Ukiah ("City"), a general law
municipal corporation.
RECITALS:
1. The plans and specifications for this work ("the Work")
are contained in Exhibit A - Bid Specification, which is attached
hereto and incorporated herein by this reference.
2. Contractor is properly licensed and qualified to perform
the work.
3. Whenever this Agreement calls for City approval or
notification, the approval or notification must be signed by the
City Manager or his or her designee.
AGREEMENT:
Wherefore, in consideration of the foregoing facts and the
terms and conditions as further stated herein, the parties hereby
agree as follows.
1. PERFORMANCE OF THE WORK
Contractor will perform the Work as further provided herein.
1.1 Time of Performance. Contractor shall commence the Work
when receiving a formal Notice to Proceed, and shall complete the
Work by no later than thirty (30) calendar days from receipt of
Notice to Proceed.
1.1.1. X [check if applicable; It is agreed by the parties to
the contract that time is of the essence and that, in case all
the work is not completed before or upon the expiration of the
time limit as set forth, damage, other than those cost items
identified in section 1.1.2, will be sustained by the City and
that it is and will be impracticable to determine the actual
amount of damage by reason of such delay; and it is therefore
agreed that, subject to Sections 1.13-1.14, below, the
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Contractor will pay to the City the sum of five hundred dollars
($500.00) per day for each and every calendar day's delay beyond
the time prescribed.
1.1.2 [c`:eck if applicable] In case the work called for
under this contract is not completed within the time limit
stipulated herein, the City shall have the right as provided
hereinabove, to extend the time of completion thereof. If the
time limit be so extended, the City shall have the right to
charge to the Contractor and to deduct from the final payment
for the work the actual cost to the City of engineering,
inspection, superintendence and other overhead expenses which
are directly chargeable to the contract and which accrue during
the period of such extension, except that the cost of final
unavoidable delays shall not be included in such charges.
1.2 Construction of Contract Documents. Contractor will
perform the Work in compliance with the plans and specifications
set forth in the attached Exhibit A. If there is any inconsistency
or conflict between the plans and the specifications, the
specifications will prevail. If there is any inconsistency between
the plans and the specifications and this agreement, the terms of
this Agreement shall prevail, unless expressly stated otherwise in
a particular specification.
1.3 Contractor furnished items. Contractor will furnish all
necessary labor, materials, tools, equipment, and transportation
necessary to perform the Work.
1.4 New SB 854 requirements
1.4.1 No contractor or subcontractor may be listed on a
bid proposal for a public works project (submitted on or after
March 1, 2015) unless registered with the Department of
Industrial Relations pursuant to Labor Code section 1725.5 [with
limited exceptions from this requirement for bid purposes only
under Labor Code section 1771.1(a)].
1.4.2 No contractor or subcontractor may be awarded a
contract for public work on a public works project (awarded on
or after April 1, 2015) unless registered with the Department of
Industrial Relations pursuant to Labor Code section 1725.5.
1.4.3 This project is subject to compliance monitoring
and enforcement by the Department of Industrial Relations.
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1.4.4 The Labor Commissioner through the Division of
Labor Standards Enforcement (DLSE) may at any time require
contractors and subcontractors to furnish electronic certified
payroll records directly to DLSE. Commencing with contracts
awarded or after April 1, 2015, all contractors and
subcontractors must furnish electronic certified payroll records
directly to the DLSE.
1.4.5 The Prime Contractor is required to post job
notices at the job site as prescribed by regulations (currently,
8 CCR §16451 (d) . )
1.5 Use of Employees.
1.5.1. Contractor and any subcontractors shall pay
all mechanics and laborers employed by them to work upon the site
of the work unconditionally and without subsequent deductions or
rebate on any account the full amounts due at the time of payment
at wage rates not less than those contained in the applicable
prevailing wage determination, regardless of any contractual
relationship which may be alleged to exist between the Contractor
and subcontractors and such laborers and mechanics.
1.5.2. Contractor shall comply with the California
Labor Code Section 1775. In accordance with said Section 1775,
Contractor shall forfeit as a penalty to the City, $50.00 for each
calendar day or portion thereof, for each workman paid less than
the stipulated prevailing rates for such work or craft in which
such workman is employed for any work done under the Contract by
him or her or by any subcontractor under him or her in violation
of the provisions of the Labor Code and in particular, Labor Code
Sections 1770 to 1780, inclusive. In addition to said penalty and
pursuant to Section 1775, the difference between such stipulated
prevailing wage rates and the amount paid to each workman for each
calendar day or portion thereof for which each workman was paid
less than the stipulated prevailing wage rate shall be paid to
each workman by the Contractor.
1.5.3. Pursuant to the provision of Section 1770 of
the Labor Code of the State of California, City has ascertained
the general prevailing rate of wages (which rate includes employer
payments for health and welfare, vacation, pension and similar
purposes) applicable to the work to be done, for straight time
work. The holiday wage rate listed shall be applicable to all
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holidays recognized in the collective bargaining agreement of the
particular craft, classification, or type of workers concerned.
Copies of the General Prevailing Wage Determination are on file in
the office of the City Engineer and are available to the Contractor
on request. The Contractor shall post the wage determination at
the site of work in a prominent place where the workers can easily
see it.
1.5.4. City will not recognize any claim for
additional compensation because the Contractor has paid any rate in
excess of the prevailing wage rate obtained from the City Engineer.
The possibility of wage increases is one of the elements to be
considered by the Contractor in determining his or her bid and will
not in any circumstances be considered as the basis for a claim
against the City.
1.5.5. Travel and Subsistence Payments.
Contractor shall make travel and subsistence payments to
each worker needed to execute the work in accordance with the
requirements in Section 1773.8 of the Labor Code (Chapter 880,
Statutes of 1968).
1.5.6. Apprentices.
Attention is directed to the provisions in Sections
1777.5 (Chapter 1411, Statutes of 1968) and 1777.6 of the
California Labor Code concerning the employment of apprentices
by the Contractor or any subcontractor under him. Contractor and
any subcontractor under him or her shall comply with the
requirements of said sections in the employment of apprentices.
Information relative to apprenticeship standards,
wage schedules and other requirements may be obtained from the
Director of Industrial Relations, ex officio the Administrator
of Apprenticeship, San Francisco, California, or from the
Division of Apprenticeship Standards and its branch offices.
Copies of Labor Code Sections 1771 (requiring prevailing wages),
1775 (imposing penalties, including a $50 per day, per worker
forfeiture, for failure to pay prevailing wages), 1776 (requiring
contractor to maintain available for inspection certified payroll
records), 1777.5 (requiring certain apprenticeship programs), 1813
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(imposing penalties for failure to make records available for
inspection) and 1815 (requiring time and 1-2 for overtime) are
available at the Department of Industrial Relations website at
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1.6 CITY Inspector. CITY may designate an architect, engineer,
other design professional or other inspector ("Inspector") to
supervise and/or inspect Contractor's performance of the Work. The
Inspector shall have no authority to change the Work, the
compensation for performing the Work or the time for completing the
Work without City's prior written approval. City shall notify the
Contractor in writing, if it designates an Inspector.
1.7 Site Conditions. Contractor acknowledges that it has
inspected the work site and any improvements involving the Work and
satisfied itself as to the conditions which can affect the Work or
its cost. Contractor has not relied on any representation by CITY
or its officers or employees as to the condition of the site or the
houses or any condition that might affect the cost of performing
this Agreement.
1.8 New Products Required. All equipment, materials or
fixtures furnished by Contractor under this Agreement shall be new
and of the most suitable grade for the intended purpose, unless
otherwise specifically provided.
1.9 Compliance with Laws. The Contractor shall give all
notices and comply with all applicable laws, ordinances, codes,
rules and regulations. The Contractor shall secure and pay for all
permits, fees, and licenses necessary for the proper execution and
completion of the work.
1.10 Protection of Site and Improvements. The Contractor
shall preserve and protect the site, grounds and any involved
improvements and shall not alter or damage any portion thereof,
except as is absolutely necessary in order to perform the Work. The
Contractor shall repair or replace, as directed by CITY, any
property that it damages, looses or destroys in violation of this
paragraph. Contractor shall assume full responsibility for
maintaining the safety of the worksite in compliance with all
applicable state and federal worker safety and protection laws and
shall maintain the worksite in compliance with all such laws.
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1.11 Inspection of Work. The Contractor shall ensure that
the Work is available for inspection by CITY or its Inspector at
all reasonable times and that no work is covered up or rendered
incapable of inspection without prior notice to CITY or its
Inspector and a reasonable opportunity for inspection. The presence
or absence of an CITY inspector or the conduct of an inspection by
CITY or its Inspector shall not relieve the Contractor from any
contract requirement or compliance with Exhibit A.
1.12 Title. The Contractor warrants that it conveys full and
complete title, free of all liens and encumbrances, to all materials,
supplies, fixtures and equipment furnished to CITY under this
Agreement and agrees to fully defend and indemnify CITY, its
officers and employees, and the houses and homebuyers included in
the Work from and against any claim, lien, charge, debt, cost,
expense or liability arising from a breach of said warranty.
1.13 Warranties. In addition to any other warranties in this
contract, the Contractor warrants that the Work conforms to the
contract requirements and is free of any defect in equipment,
material or workmanship for a period of one year from the date of
final acceptance of the Work by CITY. If CITY accepts any part of
the Work before final acceptance of the entire Work, the warranty
shall continue for the period of one year from the date of such
partial acceptance. The Contractor shall remedy, at the Contractor's
expense, any failure to conform, or any defect. [Initial if
following sentence applies / / / /] CITY shall retain _% of the
Contract Amount to secure the Contractor's warranty and shall remit
the unused portion of that amount at the end of the warranty period.
The time limit of this warranty shall not apply to any latent defects,
or gross negligence or fraud on the part of the Contractor.
1.14. Extension of Time.
Should any delays occur which the City may consider unavoidable, as
herein defined, the Contractor shall, pursuant to his or her
application, be allowed an extension of time proportional to said
delay or delays, beyond the time herein set forth, in which to
complete this contract; and liquidated damages for delay shall not
be charged against the Contractor by the City during an extension
of time granted because of unavoidable delay or delays.
Any claim by Contractor for a time extension based on unavoidable
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delays shall be based on written notice delivered to the City within
15 days of the occurrence of the event giving rise to the claim.
Failure to file said written notice within the time specified shall
constitute a wa-ver of said claim. Notice of the full extent of the
claim and all supporting data must be delivered to the City within
45 days of the occurrence unless the City specifies in writing a
longer period. All claims for a time extension must be approved by
the City and incorporated into a written change order.
1.15. Unfavorable Weather and Other Conditions.
During unfavorable weather and other conditions, the Contractor
shall pursue only such portions of the work as shall not be damaged
thereby. No portions of the work whose satisfactory quality or
efficiency will be affected by any unfavorable conditions shall be
constructed while these conditions remain, unless, by special means
or precautions approved by the City, the Contractor shall be able
to overcome them.
The Contractor shall be granted a time extension of one day for each
unfavorable weather day that prevents him or her from placing
concrete forms or placing and finishing concrete or asphalt concrete.
Such unfavorable weather day is defined as a rain day where
precipitation prevents the contractor from performing the work more
than four (4) continuous hours within the authorized work period or
a temperature day where the ambient temperature is below that
specified for the placement of materials associated with the
controlling work item for more than four (4) continuous work hours
of the authorized work period.
1.16. Saturday, Sunday, Holiday and Night Work.
No work shall be done between the hours of 6 p.m. and 7 a.m., nor
on Saturdays, Sundays or legal holidays except such work as is
necessary for the proper care and protection of work already
performed, or except in cases of absolute necessity and in any case
only with the permission of the City.
It is understood, however, that night work may be established as a
regular procedure by the Contractor if he or she first obtains the
written permission of the City and that such permission may be
revoked at any time by the City if the Contractor fails to maintain
at night adequate force and equipment for reasonable prosecution
and to justify inspection of the work.
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1.17. Hours of Labor.
Eight (8) hours of labor shall constitute a legal day's work and
the Contractor or any subcontractor shall not require or permit more
than eight hours of labor in a day from any person employed by him
or her in the performance of the work under this contract, unless
paying compensation for all hours worked in excess of eight (8)
hours per day at not less than 1 1-� times the basic rate of pay.
The Contractor shall forfeit to the City, as a penalty, the sum of
twenty-five dollars ($25.00) for each workman employed in the
execution of the contract by him or her or by any subcontractor,
for each calendar day during which such laborer, workman, or
mechanic is required or permitted to labor more than eight hours in
violation of the provisions of Section 1810 to 1816, inclusive,
(Article 3, Chapter 1, Part 7, Division 2) of the Labor Code of the
State of California and any acts amendatory thereof.
2. CONTRACT PRICE
CITY shall pay the Contractor for performance of this Agreement
time and materials with a total not to exceed amount of $77,777.00.
3. PAYMENT OF CONTRACT PRICE
3.1 City shall pay any invoice fo
by the City, within thirty (30) days
payments under this contract shall be
certificates in writing from the City
covered by the payments has been done
due fn accordance with this contract.
4. INDEMNIFICATION AND INSURANCE.
r completed work, and approved
of its receipt by City. All
made upon the presentation of
and shall show that the work
and the payments thereof are
4.1 Indemnification. The Contractor shall do all of the work
and furnish all labor, materials, tools and appliances, except as
otherwise herein expressly stipulated, necessary or proper for
performing and completing the work herein required in the manner
and within the time herein specified. The mention of any specific
duty or liability imposed upon the Contractor shall not be construed
as a limitation or restriction of any general liability or duty
imposed upon the Contractor by this contract, said reference to any
specific duty or liability being made herein merely for the purpose
of explanation.
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The right of general supervision by the City shall not make the
Contractor an agent of the City and the liability of the Contractor
for all damages to persons or to public or private property, arising
from the Contractor's execution of the work, shall not be lessened
because of such general supervision.
Until the completion and final acceptance by the City of all the
work under and implied by this contract, the work shall be under
the Contractor's responsible care and charge. The Contractor shall
rebuild, repair, restore and make good all injuries, damages, re -
erections and repairs, occasioned or rendered necessary by causes
of any nature whatsoever, excepting only acts of God and none other,
to all or any portions of the work, except as otherwise stipulated.
To the fullest extent permitted by law, Contractor shall indemnify
and hold harmless the City and its officers, directors, agents, and
employees from and against all claims, damages, losses and expenses
including but not limited to attorneys' fees, costs of suit, expert
witness fees and expenses and fees and costs of any necessary private
investigators arising out of or resulting from the performance of
the work, provided that any such claim, damage, loss or expense (1)
is attributable to bodily injury, sickness, disease or death, or to
injury to or destruction of tangible property, other than the work
itself, including the loss of use resulting therefrom and (2) is
caused in whole or in part by any act or omission of the Contractor,
any subcontractor, or anyone directly or indirectly employed by any
of them, or anyone for whose acts any of them may be liable,
regardless of whether or not it is caused in part by a party
indemnified hereunder, or by the negligence or omission of a party
indemnified herein.
In any and all claims against the City or any of its agents or
employees by any employee of the Contractor, any subcontractor,
anyone directly or indirectly employed by any of them, or anyone
for whose acts any of them may be liable, the indemnification
obligation shall not be limited in any way by any limitation on the
amount or type of damages, compensation or benefits payable by or
for the Contractor or any subcontractor under workers' or workmen's
compensation acts, disability benefit acts, or other employee
benefit acts. The obligation to indemnify shall extend to and
include acts of the indemnified party which may be negligent or
omissions which may cause negligence.
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The City shall have the right to estimate the amount of such damage
and to cause the City to pay the same and the amount so paid for
such damage shall be deducted from the money due the Contractor
under this contract; or the whole or so much of the money due or to
become due the Contractor under this contract as may be considered
necessary by the City, shall be retained by the City until such
suits or claims for damages shall have been settled or otherwise
disposed of and satisfactory evidence to that effect furnished to
the City.
4.2 Insurance. Contractor shall procure and maintain for the
duration of the contract insurance against claims for injuries to
persons or damages to property which may arise from or in connection
with the performance of the work hereunder by the Contractor, his
or her agents, representatives, employees or subcontractors.
4.2.1. Minimum Scope of Insurance
Coverage shall be at least as broad as:
1. Insurance Services Office Commercial Liability
Coverage (occurrence form CG 0001).
2. Insurance Services Office form number CA 0001 (Ed.
1/87) covering Automobile Liability, code 1 (any auto).
3. Worker's Compensation insurance as required by the
State of California and Employer's Liability Insurance.
4.2.2. Minimum Limits of Insurance
Contractor shall maintain limits no less than:
1. General Liability: $2,000,000 per occurrence for
bodily injury, personal injury, and property damage. If
Commercial General Liability Insurance or other form with
a general aggregate limit is used, either the general
aggregate limit shall apply separately to this
project/location or the general aggregate limit shall be
twice the required occurrence limit.
2. Automobile Liability: $2,000,000 per accident
for bodily injury and property damage.
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3. Employer's Liability: $1,000,000 per accident
for bodily injury and property damage.
4.2.3. Deductibles and Self-insured Retentions
Any deductibles or self-insured retentions must be
declared to and approved by the City. At the option of
the City, either: the insurer shall reduce or eliminate
such deductibles or self-insured retentions as respects
the City, its officers, officials, employees and
volunteers; or the Contractor shall provide a financial
guarantee satisfactory to the City guaranteeing payment
of losses and related investigations, claim
administration and defense expenses.
4.2.4. Other Insurance Provisions
The general liability and automobile liability policies
are to contain, or be endorsed to contain, the following
provisions:
1. The City, its officers, officials, employees, and
volunteers are to be covered as insureds with respect to
liability arising out of automobiles owned, leased, hired
or borrowed by or on behalf of the contractor; and with
respect to liability arising out of work or operations
performed by or on behalf of the Contractor including
materials, parts or equipment furnished in connection
with such work or operations. General liability coverage
can be provided in the form of an endorsement to the
Contractor's insurance, or as a separate owner's policy.
2. For any claims related to this project, the
Contractor's insurance coverage shall be primary
insurance as respects the City, its officers, officials,
employees, volunteers. Any insurance or self-insurance
maintained by the City, its officers, officials,
employees, or volunteers, shall be excess of the
Contractor's insurance and shall not contribute with it.
3. Each insurance policy required by this clause shall
be endorsed to state that coverage shall not be canceled
by either party, except after thirty (30) days' prior
written notice by certified mail, return receipt
requested, has been given to the City.
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4.2.5. Acceptability of Insurers
Insurance is to be placed with admitted California
insurers with an A.M. Best's rating of no less than A -
for financial strength, as for long-term credit rating
and AMB -1 for short-term credit rating.
4.2.6. Verification of Coverage
Contractor shall furnish the City with original
certificates and amendatory endorsements effecting
coverage required by this clause. The endorsements shall
be on forms provided by the City or on other than the
City's forms, provided those endorsements or policies
conform to the requirements. All certificates and
endorsements are to be received within 15 days from
written notice of contract award, and the work shall not
commence until the certificates and endorsements have
been approved by the City. The City reserves the right to
require complete certified copies of all required
insurance policies, including endorsements effecting the
coverage required by these Special Provisions at any time.
4.2.7. Subcontractors
Contractor shall include all subcontractors as insureds
under its policies or shall furnish separate certificates
and endorsements for each subcontractor. All coverages
for subcontractors shall be subject to all of the
requirements stated herein.
5. TERMINATION.
This Agreement may only be terminated by City: 1) for breach
of the agreement; 2) because funds are no longer available to pay
Contractor for services provided under this Agreement; or 3) City
has abandoned and does not wish to complete the project for which
Contractor was retained. City shall notify Contractor of any
alleged breach of the agreement and of the action required to cure
the breach. If Contractor fails to cure the breach within the time
specified in the notice, the contract shall be terminated as of that
time. If terminated for lack of funds or abandonment of the project,
the contract shall terminate on the date notice of termination is
given to Contractor. City shall pay the Contractor only for services
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performed and expenses incurred as of the effective termination date,
unless terminated because the Contractor has failed to
satisfactorily cure a breach after notice in which event City shall:
a. retain any amounts earned under the Contract but not yet
paid by City;
b. take possession of all material and fixtures on the job
site;
C. have the right to complete the Work and recover from
Contractor any increased cost to complete the Work above the amounts
that would have been paid to Contractor hereunder, together with
any other damages suffered by City as a result of said breach.
6. MODIFICATION OF AGREEMENT.
City may, from time to time, request changes in the Work, the
time to complete the work or the compensation to be paid for the
Work. Such changes must be incorporated in written amendments to
this Agreement. To be effective, all such changes as referred to
in this section must be agreed upon in writing by both parties to
this agreement.
7. ASSIGNMENT.
The Contractor shall not assign any interest in this Agreement,
and shall not transfer any interest in the same (whether by
assignment or novation), without the prior written consent of City.
8. APPLICATION OF LAWS.
The parties hereby agree that all applicable Federal, State
and local rules, regulations and guidelines not written into this
Agreement shall hereby prevail during the period of this Agreement.
9. INDEPENDENT CONTRACTOR.
It is the express intention of the parties hereto that Con-
tractor is an independent contractor and not an employee, joint
venturer, or partner of City for any purpose whatsoever. City shall
have no right to, and shall not control the manner or prescribe the
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method of accomplishing those services contracted to and performed
by Contractor under this Agreement, and the general public and all
governmental agencies regulating such activity shall be so informed.
Those provisions of this Agreement that reserve ultimate
authority in City have been inserted solely to achieve compliance
with federal and state laws, rules, regulations, and interpretations
thereof. No such provisions and no other provisions of this
Agreement shall be interpreted or construed as creating or
establishing the relationship of employer and employee between
Contractor and City.
Contractor shall pay all estimated and actual federal and state
income and self-employment taxes that are due the state and federal
government and shall furnish and pay worker's compensation insurance,
unemployment insurance and any other benefits required by law for
himself and his employees, if any. Contractor agrees to indemnify
and hold City and its officers, agents and employees harmless from
and against any claims or demands by federal, state or local
government agencies for any such taxes or benefits due but not paid
by Contractor, including the legal costs associated with defending
against any audit, claim, demand or law suit.
Contractor warrants and represents that it is a properly
licensed for the work performed under this Agreement with a sub-
stantial investment in its business and that it maintains its own
offices and staff which it will use in performing under this
Agreement.
10. GOVERNING LAW.
This Agreement shall be governed by and construed in accordance
with the laws of the State of California and any legal action
concerning the agreement must be filed and litigated in the proper
court in Mendocino County, each party consenting to jurisdiction
and venue of California state courts in Mendocino County.
11. SEVERABILITY.
If any provision of the Agreement is held by a court of com-
petent jurisdiction to be invalid, void, or unenforceable, the
remaining provisions shall nevertheless continue in full force and
effect without being impaired or invalidated in any way.
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12. INTEGRATION.
This Agreement, including the exhibits attached hereto,
contains the entire agreement among the parties and supersedes all
prior and contemporaneous oral and written agreements,
understandings, and representations among the parties. No
amendments to this Agreement shall be binding unless executed in
writing by all of the parties.
13. WAIVER.
No waiver of any of the provisions of this Agreement shall be
deemed, or shall constitute a waiver of any other provision, nor
shall any waiver constitute a continuing waiver. No waiver shall
be binding unless executed in writing by the party making the waiver.
14. NOTICES.
Whenever notice, payment or other communication is required or
permitted under this Agreement, it shall be deemed to have been
given when personally delivered, emailed, telefaxed or deposited in
the United States mail with proper first class postage affixed
thereto and addressed as follows:
CONTRACTOR CITY
Manley's Boiler, Inc. City of Ukiah
7931 Whitaker Street 300 Seminary Ave.
Buena Park, CA 90621 Ukiah, CA. 95482
Email: steve@manleysboiler.com Email: mhorger@cityofukiah.com
Service by telefax shall bear a notation of the date and place of
transmission and the facsimile telephone number to which transmitted.
Either party may change the address to which notices must be sent
by providing notice of that change as provided in this paragraph.
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15. PARAGRAPH HEADINGS.
-e paragraph headings contained herein are for convenience
and reference only and are not intended to define or limit the scope
of this agreement.
16. EXECUTION OF AGREEMENT.
This Agreement may be executed in duplicate originals, each
bearing the original signature of the parties. Alternatively,
this Agreement may be executed and delivered by facsimile or other
electronic transmission, and in more than one counterpart, each of
which shall be deemed an original, and all of which together shall
constitute one and the same instrument. When executed using either
alternative, the executed agreement shall be deemed an original
admissible as evidence in any administrative or judicial
proceeding to prove the terms and content of this Agreement.
WHEREFORE, the parties have entered this Agreement on the date
first written above.
lAANL BOILER C. CITY OF UKIAH
i 1 I I
Ellen J. Manle President / Sagengiac" o
City Manager
California Contractor's License Number 573413 [Number or N/A]
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EXHIBIT A
City of Ukiah
Bids muni he emuilecl, hived or hand ikliverei:4 to the cnntuct infin-matiun lister/
herein, cunt hr rile .V)I! rliecl deadline. or the hid it -ill he reh'cted
Submitted by: 'ylanley's Boiler, Inc.
(( ompan� lame
& Address) 7931 Whitaker Street
Buena Park, CA. 90621
REQUEST FOR BID
QUO SEMINARY A% I l L
1 KIAH, CALIFOR\I:A 1)5482
P: (707) 463-6233. F: (707) 3 13-362 1
D:VUE: 9/12/2017
RE:Q. N0. E36354
BIDS NILI. RE: 1111'E IVE:D I N711.
1:30 p.m., September 27. 2017
\1 NII UFI 1('F OF rill PRO C t R1 1.11 \l \f.\\ \Gt R
1,1 \n\ \R) \\ 1 i t ry ,.rt KI \11
Iii': Man liorreer
E.nlai l: nlhorgerii eiq ofukiah.conl
131 D5 ARE: RIaOt ISI FD Ft)R Ili E: 1`01.1 01,% I I E.%IS: 1LL, BIDS SHALL BE H.O.B. t KIAH, CA.
Ot k. rrrl DESCRIPTION t Ntr PRICE LVIE\DE) PRICE
I I LIMP Sunt AH equipment. labor and materials to rrmo\e arid replucc mo (? I e\istinL, Rile Boilers 577,i'77.00 $77,777.00
\\ith ('it\ supplicd tiro t_') nc\\ Ritc Boiler, at the Ch\', W wtc\\atcr Trcauncni Plant.
as Per attache l specification.
NLA\DA"TOR) PRE-BID NIEETI\G
9 a.m.. G1 ednesda}. September 20.'_01 7
Cit\ of L Liah aste\\ater Treanlent Plant
300 Plant Road. Ukiah. Cry 9,3482
Pai ment Te
SIGNA 1-1 RF.:
DAME: 09/27/2017 LEAD TIME: ARO: 1/A
PRI\ I' \AME:: Ellen Iflanlev, Pres ent IPIIONF, 562-427-314-1 L\IAII.: Steve@man evs of er.arn
TERMS:
I WEAL NREFERENCL Local Vendors shall be given an allowance of five percent (5`yo) up to a maximum allowance of $2.5UU. on any bid for
supplies. equipment and/or materials per Ukiah City Code Section 1522 U 4 A i_ocal Vendor is detined as one which 1) conducts business in an
Office or other business premises with a physical location in Mendocino County 2) holds a valid business license Issued by Mendocino County
or one of the cites in Mendocino County for that business location. and 3) has conducted business In complaince with 1) and 2) for not less than
six (b) months prior to requesting the prelerence I he City shall receive satisfactory proof that a business qualities as a local Vendor before it
may receive the local preference In the event that there Is a tie bid where one bidder is local the other is not and the bid is equal in price and
quality, the award shall go to the Local Vendor
2 Right is reserved to refect any and all bids
3 Right Is reserved to accept separate items unless specifically denied by bidder
4 Rights reserved to refect a bid from any bidder who has previously tailed to perform adequately for the City of Ukiah
5 In CASE OF UEFAUL I the City of Ukiah may procure the items quoted on from other sources and hold the original bidder liable for any increased
costs
b I he price. terms, delivery point. and delivery date may Individually or collectively be the basis of the awarding of the bid
7 In submitting the bid. bidder agrees that the bid Shall remain open and may not be revoked or withdrawn for bU days from the Did due date unless
a different time period Is specified In RF8.
8. Bidder agrees to perform according to Its bid if the City's acceptances communicated to the bidder within the time specified in number 7 above
REQUEST FOR BID
City of Ukiah
SPECIFICATION E36354
BOILER REMOVAL AND INSTALLATION
AT THE WASTEWATER TREATMENT PLANT
September 12, 2017
Mandatory Pre -Bid Meeting
9 a.m., Wednesday, September 20, 2017
at the
Wastewater Treatment Plant
300 Plant Road
Ukiah, California 95482
Bids are Due:
1:30 p.m., September 27, 2017
Purpose/Background
The City of Ukiah is seeking a qualified contractor to provide bids for all equipment, labor and materials to remove and
replace two (2) existing Rite Boilers with City supplied two (2) new Rite Boilers at the City's Wastewater Treatment
Plant.
Contact Person
The City has designated Mary Horger, Procurement Manager as the contact person for questions related to this Request
for Bid. Questions are to be submitted in writing, and can be done so by fax at
(707) 313-3621, or by e-mail at mhorger'u cityofukiah.com.
Mandatory Pre -Bid Meeting
A mandatory pre-bid meeting will be held 9 a.m., Wednesday, Septermber 20, 2017 at the project site located at the
Wastewater Treatment Plant, 300 Plant Road, Ukiah, California to fully acquaint interested Contractors with local
conditions, construction and labor required so that he or she may fully understand the facilities, difficulties and
restrictions attending the execution oft lie work under the Contract. Failure to attend this meeting will be just cause
for the bid to be rejected as non-responsive. Contractors shall thoroughly examine and be familiar with the
specification. The failure of any contractor to receive or examine any form, instrument, addendum. or other document,
or to visit the site and acquaint himself with conditions there existing, shall in no way relieve the contractor from any
obligation with respect to his or her bid or to the contract. The drawings for the work show conditions as they are
supposed or believed by the Engineer to exist; but, it is neither intended nor shall it be inferred that the conditions as
shown thereon constitute a representation by the Engineer, the City or its officers that such conditions are actually
existent, nor shall the City, the Engineer or any of their officers or representatives be liable for any loss sustained by the
Contractor as a result of a variance between the conditions shown on the drawings and the conditions actually revealed
during the progress of the work or otherwise.
Oral statements or instructions made during this mandatory pre-bid meeting will not constitute an amendment to this
solicitation. The City will determine the appropriate action necessary, if any, and may issue a written amendment to the
bid request.
The contractor shall investigate to his or her satisfaction the conditions to be encountered, the character, quality and
quantities of work to be performed and materials to be furnished and the requirements of the Plans, Special Provisions,
Standard Specifications, Standard Plans, and Contract Documents. The submission of a bid shall be considered
conclusive evidence that the contractor has made such examination and has accepted the project workplace as a safe
workplace to perform the work of the Contract.
Scope of Work
The scope of work consists of all labor, equipment, materials, and incidentals of any kind (with the exception of City
supplied materials) to remove the two existing boilers, and install, and start-up two new boilers located at the City of
Ukiah Wastewater Treatment Plant, located at 300 Plant Road, Ukiah, California.
The boilers to be replaced were manufactured by Rite Boiler, Part Number A180WGG, serial numbers 24793 and
24794, and were installed at the Plant in 1995. The boilers are used to provide heat for the two digesters. It will be the
responsibility of the contractor to remove and dispose of the existing boilers, burners, and any other items being
replaced during the course of the work.
The two (2) new replacement boilers have already been purchased and received by the City, and are awaiting
installation at the Wastewater Treatment Plant. The new boilers purchased are supplied with dual fuel burners, with
sel)(wate digester- and nano al gas gas !h•ains, and have the following description:
Rite Indoor Model A 180WGG, 43 HP, 125 PSI Hot Water Boiler with two (2) probe low water cut-offs and
relief valve set at 125 psi. With Powerflame CR2-GG-15 6-14•' water column supply natural gas pressure and
8.5" mininium digester gas pressure. With Y horse power blower motor, 460/60/3 motor with stepdown
transformer for controls, CSD -1, Cal Code, full modulation tiring. The probe low water cut-off will be at the
back of the boiler so they will not interfere with the supply water pipe. With ceramic fiber combustion
chamber with firebox access door, hinged head plates, draft gauge and 18" barometric damper shipped loose.
Digester gas train is standard aluminum body and brass valves, the pipe nipples and fittings are Schedule 40,
150 PSI Rated, 316 Stainless Steel. The boilers include manual push-pull soot scrapers installed to help keep
the heat exchanger fire side tree of siloxaine and other deposits. includes manufacturer installed inches of
water column gas pressure gauges before and after the natural gas main pressure regulator on each boiler, as
well as the same make gauges on the digester train. The gauges include test valves so you can turn off the
pressure to the gauges when not testing. Boilers have the same vent and water connection sizes and locations
as the original 1995 boilers. The boilers have ceramic fiber combustion chambers in lieu of refractory
combustion chambers. One boiler is supplied with standard right hand gas train and controls, the other with
lett had gas train and controls. Firebox access doors have been placed on the side opposite the gas train and
controls so they are not blocked off by the fuel piping.
The installation of' the Rite Boilers is to be in accordance with the Rite Boilers instruction Manual for Indoor &
Outdoor Rite Power Burner Fired Boilers, provided for as Attachment A. The start-up of the Powerflame burners is to
be performed in accordance with the Power Flame Installation & Operation C Manual, provided for as Attachment B.
The following documents have been provided for as reference to assist in the preparation of your bid:
Attachment C - WWTP Facility Drawings — 3 Drawings
Attachment D — Approved Rite Boiler Drawings — 3 Pages
The work site wil I be kept clean and tidy during the course of the work. Contractor shall be solely responsible for any
and all damages extending from the work described herein. Contractor shall restore all damaged property to its original
condition at his/her own expense.
All work will be provided for in accordance with the City's standard short form construction contract, provided for as
Attachment E.
Price
The bid price for this work will be submitted per the bid sheet provided, and shall be lump sum, and consist of all labor.
materials, equipment, applicable fees, including tax and freight necessary to perform the work as described in this bid
specification.
Terms
Payment will be made 30 calendar days after final date of acceptance of work.
The City reserves the right to award to the lowest, responsible bidder. The City also reserves the right to waive any
irregularities and technicalities and request rebids should it be deemed in its best interests to do so. The price and terms
may individually or collectively be the basis of awarding of the bid. The City also reserves the right to reject any and
all bids.
Warranty
Unless otherwise indicated, the Contractor must provide a l -year workmanship warranty from the date of final
acceptance. The Contractor shall replace promptly and at his own expense any materials and/or workmanship which
fail during this warranty period.
Indemnify and Hold Harmless
Contractor agrees to accept all responsibility for loss or damage to ani person or entity, and to defend, indemnity, hold
harmless and release the City, its officers, agents and employees, from and against any and all actions, claims, damages,
disabilities, or costs of litigation that may be asserted by any person or entity, arising out of or in connection with the
negl igent or will ful misconduct in the performance by contractor hereunder, whether or not there is concurrent, passive
or active negligence on the part of the City, but excluding liability due to the sole active negligence or willful
misconduct of the City. This indemnification obligation is not limited in any way by any limitation on the amount or
type of damages or compensation payable to or for Contractor or its agents under Workmen's Compensation acts,
disability benefits acts or other employee's benefits acts. Contractor shall be liable to the City for any loss or damage to
City property arising from or in connection with Contractor performance hereunder.
Time of Comnletion
The Contractor �N ill complete the work within 30 calendar days from receipt of formal Notice to Proceed.
Other Requirements
The selected contractor will need to comply with the following requirements:
1. Insurance - Contractor's attention is directed to the insurance requirements — see Attachment F. Contractors
shall finish to the City, upon award of contract, certificates of insurance covering full liability under
Worker's Compensation laws of the State of California, Comprehensive General Liability and Business Auto
Insurance with policy limits of not less than $1,000,000 naming the City as an additional insured party.
It is highly recommended that contractors confer with their respective insurance carriers or brokers to
determine in advance of bid submission the availability of insurance certificates and endorsements as
prescribed and provided herein. If an apparent awarded contractor fails to comply with the insurance
requirements, that contractor may be disqualified from award of the contract. If you have questions regarding
the City's requirements, please contact the City's Risk Manager at 707-463-6287.
2. Compliance with State of California and OSHA - All materials, parts and equipment furnished pursuant to
these specifications shall be in compliance with the laws and regulations of the State of California and OSHA.
The contractor shall, if requested by the City, supply certification and evidence of such compliance.
3. Legal Requirements and Permits: The contractor agrees to fully comply with all local, City, State and Federal
laws, regulations and ordinances governing performance of contractual services required, and it will be the
responsibility of the contractor to obtain any and all necessary licenses, permits or clearances, including the
actual cost of licenses.
4. License Requirements - Contractor must possess a current State of California Contractor's license and a
City of Ukiah business license. (For information business license, please contact Kathy Norris. City of
Ukiah Finance Department at 707-463-6202.)
a. The Contractor shall possess a valid State of California Class C-4 Boiler. Hot Water Heating and Steam
Fitting- Contractor license. Contractor shall provide proof of possession ofthe proper licenses and certificates of
registration necessary to perform the work. Employees actually performing the tasks shall provide proof of
proper certificates of registration for same.
b. The Contractor shall keep in force a City of Ukiah business license for the extent of the project.
c. Where subcontractors/jobbers are used, Contractor shall provide the City with proof of proper licenses,
certificates and proof of insurance for work performed.
Notice to Contractors - Contractor Registration and Prevailing Wages -No contractor orsubcontractor Inco,
be listed on a bid.for a public works project (submitted on or after March 1, 2015) unless registered irith the
Dc/R11-1111071 of7ndustrial Relationslrursuant to Labor Code section 1725.5 [with limited exceptions from this
reyttireurcut Jor bid proposes only ttrulerLcrhor Codc .section 1771.1(a)J. No c-otttrctctor• orsttbcorttr actor• micro•
be an,arded a contract for public work on a public works project (cnrarded on or after April 1, 2014) unless
registered with the Delmi-tment of Industrial Relations pursuant to Labor Code section 1725.5. The prints
contructor.shall be resporrsible,for•postingjob site notices as prescribed by regulation. This project is subject
to congViancc monitoring and enforcement h}- the Deperrttncnt of Industrial Relations.
Each laborer or mechanic of Contractor or any subcontractor engaged in work on the project under this contract
shall be paid, pursuant to provisions of Section 1770, including amendments thereof, of the Labor Code of tile
State of California, the Director of the Department of Industrial Relations. State of California, has ascertained
the general prevailing rate of wages for straight time, overtime Saturdays, Sundays and Holidays including
employer payment for health and welfare, vacation, pension and similar purposes, copies of the General
Prevailing Wage Determination (applicable to the work), for the locality in which the work is to be done can be
reviewed at Website:
%% ww .dir.ca.�-,ov/dlsr/pis d/northern.html .
The Labor Commissioner through the Division ofLabor Standards Enfirrcentent (DLSE) mcrt• at am time
require contractor and subcontractors to fiu•rrish electronic certified pa }roll records directlt, to DLSE.
Conimcw-ing rn,ith contracts awarded on or after April 1, 2015, all contractors and subcontractors must
fttrni.sh electronic certified l?aYroll records directly to the DLSE.
Bidder Qualifications
They City will satisfy itself that the potential contractors are reputable firms with a proven track record. Contractors are
requested to provide the information requested under Work Performance History Capability. References shall include
the contact name and phone number.
Bid Submission Deadline
Bids can be submitted in hardcopy, fax, or by email. Bids are due on or before 1:30 p.m, Wednesday,
September 27, 2017 to:
City of Ukiah Purchasing Department
Attn: Mary Horger
411 West Clay Street
Phone: (707) 463-6233, Fax: (707) 313-3621
Email: mhor,-,er u,citvofukiah.com
It �Nill be the sole responsibility of the contractors to have their bids delivered to the City before the closing
hour and date. Late bids will not be considered and will be returned unopened to the sender. The City will not be
responsible for any cost incurred by the Contractor in preparation of their bid.
INDEMNIFY ANI) HOLD H.�IZ11LIa� :�GItEE�1F:\T
t ontractol- ililrce:� Its idl lit', IU:" Ill» Ot dillllai?: It, -illA hcI'>U11 UI- and to klelQ11d.
mclemnity. hold harnllC,. and rcicase the ( itv, its off-Icets. a_Cnt,'and enlplovice,. fionl and against iim and all i coons.
claims. dama_es, disabilities. or Costs of, liti_ation that Fila\ he assCrted h\ all person or entity. ari inL_ out of ur in
Connection \\lilt the ncsli rnt ur \\ ilit'ul nlisCondttct in the pertirrmancc b\ contractor. herCLIlider. \\hetheror not there k
Concurrent, pa>si\C or acti\ C ne_IigCIlCe on the part ot'thc Cit\, but c\Cludin_ hahilit\ dltc to the sole aCti\C negli_cnCC
or \\illt'ul n1i,C011dtlCt ot'the ('it,. I his indenlrlification ohli_2ation is not limited in an\ \\a\ h\ am limitation on the
011101.1111 til- 1\ pC of dWlla_'c, ill' Colnlpetl alion Ila\ able to of- flitContra(101' ill- ita iil-Icnts lil)llct' Workmen's (onipcii atiUtl
act>, disuhillt\ hellefits acts or other Cmplo\ce s acts.
ConUaCtol ,hall he liable to the Cit\ t -or an\ loss or diuuage to Cit\ property arising from or ill
Connection \\ ith Contractot pCri0n n1.u1CC hCreundcr. I-hC undcrs11_111Cd tckrlo\%lcd_es that this doCwrlerlt, to_,ethcr\\ ith
OIL: rc;ultillL htlrrha"'C order issued h\ the: Cit\, the CXcrutCd Short F01111 Con u'uction Contract. the in,tuanCe
rclluircmcnt. for Contractors. and the Contractor Statement Rccardin_ iruurancc co\crage Comprise a \\rittcn agreement
hCMecn the Contractor and the Uit\ hilidin_ on hoth pitrtic,
File undersi_ned declarCs thc\ are litnliliar with the item: specified and ha\c carefulk read the RIB
,h,�CiliCation rC�luil'CIII Crlts, cIIQAcd illi of -the ti__tu-cs stated on the spccification, and aceCpts full responsihiIit\ I'm an\
Crror or omission in the preparation of -this hid.
Ffils hid is submitted h\. )check one►
hldi\ Kival ( )\\flet' - — Partnership l Corporation Other
I cLml \anm oh Bidder .Manley's boiler, Inc.
AddrC'ss oh Bidder `a I Whitaker Street, buena Park, CA. 90(,21
,l -ay IU:- 33-02O3801
Phone Nunlhcr D02-427-3[44
E=ar \unlhcr -502-.124-8626
California State Contractor's License #: , 111' !:.\piration Date: 07'31/2010
Department of Industrial Relation Public Works Reoistration #: 1000002417
By : --� - ' ' '�v - -- — --- -- I),tte 09/2712017
signature
Print or T\ pe Name: 1-Ilen I Manley President
. _— 1-itlC
WORK PERFORMANCE
HISTORY AND CAPABILITY: Contractor is requested to provide the name, locations and a narrative statement on the work performed.
WORK PERFORMED
1. COMPANY NAME:
Nissin Foods Boiler pipe welding and valve
CONTACT: Jorge Andrade
ADDRESS: 2001 W. Rosecrans Ave.
Gardena, CA. 90249
PHONE 310-327-8478
2. COMPANY NAME: County of San Bernardino
CONTACT Marty Marshall
ADDRESS 385 N. Arrowhead _
San Bernardino, CA. 92415
PHONE: 909-208-8490
3. COMPANY NAME: Ventura Youth Correctional Facility
CONTACT: Roy Calzada
ADDRESS -31 00 Wright Road
Camarillo, CA. 93010
PHONE: 805-485-8071 Ext. 3218
4. COMPANY NAME: Raytheon -El Segundo
CONTACT: John Pena
ADDRESS: 2000 E. El Segundo Blvd.
El Segundo, CA. 90245
PHONE: 310-261-8434
6
replacements.
On-going boiler maintenance, service,
testing, and repair of 64 various boilers
throughout the County of San Bernardino
On-going boiler maintenance, service,
testing, and repair of on-site boilers.
Replaced two 530 gallon water storage
heaters in 2014.
On-going boiler maintenance, service,
testing, and repair of all on-site boilers.
MANLEY'S BOILER, INC.
VARIOUS PROJECT EXPERIENCE
VARIOUS PROJECTS IN PROGRESS:
Description
Dollar Value Owners Name
Rep Name/Email
Owner Address
Boiler maintenance, service, inspection,
On-going
916-255-6187
9838 Old Placerville Road
calibration, and repair for 21 prisons in
California Department of
Maria Crews
Ste B-2
California
$ 3,286,000.00 Corrections and Rehab.
maria.crews@cdcr.ca.gov
Sacramento, CA. 95827
On-going maintenance, service and repair of all
On-going
John Pena
2000 E. EI Segundo Blvd.
on-site boilers.
as per contract Raytheon -EI Segundo
john.o.pena@raytheon.com
EI Segundo, CA. 90245
On-going maintenance, service and repair of 64
UTC Aerospace
Larry Vega
8200 Arlington Avenue
various boilers throughout the County of San
- - -
Marty Marshall
385 N. Arrowhead
Bernardino.
$_237,360.00 County of San Bernardino
mmarshall@fm.sbcounty.gov
San Bernardino, CA. 92415
Service, maintenance, repair, replace parts for
$165,000.00
3/1/2017
200193752
Fulton Vantage, Kawanee, and Peerless boilers
Eric Oates
707 West Acequia Avenue
as needed.
$ 45,600.00 City of Visalia
ericoates@ci.visalia.ca.us
Visalia, CA. 93291
Service, maintenance, repair, replace parts for
$ 50,170.52 Nissin Foods
Mike Ponce
3291 Loma Vista Rd.
Ajax and Raypak boilers as needed.
$ 70,348.00 Ventura County Medical
mike. ponce@ventura.org
Ventura, CA. 93003
VARIOUS CLOSED PROJECTS FROM THE PREVIOUS SEVEN YEARS:
2016/2017
Scheduled
Completion
Date Contract #
01/01/2017
12/31/2018 C5606805
01/01/2017
12/31/2019 170591
14-15-88
6/30/2017 131414
Contract Date of
Description
Percent
Phone
Complete
916-255-5704
On-going
916-255-6187
contract
Remove existing Ajax steam boiler. Supply and
On-going
310-261-8434
contract
$ 64,000.00
On-going
909-208-8490
contract
install new Hi -Delta Raypak boiler.
On-going
559-713-4469
contract
213-487-4444
On-going
805-204-8005
contract
Scheduled
Completion
Date Contract #
01/01/2017
12/31/2018 C5606805
01/01/2017
12/31/2019 170591
14-15-88
6/30/2017 131414
Contract Date of
Description
Dollar Value Owner's Name
Rep Name
Owner Address
Phone
Amount
Completion
Contract #
Remove existing Ajax steam boiler. Supply and
david.sheil@ash.dsh.ca.gov
Washington Moranzonl
3250 Wilshire Blvd.
$ 64,000.00
9/1/2016 15-10111
install new Hi -Delta Raypak boiler.
$ 45,423.00 One Park Plaza
washington@reaItechla.com
Los Angeles, CA. 90010
213-487-4444
_$_45,423.00
4/28/2017
17-0123C-1
Supply and install two (2) two -million btu
UTC Aerospace
Larry Vega
8200 Arlington Avenue
-
- - -
Charles Chaffee
Raypak boilers.
$ 165,000.00 Systems/ILL
larry.vega@am.jll.com
Riverside, CA. 92503
951-232-1439
$165,000.00
3/1/2017
200193752
Jorge Andrade
2001 W. Rosecrans Avenue
Burbank, CA. 91505
818-331-5834
$ 10,000.00
Boiler pipe welding and valve replacements.
$ 50,170.52 Nissin Foods
ajorge@nissinfoods.com
Gardena, CA. 90249
310-327-8478
$ 50,170.52
12/31/2016
VARIOUS
Weld repair on Boiler #4 for boiler feed piping
David Shell
10333 EI Camino Real
modifications.
$ 64,000.00 Atascadero State Hospital
david.sheil@ash.dsh.ca.gov
Atascadero, CA. 93423
805-468-2249
$ 64,000.00
9/1/2016 15-10111
David Sheil
10333 EI Camino Real
Completely rebuild the refractory for boiler #3.
$ 90,532.87 Atascadero State Hospital
david.sheil@ash.dsh.ca.gov
Atascadero, CA. 93423
805-468-2249
$ 90,532.87
8/1/2016 15-10128-000
-
- - -
Charles Chaffee
Remove old tubes and purchase and install new
cchaffee@burbankmarriott.co
2500 N. Hollywood Way
tube bundle for Raypak boiler.
$ 10,000.00— Marriott Burbank
Burbank, CA. 91505
818-331-5834
$ 10,000.00
6/1/2016 31688960492
-
— —
_m
Jackeline Bonilla
Remove old tubes and purchase and install new
jackeline.bonilla@pihhealth.or
11500 Brookshire Avenue
tube bundle for Patterson Kelly Boiler.
$ 20,000.00 Downey Regional Hospital
g
Downey, CA. 90241
562-904-5000
$ 17,777.68
2/19/2016 D11929
Replace existing underground double
containment steam and condensate lines at
California State Prison -
Mac Mimaki
44750 60th Street W.
661-729-2000
06/2016 -
California State Prison, Los Angeles County
$_ 207,000.00_ Lancaster
mac.mimaki@c_dcr.ca.g_ov
CA. 93536
Ext. 7307
$207,000.00
10/2016 C5606377
US Dept. o the
_Lancaster,
PO Box 10046
Demo existing boiler and purchase and install
Army/Infinite Energy
Jim Howie
TR11109 South Loop Rd.
07/2016 -
three (3) two -million btu boilers.
$ 275,159.34 Construction - Daggett
jhowie@iec8a.com
Fort Irwin, CA. 92310
760-386-0400
$275,159.34
09/2016 W91248 -11-D-0001
Replace two Lochinvar boilers on roof -top at The
Kimberly McDowel
5000 Clark Ave., Lakewood, CA.
Centre at Sycamore Plaza.
$ 169,995.00 City of Lakewood
kmcdowel@lakewoodcity.org
90712
562-866-9771
$169,995.00
6/13/2016 2015-5
Replace one heat exchanger and 1000 gallon
Danny Miller
590 S. Burlingame Ave., Los
310-451-8011
storage tank.
$ 56,287.98 Brentwood Country Club
facilitymgr@brentwoodcc.net
Angeles, CA. 90049
Ext. 249
$ 56,287.98
6/1/2016
San Diego Convention
Debbie Noble
111 W. Harbor Dr., San Diego,
Rebuild two roof -top K300 boilers w/ re -tubes.
$ 110,705.00 Center
debbie.noble@visitsandiego.com
CA. 92101
619-525-5383
$110,705.90
1/27/2016
E:\CeanneDocs\manleys work in progress prev yrs rev
2015
Description
Dollar Value Owner's Name
Rep Name
Owner Address
Phone
Contract
Amount
Date of
Completion Contract #
Demo four existing boilers and install customer
Santa Ana Unified School
Sonny Carrillo
1401 S. Grand Ave., Santa Ana,
Owner Address
Phone
Amount
supplied boilers.
$
32,624.00 District
isagani.carrillo@sausd.us
CA. 92705
714-936-0570
$ 32,624.00
12/1/2015
Provide all labor & materials as necessary to
Replace two 530 gallon water storage heaters.
$
165,991.00 Ventura Youth Correctional
roy.calzada@cdcr.ca.gov
93010
remove & demo old boiler; purchase & install
$165,991.00
Pasadena Community
Sandra Collins
1570 E. Colorado Blvd.,
Pasadena Community
Sandra Collins
new boiler at building C.
$
139,900.00 College
sdcollins@pasadena.edu
Pasadena, CA. 91106
626-585-7367
$139,900.00
12/29/2015
sdcollins@pasadena.edu
Pasadena, CA. 91106
Los Angeles County
Nick Wiehardt
24501 S. Figueroa, Carson, CA.
310-830-2400
Labor and materials to replace the underground
Retrofit three 500 hp burners
$
399,998.00 Sanitation District
nwiehardt@lacsd.org
90745
Ext. 5254
$399,998.00
2/1/2015
Install heat exchanger and rental boiler with
California Institute for
California Institute for
John Dickson
16756 Chino -corona Rd., Corona,
909-606-4957
two storage tanks.
$
135,400.00 Women
john.dickson@cdcr.ca.gov
CA. 92878
Ext. 7343
$135,400.00
1/31/2015
2014
E:\CeanneDocs\manleys work in progress prev yrs rev
Contract
Date of
Description
Dollar Value Owner's Name
Rep Name
Owner Address
Phone
Amount
Completion
Contract #
Roy Calzada
3100 Wright Road, Camarillo, CA.
805-485-8071
Replace two 530 gallon water storage heaters.
$
165,991.00 Ventura Youth Correctional
roy.calzada@cdcr.ca.gov
93010
Ext. 3218
$165,991.00
4/11/2014
Pasadena Community
Sandra Collins
1570 E. Colorado Blvd.,
Replace boiler in building D
$
32,559.00 College
sdcollins@pasadena.edu
Pasadena, CA. 91106
626-585-7367
$ 32,559.00
2/18/2014
Labor and materials to replace the underground
steam & condensate lines; and install heat
California Institute for
John Dickson
16756 Chino -corona Rd., Corona,
909-606-4957
exchanger and rental boiler with two tanks.
$
112,002.00 Women
john.dickson@cdcr.ca.gov
CA. 92878
Ext. 7343
$112,002.00
8/29/2014
Gary King
8039 Beach Blvd., Buena Park,
Remove and install new Rite boiler.
$
109,896.00 Knott's Berry Farm
gary.king@knotts.com
CA. 90620
714-220-5295
$109,896.00
4/25/2014
2013
Contract
Date of
Description
Dollar Value Owner's Name
Rep Name
Owner Address
Phone
Amount
Completion
Contract #
Los Angeles Unified School
Barrett Elementary School
District of Los Angeles
Dave Perez
419 W. 98th Street
Replace and install hot water and steam boilers.
$
60,123.18 County
david.perez@lausd.net
Los Angeles, CA. 90045
714-328-7997
$ 60,123.18
6/28/2013
Retube D -style Cleaver -Brooks, install Coen
Rob Swenson
2025 E. Harbor Dr.
burner, overhaul economizer.
$
957,400.00 CP Kelco
rob.swenson@cpkelco.com
San Diego, CA. 92113
619-595-5038
$957,400.00
8/13/2013
2012
Contract
Date of
Description
Dollar Value Owner's Name
Rep Name
Owner Address
Phone
Amount
Completion
Contract #
Jorge Andrade
2001 W. Rosecrans Ave.
Install six boilers and all equipment.
$
112,800.00 Nissin Foods
ajorge@nissinfoods.com
Gardena, CA. 90249
310-327-8478
$112,800.00
8/1/2012
2011
Contract
Date of
Description
Dollar Value Owner's Name
Rep Name
Owner Address
Phone
Amount
Completion
Contract #
Mark Stephenson
mark.stephenson@
9655 Granite Ridge Drive #100
Burner & boiler install
$
193,861.00 Bumble Bee
bumblebee.com
San Diego, CA. 92123
562-204-4915
$193,861.00
9/1/2011
2010
Contract
Date of
Description
Dollar Value Owner's Name
Rep Name
Owner Address
Phone
Amount
Completion
Contract #
Ray Carpenter
rcarpenter@
35435 Pala Del Norte Rd.
Boiler repairs
$
335,458.00 Orange Grove Energy
orangegroveenergy.com
Pala, CA. 92059
760-615-2010
$335,458.00
12/27/2010
E:\CeanneDocs\manleys work in progress prev yrs rev
04, of Ukiah Boiler Removal & Installation at the N'WTP - RFB
SUBCONTRACTORS: The bidder must submit a list of subcontractors whom he proposes to employ on the work with proper firm
name and business address of each.
Subcontractor's Name None Work to be performed
Address
City/State/Zip
Phone Number Fax Number
License Number/Type/Expiration Date
DIR PW Registration #
Subcontractors Name
Work to be performed
Address
City/State/Zip
Phone Number Fax Number
License Number/Type/Expiration Date
DIR PW Registration #
Subcontractors Name
Work to be performed
Address
City/State/Zip
Phone Number Fax Number
License Number/Type/Expiration Date
7
DIR PW Registration #
Cit l• of I 'Airrh Boiler Removal & Installation at the !{'JVTP - RFB
RIDI)FR(()\IR\(-I-OR SI \[1-.111:\I
RFG \RUIVi I\tit R \\('I ('(A I It Vel
Clo he submitted %%ith Kid)
li DDI-RIIFRFRI(FRTIFIESthmhe,liM,wiccccd,mduWamanddicinsuranceeu�cra,ercyuirement.specitiecl
ut the Rcyuest tiff Fiid lor.
IIOTI-'R MAI(A \l A\I) I\S I \I I \ IlU\ \ I I IIF \\ \S I I \\ \ I I t( I lu \ l \IF\ I IT \\ I
Should m I ht ;+warded the contract. sic I cutin that "e I can nuet the spec hied requirement; for in,urunce. inelu3in,
ntNurancc ",\era�c of the subcontractors. and agree to name; the ( its of t kiah as kdtlitional Insured for the %%ork
specified. \nd cce I cc ill eompl� Stith the pt -c,\ i;ion> of Sect I,nj ;?tln of the I emploser to
he inavol against hahilitt Or ttorkc•r', onnpensmion or W undertake sclt-tnsit rance in accordance \t ith the Pro\ iIiuttS ul
that LOdC. hCfLne 1:0111ntcncin, the performance of the \\cork �peiihed.
Manlcy'� 1;mlcr, Inc.
Plc.uc Print i Pcrurn. I irm- or ('orp,mationl
Signature of ko�t nivcd Itrhresentatite
Ellen J :\tanlr�, Pl-eSidCllt
Plea,c I'rint (\anrr N. l itis Irl ,luthorved Rchrr,cntati�ci
09i29/201 362-427-31.1.4
Date
Phone A'umhci
8
PURCHASING DEPARTMENT
411 West Clay Street, Ukiah CA 95482 lip �� f Ukiah
(707)463-6233 J
mhorger(a,cityofukiah.com
SPEC. E36354 — BOILER REMOVAL AND INSTALLATION AT THE WASTEWATER TREATMENT PLANT
Addendum No. 1
September 26, 2017
The following is Addendum No. 1 to SPEC. NO. E36354 Boiler Removal and Installation at the Wastewater
Treatment Plant.
IF YOU SUBMIT A PROPOSAL, ACKNOWLEDGMENT OF THIS ADDENDUM MUST BE SHOWN ON THIS ADDENDUM.
IN ADDITION, THIS SIGNED ACKNOWLEDGMENT MUST BE SUBMITTED WITH YOUR PROPOSAL, OR IT MAY BE
DEEMED AS NON-RESPONSIVE,
This Addendum is hereby made part of the Contract Documents to the same extent as though it were originally
included therein.
I. BID DEADLINE HAS CHANGED: The new deadline to submit bids is 1:30 p.m., Friday, September 29,
2017.
II Attachment B — Power Flame Installation & Operation C Manual. The incorrect document was issued
with original bid request. It is replaced with the manual attached.
III The following is added to the Scope of Work:
A Existing Gas Supply Lines:
1. Contractor to re -pipe the existing gas supply lines to remove from location between the
boilers, to keep clear and open for future boiler maintenance, and to accommodate the new
location of the replacement boiler valve trains. Please see Exhibit 1 for proposed relocation
of the lines.
2. All valve, gauges and piping are to be replaced with new.
3. Add additional ball valve to inches -in -water gauge, shown in Exhibit 2.
4. Repaint the gas supply lines to "Industrial Yellow" to follow ANSI guidelines.
B. Existing Water Supply Lines:
1. Outlet: Add Emergency Connection Outlet as shown on Exhibit 1, 3 and 4. Replace existing
tee with cross fitting. This will need to be done prior to the replacement of the boilers, to
minimize down time of digester operations during the remainder of the project, and to also
enable future maintenance work on boilers as needed once project is complete. Add
additional temperature gauge.
2. Inlet: Add Emergency Connection Inlet as shown on Exhibit 1 and S. Replace existing 90 degree
elbow on inlet water with a tee, to accommodate the additional emergency connection inlet
as shown on Exhibit 1. This will need to be done prior to the replacement of the boilers, to
minimize down time of digester operations during the remainder of the project, and to also
enable future maintenance work on boilers as needed once project is complete.
3. Exhaust Drain Plumbing: Current location shown in Exhibit 6. To be relocated from the
middle of the boilers, to the outside of the boilers, to open up space between the boilers for
maintenance.
Page 1 of 2
4 Replace all existing butterfly valves with new, and add as needed per Exhibit 1.
a. For informational purposes, existing valves are a (DeZurik i#9240536). This model
has been replaced by the manufacturer. See Exhibit 7 for manufacturer drawing.
Use this valve, or equal.
5. All plumbing, inlet and outlet, to be replaced, including all insulation wrap.
6 Replace all temperature gauges.
All other `erms and conditions remain in full force and effect.
Mary V. Norger
Procurement Manarzer
ACKNOWLEDGMENT
I hereby acknowledge that I have received this Addendum No. i and have reviewed and considered it before
submitting my proposal.
Signed: gate:
Hen J Mani President
Company Name MMIlt-v's Boiler, InC.
Page 2 of'-)
EXHIBIT 1
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EXHIBIT 3
EXHIBIT 4
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EXHIBIT 7
VALVE SIZEDIMENSIONS
HORIZONTAL
1
1
2'32
59,
VERTICAL
IN MM
IN
MM
A
B
C
D I
E j
F
G
2
50
1.67
6.50
2.36
5.53
.57 1
4 5/8-11 INCU
4'75
[42
1651
[601
[140]
[141
11211
1.79
7.28
2.76
6.02
5.50
2-1/2
65
[45]
1651
[701
[1531
.57
[14] 1
4 518-11 UNC
11401
1.79
7.58
3.15
6.20
6.00
3
80
[451
[1931
1801
[1571
.57
[141
4 5/8-11 UNC
11521
2.02
9.00
3.54
6.93
7.50
4
100
[511
[2291
[90]
[1761
.57
[141
8 5/8-11 UNC
[1911
5
1258
314-10 UNC
'
1551
[254]
[1 12]
[1911
[141
[2161
2.18
11.22
5.04
7.97
9.50
6
150
[551
[2851
[1281
[202
.57
[14
8 X4-10 UNC
[2411
DOTTED LINES INDICATE
OPTIONAL LOCKING DEVICE
PROVIDED BY CUSTOMER
(SEF DF TAII 'A" R NOT 5)-
-T � �a
10.24
[2601
E
MOUNTING HOLES FORf
PIPELINE MOUNTING"F" OTY AND SIZE OFTAPPED HOLES
ON A "G" DIA BC
(ANSI STANDARD,-
�„B„-1/1' � C
NOTE:
1. DRAWING SHOWS MOUNTING HOLES FOR
ANSI CLASS 125150 FLANGES.
2. FOR FLANGES OTHER THAN ANSI STANDARD
SEE D10478 FOR DIMENSIONS.
3. DO NUT USE GASKETS BETWEEN VALVE
AND MATING FLANGES.
4. FLOW MAY BE IN EITHER DIRECTION
5. LEVER WILL USE A.2817I DIA X 2,00[511 VERTICAL
X.81(211 HORIZONTAL ADJUSTABLE SHACK �E
PADLOCK, DIVENSIONS ARE IN THE LOCKED
POSITION.
NOTICE
HIS DRAWING DOES NCT SHOW' ACTUATOR ACCESSORIES. IF ACCESSORIES
ARE REQUIRED. REFER TOTHE APPROPRIATE ACCESSORY INSTALLATION
DRAWING FOR DIMENSIONS AND OTHER RELATEC INFORA^ATION.
�u
A
ACTUATOR MOUNTING POSITIONS f��\\
f \'� LJ D eZ U R I I ` BOS-CL BUTTERFLY VALVES SIZE 2 - 6 LUGGED
\ \ \/ L710 POSITION LEVER ACTUATOR
STANDARD POSITION 180' POSITION
SHOWN ON THIS DRAWING _ Sortell, [VIN USIA 66377
WC�_ - rrrcrr SN o CEG A60403
u m a vVrvv BZUiIk.c 0171 Cl sn `' Iz 1e,l�
HORIZONTAL
1
1
2'32
59,
VERTICAL
DETAIL "A"
LOCKING DEVICE
(PROVIDED BY CUSTOMER
SEE NOTE 5)
�u
A
ACTUATOR MOUNTING POSITIONS f��\\
f \'� LJ D eZ U R I I ` BOS-CL BUTTERFLY VALVES SIZE 2 - 6 LUGGED
\ \ \/ L710 POSITION LEVER ACTUATOR
STANDARD POSITION 180' POSITION
SHOWN ON THIS DRAWING _ Sortell, [VIN USIA 66377
WC�_ - rrrcrr SN o CEG A60403
u m a vVrvv BZUiIk.c 0171 Cl sn `' Iz 1e,l�
ATTACHMENT A
�l` f,
b o i l e r- s
INSTRUCTION MANUAL
FOR
INDOOR & OUTDOOR RITE
POWER BURNER FIRED*
BOILERS
70 Horsepower 125 Psi Hot Water Boiler
Rite Engineering & Mfg Corp.
5832 Garfield Ave.
Commerce, CA 90040
Tel: (562) 862-2135
Fax: (562) 861-9821
www.riteboiler.com
Read instructions carefully before proceeding with installation and operation.
Post and maintain instructions in legible condition.
"Excludes Durafin Boilers. Please check website for updates and addendas to the manual. 111) 2012
TABLE OF CONTENTS
SAFETY WARNING NOTICES:
Your physical safety and the safety of others is very important. Throughout this
manual we have provided safety warning notices to alert you to potential safety hazards. A
safety notice will be preceded by:
DAN G� IT MEANS: You CAN be KILLED or SERIOUSLY HURT if
you don't follow instructions.
EQUIPMENT WARRANTY NOTICES:
When properly installed, operated and maintained, Rite Boilers can easily offer forty
or more years of service. Throughout this manual we have provided equipment warranty
notices to alert you to potential practices that could lead to premature repairs. An equipment
warranty notice will be preceded by:
CAUTIONI IT MEANS: Failure to follow these instructions will void
warranty and may lead to premature repairs.
Page Number
1.
SAFETY WARNING NOTICES .....................
See Below
2.
EQUIPMENT WARRANTY NOTICES .................
See Below
3.
RECEIVING...............................1
4.
STORAGE................................1
5.
PLACEMENT ..............................2
6.
INSTALLATION .............................
2-8
7.
WATER TREATMENT AND DERATIONS ...............
9-10
8.
START-UP ................................
10-15
9.
SEQUENCE OF OPERATION .....................
16
10.
OPERATION, MAINTENANCE AND SERVICE ............
16-21
11.
WEATHERPROOF - OUTDOOR BOILERS ..............
22
12.
TROUBLESHOOTING .........................
23-39
13.
REMOVAL FROM SERVICE (LAYUP) .................
40
14.
GLOSSARY ...............................
41-42
15.
HOT WATER SYSTEM PIPING ....................
43-46
16.
STEAM SYSTEM PIPING .......................
47-51
17.
WARRANTY ...............................
Back Cover
SAFETY WARNING NOTICES:
Your physical safety and the safety of others is very important. Throughout this
manual we have provided safety warning notices to alert you to potential safety hazards. A
safety notice will be preceded by:
DAN G� IT MEANS: You CAN be KILLED or SERIOUSLY HURT if
you don't follow instructions.
EQUIPMENT WARRANTY NOTICES:
When properly installed, operated and maintained, Rite Boilers can easily offer forty
or more years of service. Throughout this manual we have provided equipment warranty
notices to alert you to potential practices that could lead to premature repairs. An equipment
warranty notice will be preceded by:
CAUTIONI IT MEANS: Failure to follow these instructions will void
warranty and may lead to premature repairs.
RECEIVING
1. Before signing Bill of Lading, check for any signs of
external damage. Be sure you have received all the
pieces noted on the bill. Barometric Dampers are
shipped loose.
2. DANGER Offload the boiler as shown in Figure 1.
Follow safe rigging procedures and use load rated
equipment.
IIIIIi1G
BURNER
Figure 1
POINTS
SPREADER BAR
TING LUG
SKID
ICAUTION1 Forklift underneath base only if forks are
long enough to extend rail -to -rail (Dimension B in
catalogs).
3. ICAUTION Place the boiler gently onto a firm, level
surface. Hard drops, or rigging the boiler on its side
unless pre -approved, can cause damage.
CTnl4ArZF:
1. If the boiler is temporarily stored outdoors it must be
completely protected from the elements by a tarp or
other means.
2. Keep the Barometric Damper and any other equipment
shipped loose with the boiler, otherwise they have a way
of becoming lost.
3. Leave plastic cap plugs in place and keep debris from
entering boiler stack(s) and plumbing connections.
PLACEMENT
1. Boiler may be placed directly onto pad as shown in
Figure I or moved on rollers as shown below in Fi,urc
2:
Figure 2
=EL BASE
2. The boiler must be installed on a level. concrete house-
keeping pad or other approved non-combustible surface
that has been engineered to support the operating weight
of the boiler.
3. If the boiler was shipped on a wooden skid, remove the
skid prior to final placement on the pad.
4. When anchoring the boiler to the pad observe th
following:
4.1 See job specification for any special
seismic anchorage requirements.
4.2 If in doubt, contact your local
Building & Safety Dept. or a qualified
mechanical engineer for assistance.
4.3 Refer to appropriate Rite brochure
for boiler weights, water content
and dimensions.
4.4 Boilers not shipped on wooden skids
will require anchor plates (by others)
5. When installing on a concrete pad be sine the pad is big
enough in length and width. The minimum requirement
is that the pad must extend beyond the anchor plate holes
by at least six (6) times the anchor bolt diameter. (See
Figure 3 on the next page).
PG 1 RECEIVING / STORAGE / PLACEMENT
Boilers Shipped Boiler Foot
On Wooden Skids Detail & Section
,A„
Dimension
(See Catalog)
Top
0
View
Boiler Foot
(see detail)
Boilers Shipped
On "C" Channel Concrete Pad
Or I -Beam Detail & Section
Concrete—
Pad
(see detail)
O %6" Hole
Boiler
Stack
INSTALLATION
General
1. In most cases the installation will be carried out by a
licensed contractor who must pull the required permits
before starting the job. Before the boiler is started up, all
the work permits should be signed off.
2. The installing contractor must carry out the work
according to state and local codes which may exceed
nationally recognized codes such as the Uniform
Mechanical Code, Uniform Plumbing Code, National
Fire Protection Agency, ASME CSD -1, National Electric
Code, etc. Additional insurance requirements or job
specifications may also be required. For example, it is
mandatory that Section 1 Boilers are piped up in part by
an ASME stamp holder in accordance with B31.1 of the
ASME Power Piping Code.
3. Always lay out and install the largest components first.
Start with the stack system and combustion air ducts,
followed by the water or steam mains next and do the
smallest diameter runs like water make-up and drain
lines last. Plan carefully. The best installations are those
where the largest components are run as straight and
direct as possible.
Combustion / Ventilation Air
I . Provide at least L'_ square feet of free air opening from
outside for every 1 million btuh of maximum rated input
for combustion. Check local codes for exceptions.
Figure 3
INSI AI.I.ATION / COMBUSTIONNENTILATION AIR PG 2
y 6xd �—
6xd
Top o
4iichorPlatcs t'xd
/
And Field Weld
By Others
2. Provide the same size opening at a high point in the
room for ventilation.
3. If additional ventilation is required it is better to force air
into the room. Avoid exhaust fans whenever possible.
4. Louvers can significantly reduce free air openings. If the
free area is not known, it shall be assumed that:
4.1 Fixed wood louvers will have 20-25`%, free
air opening.
4.2 Fixed Metal louvers will have 60-70`%, free
air opening.
4.3 Metal mesh screen (minimum 1/4") will
have 98% free air opening.
4.4 Blade type motorized Combustion Air
Dampers (CAD) will have 95°/, free air
opening.
5. Doors and windows that can be closed are not considered
to be a source for combustion or ventilation air.
6. When combustion air dampers are used, make sure an
electrical interlock (end switch) proves the dampers are
fully open before the boiler is allowed to tire.
7. DANGER Exercise caution anytime a fan is used to
exhaust air from a boiler room. Negatively
pressurized boiler rooms can cause poor combustion and
products of combustion to spill out of the barometric
damper into the boiler room. Be sure the air pressure in
the boiler room is the same as it is outdoors under all
operating conditions.
8. CAUTION Determine if the boiler room is next to
another equipment room and the two share a common
door. If the other equipment room contains air handling
equipment, boiler room's air pressure can go negative if
the connecting door is left open. In such cases, a door
interlock switch must be used to prevent the boiler from
firing unless the connecting door is closed.
Draft Control
Rite Power Burner Fired Boilers require a slightly nega-
tive firebox pressure (-.01" w.c.) at all firing rates. The
burner blower motor is therefore required for combustion
purposes only and not to force the products of combustion
through the boiler and out the stack. Natural draft makes
use of the leftover heat going up the stack to create all the
draw necessary for proper operation. The barometric
damper balances the draft at the vent connector as the
stack heats and cools and firing rates change. A slightly
greater negative pressure at the vent connector minus the
pressure drop through the tube bundle yields the -.01" to
-.03" w.c. negative firebox pressure.
2. ICAUTIONIThe Barometric Damper must be properly
installed and adjusted at the jobsite. It should be located as
close to the vent connector as practical with the proper
offset (See Figure 4).
3. Barometric Dampers must have the right number of
washer weights to produce a draft at the vent connector of
between —.03" to —.09" w.c. when firing. Increasing the
number of weights makes it harder for the damper gate to
open. This results in less dilution air entering the stack,
thus increasing the boiler's draft. Too much draft is better
than no draft (which can cause sooting and overheating)
but keep in mind that too much draft reduces heat
transfer efficiency and can pull the flame off the burner
head or diffuser to a point where the air/fuel mixture
becomes so poor that the flame pulsates and becomes
unstable.
4. Factory mounted draft gauges are standard on all boilers.
They should be used for adjusting the barometric during
start-up and then periodically checked during routine
maintenance to make sure the draft stays within range.
The fluid will slowly evaporate and must be replenished
from time to time. Use only Dwyer .826 Specific
Gravity Red gage oil and add with an eyedropper to
prevent overfilling.
Stack Requirements
Natural gas or propane fired boilers are U L. listed for
use with Type B gas vent provided a barometric damper
is installed as shown in Figure 4. Check local codes for
exceptions. Type B is double wall stack, widely available
from a number of different manufactures. It is relatively
inexpensive, easy to install and available in
3" through 30" diameters. Type B vent is suitable for
Category I appliances only - combustion equipment
defined as having net stack temperatures less than
400° F., operating with negative draft to the stack
termination and producing non -condensing flue gasses.
Oil fired boilers. combination gas/oil fired boilers and
digester gas boilers cannot use Type B vent. They must
use a stack that has Type 316 Stainless Steel inner liner
or better to prevent sulfuric acid corrosion. The
barometric damper installation requirement is the same,
however the red stop hardware on the barometrics for oil
tiring should not be removed.
2. Refer to gas vent manufacturers catalogs for detailed
installation instructions. Most vent manufacturers offer
free engineering support for specific job requirements
as one of their selling tools. This can take the guesswork
out of unconventional stack designs.
3. It is good practice to incorporate a vent support plate for
independent stack support and an adjustable length
(telescoping) section for future boiler/stack separation.
This will facilitate fireside tube cleaning should it ever be
required. Terminate Type B vent stack with a B vent rain
cap except in those locations where frequent high winds
may necessitate a Breidert type cap available from Rite.
4. CAUTION A horizontal stack run must not exceed
75% of the vertical stack height (NFPA 54 7.6.1d)
without the addition of an engineered mechanical draft
system (induced draft fan).
PG 3 1NSTALI ANON
Stack Requirements continued
CAUTION Boiler installations \pith unavoidable
nc,ati\c air conditions - such as factories with exhaust
fans - will generally require engineered mechanical draft
systems.
6. CAUTION_ Never reduce the boiler vent connector 8
diameter without written factory approval. Stack size
can often be safely reduced at substantial cost savings but
only after a review and written approval by either the
vent manufactUrer or Rite.
7. FC--AU--TI-O--N-1 If the stack diameter is reduced from the
vent connector diameter, the draft gauge "Good" range
(green) becomes meaningless because the smaller
diameter stack requires a higher CFM and therefore a
higher negative static pressure at the vent connector. In
order to find the correct draft, remove the 1/8" pipe plus
at the rear firebox view port and measure the firebox
Opt—al [
Spill Svnr
B"mei
Figure 4
draft at high tire. It should be between -.01" to -.03 w.c.
Adjust the washer weights on the barometric damper
until this is achieved and then mark the draft gauge at the
vent connector with the new correct setting.
Firebox pressure must always remain slightly negative
when the boiler is firing. After setting up the burner and
draft, always verify firebox pressure with a simple smoke
test: Open the front viewport after the boiler has been at
high fire for at least ten minutes and provide a smoke
source (or something similar) and inch or so from the
opening. If the smoke is gently pulled in, the draft is
good. If the smoke is rapidly pulled in, the draft is too
high. [CA--U--T-1-0-N-1 If the smoke is unaffected then the
firebox is at neutral pressure and needs a little more draft.
Smoke blowing away from the opening means the
firebox is under positive pressure and corrective action
must be taken immediately.
`r Bullhead
Vent Tee
Reduced Diameter
Stack Section
(If Required) 7�
Flue Gas
1
of Boder Casng
LMIiW,
Control Table for Barometric Dampers
D—per Sve (A) 18
12 14
16 18
28
24 28
72
(:OW Length (B) 4-3/8"
53/4" 1-118"
8-3/8" 8-1/4"
9-5/8"
12.3/8" 13-1/8"
15-314"
NOTE: BE SURE TO USE CORRECT COLLAR LENGTH. TOO SHORT OR TOO LONG MEANS A LESS
EFFECTIVE CONTROL.
Barometric Damper Location For Indoor Boilers
(Barometric dampers cannot be installed on outdoor boilers)
INSTALL/V110N PG 4
Clearances
1. U.L. 795 requires the following minimum clearances to
combustible construction from the boiler:
CLEARANCE TO COMBUSTIBLE
MATERIALS
MODELS
FROM
ABOVE
FROM
FRONT
SIDES
R REAR
VENT
CONNECTOR
48W - 1250W (Water)
200
18
210
21
48S -1250S (15# Steam)
18"
48"
18"
18"
P9.5 - P250 (150# Steam)
PW9.5-PW250 (Water)
48"
96'
36"
36"
2. For tube cleaning or replacement, leave an area in front
of the boiler that is approximately the length of the boiler
jacket and 24" or more at the rear. Codes typically
require a minimum 24" clearance from the non -controls
side of the boiler and 36" or more around the controls
side. The National Board I-2330 clearances for Section I
boilers(Rite "P" & "PW" Series) require minimum 36"
clearance to any obstruction around the sides and back.
Pennsylvania requires 30" clearance around all boilers.
Always check state and local code clearances before
laying out the boiler room.
3. Avoid blocking headplates with pipes or other obst-uc-
tions. For boilers ordered with optional hinged
headplates, leave room for the headplates to swing
completely open 180°. See headplate swing dimension
"T" in boiler catalog.
Piping - Water Boilers
1. See recommended piping diagrams at the back of this
manual, pages 43 to 46.
2. CAUTION All Rite Boiler waterside surfaces are
thoroughly cleaned prior to shipping so a boil -out
procedure is not required. Taking a few extra minutes to
remove thread cutting oil and other contaminants from
the field piping as it is being assembled can reduce or
eliminate the need for chemically flushing the system.
3. Always install the system pump so that the suction side
is nearest the boiler hot water outlet. This lowers the risk
of air entering the system and does not impose the
system head on the boiler. Always pump away - not
toward - the expansion tank system connection.
4. Rite Hot Water Boilers can be fired safely with the
system pump off as long as there is water in the boiler
and the low water cut-offs detect water. There is no
required minimum or maximum flow rate through a Rite
PG 5
boiler and a flow switch is not a safety requirement.
5. CAUTION Alxvays arse dielectric unions or dielectric
flange kits when connecting copper l ipe to the boiler to
avoid galvanic electrolysis.
6. An expansion tank must be installed in every hot water
heating system. The tank can be bladder or compression
type. Do not use open -to -atmosphere type. To order the
correct size tank you must know: Total system volume in
gallons; minimum anticipated system water temperature
at start-up; maximum anticipated system operating
temperature and minimum system operating pressure.
Minimum system operating pressure can be calculated
by dividing the overall height of the system piping above
the boiler (in feet) by 2.31. For exceptions, see next
paragraph.
7. Minimum system water pressure requirements for sea
level to 3000 feet elevation are as follows:
Maximum Boiler Operating
Temp. (°F)
Minimum System Pressure
(PSIG)
180
12
190
15
200
18
210
21
220
24
230
27
240
30
For elevations 4000' and higher, maintain a mininunn 30
psi system pressure. For Section I High Temperature Hot
Water boilers, refer to the steam tables to find the
corresponding pressure to the maximum operating
temperature and then add an additional 15 psi to that
pressure to find the minimum system pressure.
8. It is a good idea to install a relatively inexpensive water
meter in the water make-up line. On closed loop heating
systems it is the best way to detect system water loss
early on before harmful amounts of entrained solids and
oxygen are introduced into the boiler system via water
make-up.
9, CAUTION Never let chilled water from a cooling sys-
tem circulate through the boiler under any circumstances.
10. CAUTION Reheat systems must not allow the chilled
water loop to inadvertently cool down the heating loop
inside the air handler(s).
11. DANGER Never use compressed air to test water
system piping for leaks. Use water only.
INSTALLATION
Piping - Stearn Boilers
1. Scc recommended piping diagrams at the back of this
manual, pages 47 to 51.
2. Do not reduce the steam boiler outlet nozzle size.
Reducing the diameter of the pipe of the boiler's outlet
nozzle to the steam main may raise steam exit velocities
to the point at which water is "lifted" or carried over from
the boiler into the main.
3. Use black pipe - never galvanized pipe - for steam mains
and blow -down lines. Condensate return lines should be
constructed of Schedule 80 pipe or Type K copper. If
copper is used, be sure the fittings are silver soldered
rather than soft soldered as condensate return tempera-
tures are often at or near the soft solder melting point.
Use dielectric unions or flange kits when connecting
copper to steel.
4. It is a good idea to install a relatively inexpensive water
meter in the make-up line to record the amount of
make-up water you are using and help keep the water
treatment program on track.
5. For Rite steam boilers (low and high pressure) the boiler
feed pump should be sized to deliver the following
GPM per boiler horsepower (BHP) at operating pressure
as shown at the bottom of this page.
• I RHP = 34,000 BTU output.
• .069 x BHP z The actual GPM rate of
evaporation. Recommended feed rate is 2.5 to 3 times
this rate.
6. Section I Boilers with heating surface greater than 500 tt'
(Rite P125 and larger) must have 2 feed water pumps
each capable of supplying the required GPM at a
head pressure 3'%, higher than the safety valve setting per
PG 61.1 of the A.S.M.E. Code.
7. 1 DANGERI Never use compressed air to test steam sys-
tem piping for leaks.
Gas Piping
1. The use of teflon tape is not recommended. Thoroughly
clean all thread cutting oil and other debris such as metal
chips, welding slag and pipe dope from inside the gas
piping during assembly.
BOILER HORSEPOWER INPUT
MBH
9.5 398
STEAM
LB/HR
328
RECOMMENDED
GPM 1 RATE
2
10
419
345
2
12
502
414
2.5
15
628
518
3
20
838
690
4
30
1255
1035
6
40
1674
1380
8
50
2093
1725
10
60
2511
2070
12
70
2931
2415
14
80
3348
2760
17
100
4185
3450
21
125
5230
4313
26
150
6276
5175
31
200
8369
6900
41
225
9425
7762
47
250
10456
8625
52
275
11500
9487
57
300
12500
10350
62
1Ns,rnt.LXF10n PG 6
Gas Piping continued
2. CAUTION A drip leg is recommended at or near the
connection to the gas train. If an optional wye strainer is
used it should have a 40 mesh screen.
3. Be sure the natural gas supply pipe is large enough to
deliver the required CFH at the inlet pressure required. If
in doubt, refer to the Uniform Mechanical Code or NFPA
54 gas line sizing tables.
4. CAUTION When pressure testing a new gas line with
air, be sure the boiler's main and pilot cocks are in the
closed position and disconnect the union or flange con-
nection between the main gas cock and the drip leg. This
will prevent over -pressurization damage to the gas train
valves and controls.
5. If the gas train is supplied with a normally open vent
valve, it is a good idea to install a full size sight -flow
indicator on the discharge side of the valve for visual
confirmation that the valve is closed when the boiler is
firing. Regular checks can prevent the loss of natural gas
out the vent valve should the valve fail to close when
energized.
6. Per current U.L. 795 standards, the boiler's gas train will
require that one or more separate vent lines be piped
outdoors to a safe point of discharge.
6.1 The following two types of valves mast be
Burner & Electrical
I. CAUTION Most burners require support under the
housing to reduce the cantilever effect. Screw a support
pipe into the coupling underneath the burner and into the
floor plate flange. Adjust or shim until burner is sup-
ported. See Figures 4 and 5.
2. The correct voltage must be supplied to the boiler/burner
as per the nameplates and connected to the proper point
of connection per the wiring diagram. If the burner door
is hinged, run the supply power in flexible conduit from
the side of the boiler so the door can be swung open
without disconnecting the power or conduit. If three
phase power is required and no stepdown transformer is
provided, run a separate 120/60/1 control circuit or add a
stepdown transformer sized per the burner manufacturer's
recommendation. CAUTION Do not add additional
loads to a stepdown transformer without burner nnanufac-
turer's approval. Power supply must be clean and all
stepdown transformers must be grounded to neutral.
Voltages over 132 VAC or under 102 VAC are out of
range and can cause safety controls to fail or malfunction.
3. When connecting power to the boiler make sure the
polarity is correct and that there is less than .5 VAC
between the neutral supply wire and the "'round
conductor. Check that fan wheel rotation is correct and
that separate oil pump motor rotation is also correct if'
supplied.
rented individually: 4. CAUTION A good electrical ground to the boiler
1. Gas pressure regulators (except those approved
service connection is essential for two reasons: Poor
for use with vent limiter).
grounding may cause the flame safeguard control to
2. Normally open vent valves.
malfunction and stray voltages may cause electrolysis
within the pressure vessel.
6.2 Diaphragm operated gas valves and diaphragm
operated gas pressure switches that require
5. CAUTION Electrolysis due to poor electrical ground -
venting (look for threaded vent pipe connection
ing and/or stray voltages passing through the boiler to
on valve or switch body) may be manifolded
ground has been known to cause severe pressure vessel
together into a single common line provided it
damage. The problem usually goes unnoticed until a tube
has a cross sectional area not less than the area
leak occurs and the cause turns out to be a small crater
of the largest vent line plus 50% of the area of
on the inside of the tube - often underneath a small and
all additional vent lines.
otherwise insignificant looking mud deposit. While this
problem is relatively rare, it should be checked for by a
6.3 DANGER DO NOT pipe any gas vents into the
skilled electrician before the boiler is put into service in
combustion chamber or stack.
the following manner: Using a digital multimeter with
sharp probes, check for the presence of millivoltage
6.4 FNOTICEI Always terminate vents away
(AC) between any bare metal spot on the pressure vessel
from air intakes or sources of ignition. Be sure
and the building ground. A reading of 2 millivolts or less
that moisture and insects cannot enter the vent
is good and no corrective action is required. If over
pipes. Always utilize a drip leg to keep moisture
2 millivolts, either find the cause and correct it or install
from traveling back down vent tubing and
a separate ground rod dedicated to the boiler. Annual
damaging the diaphragms. See Figure 5,
testing will show if the ground rod needs to be turned in
order to break off deposits that can insulate and inhibit
its grounding effectiveness.
PG 7 INSTALLATION
Building Automation Systems (BAS)
CAUTION Rite Hot Water Boilers must not be oper-
ated with return water temperatures continually less than
135° to 140° F (see pages 44 - 46 for low temperature
supply systems). Outdoor reset controls must be carefully
programmed not to reset boiler supply water tempera-
tLIres so that return water temperatures could fall below
135".
2. CAUTION For HVAC reheat systems, the heating
system pump should be programmed to turn off no more
than 10 minutes atter an unscheduled boiler shutdown
(such as a limit or flame failure) in order to prevent the
heating water from getting chilled in the air handler and
circulated back to the boiler where it will condense.
3. CAUTION Care must be taken when integrating
Building Automation Systems (BAS) and associated
Energy Management Systems (EMS) with the boiler
control circuit. BAS and EMS systems - while well
intentioned - have been known to override boiler control
systems and inadvertently create poor or unsafe operating
conditions. EMS and BAS systems may receive informa-
tion from the boiler control system but signals sent by the
BAS or EMS to the boiler control system should be
limited to establishing load demand and Initiating start/
stop sequence. BAS and EMS systems must be pro-
grammed not to allow• return water temperatitre to the
boiler below 135° to 140"F
4. CAUTION Do not use solid state Triac type relays to
enable/disable boiler. Use only electro -mechanical or ice
cube type relays. The following operating recommen-
dations for Rite Boilers should be part of any EMS
Strategy:
(PREFERRED)
4.1. Leave the boiler and primary loop pump on during the
heating season while turning off all secondary loop
pumps, air handlers, etc when heat is not required. Fuel
consumption during `off hours" will be limited to boiler
and primary loop piping radiant losses which are
generally small. A night temperature setback control may
also be used to reduce system water temperature to 135"
to 140" F. - the minimum recommended return water
temperature.
Roof
Bug Screen
Supp
Common
Vent Line
(If Required)
INSTALLATION PG 8
Flashing
Union(s)
Copper, Block Or
Galvanized Pipe
Gas
Pressure Regulator
Vent Line (If Required)
Vent _1 Drip Legs
Tubing
Figure 5
(ACCEPTABLE)
4.2 Leave the boiler on and turn the primary loop pump
OFF. Due to natural internal circulation, pumped water
flow tlu•ough a Rite Boiler is not required when firing.
Important: When system heat is again required, the cool
system water should be blended slowly back into the
boiler so the boiler's water temperature doesn't fall
below 135' E This can be accomplished manually or
with automatic controls.
5. While initial or infrequent cold start-ups are considered
routine and will not harm the boiler - failure to follow
the above strategies will cause repeated Thermal Stress
Cycling. Although Rite Boilers are designed with floating
heads to minimize the stresses of tube expansion and
contraction, tube loosening (the "slippage" of the rolled
portion of the tube in the tube sheet) may occur if the
boiler is subjected to repeated cold start-ups or
excessive on - off cycling.
6. Boilers owners and specifications engineers should take
the following quote from the ABMA's "Guideline for
the Integration of Boilers and Automated Control
Systems in Heating Applications " into account:
"Automatic programmed de -energizing of boilers
should be very closely examined. It is (also)
questionable as to the real energy savings to be
realized in cooling a boiler or a system on a regular
basis only to reheat it in a short time later".
WATER TREATMENT
System Flush/Boilout Procedure: Boiler tubes are typi-
cally coated on the outside with rust inhibitors. On fire -
tube boilers. these and other contaminants are in contact
with the water and should be removed or priming and
foaming may result. This is generally done by the install-
ing contractor following a boil -out procedure given by
the boiler manufacturer. There are no such coatings
inside a Rite watertube boiler. After the tubes are rolled,
all traces of tube rolling grease are removed along with
any other contaminants. A Rite boiler may therefore be
put directly into service without a time consuming boil -
out procedure.
If the system piping recommendations in paragraph 2 on
page 5 are followed by the installer, the need for a system
flush can also be eliminated.
For more information on what a boilout procedure and
system flush entails, contact the factory.
2. WATER TREATMENT FOR CLOSED HOT
WATER SYSTEMS: Closed hot water systems require
some chemical treatment as no system is completely
tight 100%, of the time. "I'hcse chemicals are introduced
into the system via 2-5 gallon chemical pot feeders. The
chemical treatment can vary depending on the systems
operating temperature and pressure. Consult with a
qualified water treatment specialist for further
information. Regularly monitor that the expansion tank
is working proper and the relief valve is not discharging
water. Keep the system tight and free of leaks. Soft water
make-up is not required. A pH level of no less than 9
Should be maintained. CAUTION A pH level below 7
will cause an acidic attack of the pressure vessel and void
the warranty.
3. ICAUTIONI For metal finishing systems that use heat
exchangers or coils, check the boiler water regularly for
low pH which would indicate a breach between the boiler
water and the acid baths.
4. GLYCOL: Glycols reduce heat transfer efficiency and can
cause corrosion if the water quality is poor. If glycols are
used, consider these tips and guidelines:
4.1 Consult your glycol distributor. Rite is a steel
watertube boiler.
4.2 Use only enough glycol for "burst" protection, not
"freeze" protection.
4.3 Use only with good quality water defined as having
less than 25 ppm of chloride and sulfate; less than
50 ppm of calcium and magnesium and less than
100 ppm (5 grains) of total hardness.
4.4 Higher flow rates will reduce film coefficient of
glycol and thus proportionally improve heat
transfer.
4.5 Higher operating temperatures will also improve
heat transfer efficiency of glycols but not as much
as higher flow rates.
4.6 Never exceed more than 50% glycol in solution.
4.7 Ethylene glycol is better at transferring heat than
propylene glycol. Ethylene glycol is highly toxic if
ingested.
4. NATER TREATMENT FOR STEAM BOILERS:
CAUTION Failure to maintain an effective water
treatment program as outlined below will void
warranties and lead to premature pressure vessel
failure. There are three basic components for effective
scale and corrosion prevention in steam boilers.
4.1 SOFT WATER MAKE-UP: All fresh water make-
up must come through a softener 100% of the time
CAUTION Avoid deionized or reverse osmosis
systems that lower pH levels.
4.2 BLOW -DOWN: It is recommended that a boiler be
blown down a minimum of twice per R hour shift.
The goal is to keep the TDS (Total Dissolved Solids)
level between 2200 and 2600ppm. A uniform 15
second to 30 second blow -down is typical for most
boilers when they are in proper control ranges.
Subsequent boiler water analysis is required to
properly determine exact length and frequency. To
properly blow -down a boiler a washing action is
recommended. This is achieved by slowly opening
the blow -down valve for approximately 5 to 10
seconds, then slowly closing the valve and repeat
again, until the recommended time has been
achieved. This allows the solids to remain
suspended for more uniform removal during the
blow -down procedure. The water column also must
be blown down at least once per shift; this helps to
keep the column clear of debris and allows the
operator to determine if the low water cut-offs and
pump start controls are working. The blow -down
tank should also be drained and flushed at least once
every six months to help remove sludge and
scale build up which can cause back pressure on the
boiler leading to insufficient blow -downs.
4.3 CHEMICAL TREATMENT: Use an automatic
chemical metering pump to inject boiler chemicals
into the boiler feed line. The metering purnp should
PG 9 WATER TREN111ENT
WATER TREATMENT continued
be wired in series with the boiler feed pump and the
point of connection should be a stainless steel tee
down steam of the check valves and just before the
shutoff valve at the feedwater inlet connection (see
Page 48). Feeding chemicals directly into the
feedwater tank is preferred by some water treat
merit specialists. If so, be aware that these chemicals
can be highly corrosive to feedwater tanks at the
point of entry and the dispersal in the tank dilutes
their effectiveness inside the boiler where they
are intended. In addition, pump seals exposed to
high concentrations of chemicals often fail prematurely.
5. CAUTION Annual or more frequent waterside
inspections will confirm the effectiveness of your water
treatment program. A successful program is one that
keeps both scale and corrosion in check.
6. Some low pressure steam boilers are installed in gravity
return heating systems that do not have a return tank or
feed pump (seepages 50 & 51). In most of these systems
there is no water treatment taking place. For these instal-
lations. use soft water make-up and install a water meter
in the make-up line. Check the low water cut-offs once a
month by performing a slow steam evaporation test as
described on page 18. Blow -down these boilers only
when the TDS exceeds 2600 ppm.
7. The plI of a steaming boiler should be between 10.5 to
11.5. P/Alkalinity: 200-400 ppm. M/Alkalinity: 400-
800 ppm. Sulfite: 20-60 ppm. Hardness (soft water):
0 -Trace. Chlorines: 5 to 7 times the supply soft water
level.
Altitude Derations Above 2000'
CAUTION In most cases, power burners can be pro-
vided with larger fan wheels and motors to compensate
for lower air densities at higher elevations. The required
input/output at elevation should be agreed upon by all
parties bdbi-e an order is placed so there is no confusion
as to the actual input/output that the boiler will do.
WATER TREATMENUSI'ART UP/DERATIONS PG 10
START - UP
1. CAUTION / DANGER Only highly qualified trained
and licensed individuals should be asked to do boiler/
burner start-ups.
2. It is the contractor or owner's responsibility to complete
steps 3-11 below before requesting start-up in order to
avoid the cost of more than one site visit.
3. Verify that the installation instructions have been followed
and that all permits have been signed off.
4. Make sure the system pumps are running and most
importantly that there is a waY to drop the loud.
5. CAUTION I Make sure air has been bled from the natural
gas supply line and that the supply pressure is within the
range shown on the boiler shop sheet. A pipe tee with
plug has been provided in the boiler's pilot gas line near
the main gas cock for this purpose. If the supply gas
pressure is over 28" w.c., make sure the boiler has been
supplied with suitable high pressure regulators (main and
pilot). If in doubt, consult factory bcfiore turning on the
gas to the boiler.
6. For oil, make sure there is oil in the tank. Prime the oil
pump and circulate the oil without the burner firing.
Check the suction line to the oil pump and make sure it
doesn't exceed 10 inches mercury of vacuum or more than
3 PSIG positive pressure. Bleed air from lines through
bleed valve on integral pumps. Make sure teflon tape was
not used on any oil line piping and check unions, packing
glands strainer caps etc. for tight seal to prevent oil leaking
out or air being sucked in. Make sure the oil storage tank
foot valve (check) is holding when the pump is off.
7. iCAUTIONI Make sine there is water in the boiler. For
hot water boilers, make sure the system has been filled
and air has been bled from all manual bleed valves.
8. For hot water boilers, verify that an expansion tank has
been installed and that if a valve is installed between the
tank and system it must be open. An elevated, compres-
sion type tank should have water in the lower third of the
gauge glass when filled. The air pressure in bladder/dia-
phragm tanks should be slightly higher than the regulated
make-up water pressure and the tank should be pressur-
ized before the boiler and system is filled with water. If
expansion tank is sized and operating properly, the boiler
pressure gauge should show a negligible increase in pres-
sure while going from a cold start-up to operating tem-
perature. See page 13, paragraph 31 for exception.
START - BJP continued
9. For steam boilers, make sure the feedwater system is
operating properly and that all make up water is coming
through a water softener. Make sure that a blow -down
tank or separator has been installed per code. Coordinate
the chemical treatment start-up to overlap the boiler
start-up.
10. Make sure any intake or exhaust fans or other equipment
that can change air pressure conditions in the boiler room
are operational and make sure the start-up person is
aware of them.
11. Provide the start-up technician the "As Built" wiring
diagram and the burner installation and instruction
packet hclbre site visit. In addition, burner O & M
manuals that contain additional information can be found
on-line at http://www.riteboiler.corn/om-nianuals.htin1.
12. [CAUTION/ DANGER Boiler/Burner start-up
Should be performed only by qualified technicians. If pos-
sible, the boiler operator(s) should witness the start-up.
13. Prior to going to the job site, the start-up technician
Should verify with the installing contractor that steps
3-10 have been completed. If on arrival you find any
aspects of the installation incomplete, wrong or question-
able - do not leave the site before making a complete
survey of everything that needs to be reviewed or cor-
rected. Go over this list with the installing contractor.
Failure to provide a complete list of corrections can lead
to back charges by the contractor.
14. For hot water boilers, set aquastats as labeled in the
following manner:
OPERATOR or LOW FIRE:
Between 155" F. and 230° F.
HIGH FIRE (if used):
5 to 10 degrees less than low fire.
MODULATION (if used):
Set so that the burner reaches minimum firing
rate prior to the operator aquastat turning off
the burner.
HIGH LIMIT:
20 degrees or more above operator or low fire
control.
15. For low pressure steam boilers (15 PSI) set pressure
controls as follows:
OPERATOR or LOW FIRE:
Between 3 and 12 PSI.
HIGH FIRE (if used):
1 - 3 PSI less than low fire .
MODULATION (if used):
Set so that the burner reaches minimum
firing rate prior to the operator pressuretroll
turning off the burner.
NIGHT SETBACK (if used):
Usually 1 -2 PSI.
HIGH LIMIT:
13 - 14 PSI.
16. For High Pressure Steam Boilers (M.A.W.P. 100-150
PSI) set pressure controls using similar ratios to low
pressure steam boilers. The high limit pressure control
Should be set at least 10 PSI less than the boiler's relief
valve setting.
17. Rite power burner fired boilers manufactured after
January 1, 2011 will be supplied with ceramic fiber side
and rear panels instead of cast refractory. The burner
door will still be cast refractory. If no refractory curing
instructions are taped inside the burner panel cover then
no cure time is required during start-up.
CAUTION If curing instructions are provided then the
instructions must be followed or refractory spalling
could result.
18. Refer to the burner manufacturers O & M Manual and "As
Built" specification sheet. Verify that the electrical and
fuel supply requirements are met. Follow the burner
manufacturer's start-up recommendations. If these cannot
be obtained, steps 19-37 in this section provides a general
outline of common power burner start-up procedures
except for some low NOx and surface combustion type
burners. For water boilers, record the boiler pressure
when the system pump is both on and off prior to tiring the
boiler for future reference.
19. Bump the burner motor starter or contactor and check fan
rotation. If backwards, change any 1 leg of 3 phase power
supply. If there is excessive vibration the fan wheel may
need to be balanced or replaced.
20. If the burner is straight gas or combination gas/#2 oil. set
selector switch to gas. Tum the pilot gas cock off. Turn
the downstream leak test cock off. Install a gas pressure
gauge where it can sense the supply gas pressure to the
inlet of the gas train. Open the upstream main gas cock
slowlti•. Manually reset the high and low gas pressure
switches if supplied, making sure the setpoints are
properly set.
PG 11 STARTUP
START - U P continued
21. Twin the burner power switch on. Manually reset the low
water cut-off and flame safeguard controls if required.
The burner should sequence to a prepurge (fan on only)
stage for 10 to 60 seconds depending on the size of the
burner. The burner should then sequence to a pilot trial for
ignition. On many straight oil fired burners, there is no
PTFI and the spark ignition will directly light off the atom-
ized oil. Some straight oil and combination gas/oil burg-
ers will use a natural or L.P. gas pilot to light off the oil.
All gas pilot burners should lock out on flame failure due
to the pilot cock being closed. DANGER It is important
to check that the spark ignition alone does not cause any
flame signal whatsoever. If this occurs, it must be
corrected before proceeding to the next step.
22. Open the pilot gas cock and carefully bleed off any air in
the pilot tubing. When you smell gas immediately tighten
the tubing fitting back up. If the gas is L.P. (propane)
make sure all piping is leak tested and tight. Propane is
heavier than air and will accumulate on the ground if it
leaks. Manually reset the flame safeguard control and
allow the burner to sequence to a pilot trial for ignition.
On burners with inputs 2.5 million BTU's and less, the
Pilot is usually intermittent which means the pilot valve
(but not the spark) remains on all during the main flame
cycle. On burners larger than 2.5 million BTU's, the pilot
is interrupted, meaning both the ignition transformer
spark and the pilot valve turn off approximately 10
seconds after the main flame lights.
23. For burners with intermittent pilots, the main fuel valves
will open only after a pilot with sufficient flame signal
strength is established. The flame scanner will not differ-
entiate between seeing the pilot flame and the main flame.
To bring on the main flame, slowly open the downstream
leak test cock.
24. For burners with interrupted pilots, open the downstream
leak test cock first. If the pilot establishes itself within 10
seconds, the main fuel valves will begin to open. If the
main burner is not successfully lit before the pilot is extin-
guished, the flame scanner will see this and immediately
shut off all the fuel valves and lock the burner control out.
25, CAUTION / DANGER A pilot turndown test must
be performed. This involves reducing the size of the pilot
flame to a point that is at the minimum detectable flame
safeguard level but can still light off the main flame reli-
able. Do not proceed until this is done.
26. Sequence the boiler to main flame. For modulating or
high -low firing burners, hold the burner at low fire and
then adjust the air/fuel ratio to the burner manufacturers
recommended settings. Leave the burner on for 30
START UP PG 12
minutes then turn the burner off for at least twenty-five
minutes. Use this time to check the following: gas leaks
on the gas train; water leaks around the headplates and
boiler piping; control voltage supply in range (not less
than 102 and not more than 132 VAC.); loose electrical
and conduit connections.
27. For hot water boilers, check the low water cut-oft(s) to
verify that they will shut the burner off in the event of low
water. If two low water cut-offs are used, tem1mrurilrr
jumper the primary LWCO after it has turned the burner
off in order to test the auxilary. ICAUTIONI Do not use
"Test" buttons on probe low water cut-offs for this test but
do an actual slow drain test by closing off the water supply
and return valves on the boiler, lifting the relief valve
handle to relieve pressure and break the vacuum and
cracking open the drain valve at the back of the boiler.
The burner should cut off when the water level drops 4-5
inches below the top of the headplate. When finished,
close the drain valve, crack open the return water valve
and raise the relief valve handle until all the air is purged
out. Make sine the relief valve resects tightly then open
the supply and return water valves to their original posi-
tion.
28, 1 CAUTION I For steam boilers, let the feed pump or feed -
water valve fill the boiler to normal operating level and
then perform a slow steam evaporation test as described on
page 18.
29. As the boiler heats up, re -tighten the headplate bolts uni-
formly. Work from the centers to the corners as you go:
center left bolt, center right bolt, center top bolt, center
bottom bolt, etc. Make sure all bolts are moderated- tight
when finished. If hand holes are supplied make sure the
crab mut is snug as well. If insulated headplate covers are
provided, leave them off until the very end of start-up.
CAUTION Tightening headplate bolts beyond what is
required to prevent leaks will reduce gasket service life.
30. After the 25 minute standby (burner off) as described
in step 26, remove the low fire hold if applicable and
allow the burner to sequence to high fire. Check fuel
input rate and make sure it is below• the hoiler name-
plate (not the burner) maximum input rating. Adjust
the burner air damper to meet the burner manufactur-
ers recommendation for excess air (or 02) at high fire.
Make sure the boiler draft stays in the green range at
high fire: If not, adjust the number of washer weights
on the barometric damper or recalibrate auto draft fan
system (if supplied) until it is. If flue gas recircula-
tion is installed, make sure the FGR butterfly damper
is open just enough to achieve the NOx requirement,
but not so open that the flame becomes unstable and
START - UP continued
the burner rumbles. Excess rumbling indicates too
much flue gas is being introduced into the air/fuel mix.
It is important to check this when the firebox is both hot
and cold to find a setting that satisfies both conditions. It
is also important to remember that excess air (O,) will
change with the density of air. At cooler air tempera-
tures, there will be more air (and Oz) per cubic foot than
at warmer temperatures. O,) trim sensors automatically
adjust for this but are generally to costly for boilers
below 300 horsepower. It is therefore advisable that
when tuning a burner on a warm day, adjust the excess
air (O,) on the low side and on a cold day adjust to the
high side of the manufacturers recommended range. For
modulating burners, make air/fuel ratio adjustments
throughout the curve to maintain good combustion read-
ings between previous established minimum and maxi-
mum firing rates.
31. For hot water boilers, check the boiler pressure at the P&T
gauge with the system pwnp on and when the boiler is at
or near the system maximum operating temperature.
Compare the pressure with the pressure noted on Page 11,
step 18. If the expansion tank was correctly sized (and
pressurized if bladder type) and working properly, then the
pressure should have risen only slightly from when the
system was cold. In some cases the tank will be sized to
allow larger pressure differentials. If so, the differential
Should be documented and made known to the start-up
person and in all cases must be well below the boiler relief
valve setting. The pump when operating at full RPM
Should also have little or no effect on the pressure in the
boiler. CAUTION Any deviation from this must be
corrected at once.
32, 1 CAUTION For hot water boilers, check the return water
temperature to the boiler and make sure that the return water
temperature is at least 135" to 140" F. for natural gas and
propane fired boilers. For #2 oil (diesel) and digester gas
fired boilers, the return water temperatures should be sig-
nificantly higher to avoid condensation in both the boiler
and especially the stack. Check with the factory for recorn-
mendations if in doubt. Failure to do so can lead to con-
densing which is not covered by warranty. If indoor - out-
Notes:
door reset is used, make sure that it is programmed to avoid
condensing return water temperatures to the boiler under all
outside air reset conditions.
33. For water boilers in systems with fixed speed system pumps
and P.I.D. temperature controls, auto tune the P.I.D. loop
atter the system is up and operating normally. On systems
with variable speed pumps, do not auto tune P.I.D. controls.
For boilers without P.I.D. controls, adjust aquastat set points
and differentials to minimize excessive burner cycling
while still satisfying the system design temperature
demands.
34. For steam boilers, make sure the feedwater system is
working properly. If a chemical feed pwnp is used, be
sure it is wired in series with the feedwater pump.
CAUTION Chemicals fed directly into condensate return/
feedwater tanks have been known to damage feedwater
pump seals. Chemical Treatment and blow -down proce-
dure should be established and monitored by a water
treatment specialist. Steam boilers operated �%ithout
chemical treatment will not be covered by warranty against
failure from scale or corrosion of the tubes or heat
exchanger.
35. Check steps 6-8 on page 4. Make sure burner linkage
assemblies or servo motor actuators run smoothly and don't
bind throughout the tiring range. Make sure all linkages
and servo motor fasteners are tight. Consider marking final
ball joint locations and other air -fuel -FGR settings with
tamper proof paint.
36. Secure all guards, covers etc. and reinstall insulated head -
plate covers if supplied.
37. Be sure the owner/operator receives a copy of this O & M
manual, the burner manual, cut sheets of all safety and oper-
ating devices furnished with this boiler along with a copy of
your start-up report. See next page for suggested start-up
form.
PG 13 STARTUP
BOILER / BURNER START UP INFORMATION & TEST DATA (page , of 2)
The following inforniation shall be recorded for each boiler/burner start up:
Job Name
.lob Location—
Rite Model & Serial #
Burner Mfg Make/Model & Job or Serial #
Burner MFG. Job or S.O.#
Start Up Date
Start Up Contractors Name
Phone
Name of Technician Performing Start Up
Type of Gas Natural J LP .J Other
Fuel Oil Grade
No
Gas Firing
Gas Pressure at Train Inlet
Flame Signal Readings
Vent Connector Draft Gauge
Burner in Off Position " W.C.
Pilot
Low Fire
Low Fire
High Fire
Gas Pressure at Train Inlet
High Fire
Low Fire
Net Stack Temperature
High Fire
O, & CO,
(at vent connector, less ambient)
Low Fire
Low Fire
Gas Pressure at Firing Head
High Fire
High Fire
Low Fire
High Fire
CO
Combustion Efficiency
Low Fire
Low Fire
Gas PreS5Ure at Pilot Test Tee
High Fire
High Fire 0
Input Rate BTU/HR
NOx Measured (Corrected to 30/, O,_)
Power Supply
Low Fire
Low Fire
Volts—Ph—Hz
High Fire
High Fire
Control Circuit Volts
Blower Motor amps at high fire
Over Fire Draft (Combustion Chamber)
Low Gas Pressure Switch
Low Fire
Setpoint " W.C.
High Fire
High Gas Pressure Switch
Setpoint " l'<'.C.
Oil Firing
I ligh Fire Vacuum Reading at Oil
Pump Inlet " H.G
Gas Pressure at Pilot -Crain Inlet
(if applicable)
Gas Pressure at Pilot Test Tee
(if applicable)
Oil Nozzle Supply Pressure
Low Fire
High Fire
Oil Nozzle Bypass Pressure
Low Fire
High Fire
Power Supply
Volts—Ph—Hz—
Control
olts Ph Hz—
Control Circuit Volts
Blower Motor amps at high fire
Remote Oil Pump Motor Amps at
High Fire
Flame Signal Reading
Pilot (if applicable)
Low Fire
High Fire
GPH Firing Rate
Low Fire
High Fire
O, & COz
Low Fire
High Fire
Bachrach Scale Smoke Number
Low Fire
High Fire
Low oil pressure switch (PSI)
Settings: cut in cut out
Over Fire Draft (Combustion Chamber)
Low Fire
High Fire
Vent Connector Draft Gauge
Low Fire
High Fire
Net Stack Temperature
(at vent connector, less ambient)
Low Fire
I ligh Fire
Combustion Efficiency
Low Fire 0
High Fire 0
NOx Measured (Corrected to 3% O,)
Low Fire
High Fire
High oil pressure switch (PSI)
Settings: cut in cut out
Control Settings
General
Operating control cut out setting Operating control cut in setting Limit control setpoint
STAR"1' UP FORM PG 14
BOILER / BURNER START UP INFORMATION & TEST DATA (page2of2)
Operation Checklist
Checked for Proper Operation of: l
No N/A (N/A Not Applicable) Yes No N/A
Low water cut off ( )
( ) Barometric damper ( ) ( ) ( )
High Limit ( )
( ) Boiler room combustion air and ventilation ( ) ( ) ( )
Operator control ( )
( ) provisions correct
Modulation or high -low control ( )
( ) Oil tank vent system checked ( ) ( ) ( )
Flame safeguard control ignition failure ( )
( ) All oil lines checked for leaks ( ) ( ) ( )
Flame safeguard control main flame failure ( )
( ) All gas lines checked for leaks ( ) ( ) ( )
Burner air flow switch ( )
( ) Gas lines and controls properly vented ( ) ( ) ( )
Induced draft fan controls ( )
( ) ( ) Expansion tank ( ) ( ) ( )
Over fire draft controls ( )
( ) ( ) Relief valve ( ) ( )
Fresh air damper end switch ( )
( ) ( ) BAS, EMS or DDC system integration ( ) ( ) ( )
Feed water system ( )
( ) Other system components (specify) ( ) ( )
Notes:
Starting (cold) water boiler pressure Water boiler pressure at operating temperature
Notified
of the following system deficienc
PG 15 sTARTAT FORM
SEQUENCE OF OPERATION:
The following is intended to provide a general overview
as to how most power burners work. Given the variety of
manufacturers and changing technologies, always refer to the
burner O & M manual specific to the job for more complete
and accurate sequence of operation than the following
generic outline below:
When there is a call for heat, the burner fan motor will
come on and initiate approximately 4 combustion chamber air
changes during what is called prepurge. The purpose of this
is to force any unburned fuel in the combustion chamber out
of the stack prior to pilot ignition if fuel valves are not tightly
closing off when the boiler is in standby.
Except for on-off fired boilers, following prepurge the
burner will modulate to a low fire position prior to light -off.
A pilot trial for ignition will then occur during which a pilot
flame of sufficient strength must be established before main
fuel valves are energized. On some #2 oil fired burners,
direct spark ignition of the main fuel may occur in lieu of a
gas pilot.
If the pilot signal is too weak, the burner control will lock
out on pilot flame failure. Otherwise the main fuel valves
will be energized within 10 seconds of an established pilot.
On boilers 2.5 million BTU's and less, the pilot valve may
remain on (intermittent pilot) during the main fuel on period.
On boilers over 2.5 million BTUH, the pilot valve will be
de -energized (interrupted) after the main flame establishing
period (usually 10 seconds) in order that the scanner or flame
rod "prove" main flame.
Once main flame is established, the burner (except for
on-off fired models) will respond to load demand and modu-
late accordingly. When the low fire or operator setpoint is
reached, the fuel valves will close and following a short post
purge, the blower motor will turn off. This constitutes one
full burner cycle. The boiler/burner is now in standby mode
waitine for the next call for heat.
OPERATION, MAINTENANCE
AND SERVICE
General
Maintaining a boiler log and following the recommenda-
tions in this section will help your boiler operate at peak
efficiency and reduce service calls. It is impossible to
cover all potential problems or questions when it comes
to operation, maintenance and service. Detailed cut
sheets of various components provided with your boiler
and burner O & M Manuals should be referred to when
necessary. Retubing and refractory replacement instruc-
tional videos are available on line at invu'.riteboileys.
com. Unless you are a skilled technician, we highly rec-
ommend you call one when you spot a problem rather
than attempt to repair it yourself. Above all else, use
common sense.
The combustion chamber and insulation should last many
years provided the boiler has:
a) Operated with return water temperatures above 135'F
SEQUENCE OF OPERATION/ PG 16
OPERAI'ION, MAINTENANCE AND SERVICE
b) not been overfircd
C) operated with ample draft (minitmttn -.01" W.C. in
combustion chamber)
d) Not beers sttbjectecl to negative room conditions.
3. Small cracks in the burner door refractory are considered
normal. Check the condition of the ceramic fiber com-
bustion chamber panels once a year. Pack 2600° F. rated
fiber into any voids or areas where the fiber has shrunk
or is no longer tight. If exterior boiler jacket shows signs
of heat discoloration, check firebox pressure at high fire
for positive pressure and check input and draft. Turn the
burner off and after cool down period, access the inside
of the combustion chamber. Check for soot in the tube
bundle and/or gaps in the ceramic fiber panels that cor-
respond to hot spots on the jacket.
Gas train components are maintenance-fi-ee. Two or
three times a year check all ball joint linkages on the
burner for tightness. Check fan wheel for excessive
vibration or blade loading, especially in dirty air environ-
ments. The flame scanner glass should be wiped clean
from time to time. Oil filters will need to be cleaned or
changed if supply pressure to the pump begins to decline.
Most unscheduled shutdowns can be traced by referring to
the burner wiring diagram. On most burners a keyboard
display module can be plugged into the flame safeguard
control to provide a fault history. If the boiler is off due to
an open limit switch, remove the cover from each limit
beginning with the first limit shown on the diagram and
check with a voltmeter until you Find the one that is locked
out (open). After correcting the problem, manually reset the
switch or control. DANGER Electrical work should be
carried out by qualified technicians only.
6. If you notice flue gas temperatures going up over time, it
is usually an indication that the tubes need cleaning. It is
neither difficult nor expensive to waterside clean a Rite
Boiler and doesn't require chemicals. You will need a
couple of headplate gaskets and one or two heavy duty
tube brushes which can be purchased from your Rite
Representative. You will need to remove the front and
rear headplates, or simply swing them open if they are
hinged from the factory to attain complete waterside
access. Most boilers can be cleaned and put back into
operation in half a day. See steps 1-4 on the nest page.
7. The following efficiency loss due to scale in tubes
applies to all boilers:
SCALE, THICKNESS (IN INCHES) EFFICIENCY LOSS
1 '64" 4'Y,
1732" 8%
l; 16" 12%
118" 18%
3! 16" 27%
It pays to have a clean boiler. It pays to have a boiler
that's easily cleaned!
Waterside Tube Cleaning Procedure For Rite Boilers
with Standard Pilley Brush*
STEP 1
Remove (or swing open if
hinged) both headplates.
Install temporary splash/mud
shields as shown.
STEP 2
Use a standard hose with
a gun type nozzle that will
deliver a sharp stream of
water. Begin by rinsing out
all the tubes starting from
the top and working
down.
FRONT �
Figure 7
STEP 3
Brush out the top row of tubes, making two full
passes per tube. Because mud or scale will load up
the brush, dip the brush into a bucket of water after
each pass. Tube brush has 1/4" female pipe thread
connection. Mount onto a 1/4" pipe or 1/2" pipe using
a bell reducer and 1/4" NPT nipple. The pipe handle
should be approximately as long as the boiler. Where
space between the boiler and an obstruction does not
permit the use of a single length of pipe, use shorter
threaded and coupled lengths that you can join
together and take apart.
STEP 4
Thoroughly rinse the top row of tubes out after
brushing. Repeat this process one row at a time, top
to bottom, until all tubes are clean.
To Elevated
Expansion Tank
(Valve Off)
Temporar
Supply
(Valve Off)
Splash Shield
*For more aggressive tube cleaning solutions, see our video
showing our electrically operated tube cleaning machine that is
available for rent.
Optional Bottom Water
Return Location
(Water boilers Only)
Figure 6
Water
_� FRoryr
Figure 8
U
Figure 9
PG 17 OPERATION, MAINTENANCE AND SERVICE
Steam Boilers
Slow Steam Evaporation Test Procedure
pipe cross on top of the rear header drum) senses a low
Auto LWCO water condition. This should cause the burner to shut off.
'�-
probe housing Temporarily jamper the automatic low water cat-nff
common and normally open terminals to bring the
burner back on.
Auto LWCO
probe level
- Manual reset
LWCO probe
8. CAUTION On steam boilers it is necessary to
check the feedwater and low water cut off devices
once a month by performing a slow steam
evaporation test: With the boiler under load and the
water level between the top and middle probes on
the water column, shut off the electrical disconnect(s)
to the boiler fcccl pumP(s). Open the electrical panel
marked "Boiler Feed Pump Controls and Low Water
Cut -Offs" and look for a red L.E.D. light (illumi-
nated) on the top P.C. Board and two red L.E.D.
lights (right hand illuninated, left hand not illumi-
nated) on the lower P.C. Board.
Top P C. Board
Automatic low
water cut-off
Lower PC Board
Pump start and
manual reset low
water cut-off
Pump contactor
d L E D light
L.E.D. lights
8.1 The following should happen as the water
slowly drops in the gauge glass: Approximately 5
seconds after the water drops below the level of the
middle probe, the left hand light on the lower P.C.
Board should illuminate and the bottom relay
(labeled "pump contactor") should Pull in. To verify,
momentarily restore pump disconnect to the "on"
position and make sine the pump starts, then turn the
pump disconnect off again.
High water level probe
fitting (if used)
1/2" Overflow fitting
(to steam trap. if used)
__--Pump off probe
—Pump on probe
Tubular gauge glass
8.2 When the water drops to a level approximately
I" to 1 1/2" above the bottom of the gauge glass, the
top P.C. board's light should go out. This indicates
the primary low water cut-off (probe is located in
OPERA'T'ION, MAINTENANCE AND SERVICE PG 18
8.3 The water level should continue to drop
slowly as the burner continues to fire. Atter the water
level reaches the bottom of the glass and falls below the
bottom probe on the water column, the lower P.C.
Board's right hand light should go out and the burner
should shut off. Note that there are time delays of a few
seconds built into both P.C. Boards so the switching
action occurs shortly after the water crosses a probe in
either direction. I CAUTIONJ Do not allow the boiler to
keep.firhtg if the water disappears from the gaage glass
far longer that 15 seconds. Ttu'n the power switch nff.
8.4 If everything works correctly as described, above,
reprove the temporar1, jamper on the automatic low mater
cert qff and turn boiler feed pump disconnect(s) back on.
When the water level rises above the bottom probe on the
water column, reset the low water cut-off push button
switch. The middle P.C. Board's right hand light should
come on. As the water level approaches the middle
probe, the top P.C. Board's light should automatically
come on. At this point both low water cut-offs have
"remade" and the boiler should attempt a PTFI and light -
off with the feed pump continuing to run. When the water
level reaches the top probe, the middle P.C. Board's left
hand light and the feed PUMP should both turn off. This
completes the slow steam evaporation test for probe style
low water cut-off and pump start controls.
8.5 Failure of any of the relays or controls to operate
as described above requires immediate attention: Turn
burner switch off and let boiler pressure drop to zero.
DANGER Only when you are certain there is no
pressure in the boiler, remove the three column probes
(and the vertical probe in the rear header drum by remov-
ing the entire probe housing from the pipe cross if the test
proved it defective). Clean probes thoroughly using a
shop cloth, wire brush or wire wheel. If there is a build-
up of scale or mud on the probes, contact your water
treatment company to review the water treatment pro-
gram. The solution may be as simple as blowing down
the steam column more often. For process steam boilers,
blow -down the column once every eight hours. For low
pressure steam heating boilers, blow -down the column
once a day. Reinstall probes and corresponding "top",
"middle" and "bottom" probe wires labeled accordingly.
Check ground wires and all other wiring to the P.C.
Boards for loose connections, shorts or other defects.
Repeat the test. If problems persist, contact the factory.
Steam Boilers continued
0
10. On steam boilers, the gauge glass, trycock(s) and water
column must be clean and in good working order at all
times. Steam or water seepage around the gauge glass
packing nuts will cause the glass to erode and weaken.
Extra gauge glass, brass friction washers and packing
gaskets should be kept on hand. Your Rite Representative
can supply these items to ensure proper gauge glass
length and pressure rating. If tubular gauge glass break-
age or erosion becomes an issue, consider replacing with
a Rite reflex type water gage.
11. When replacing gauge glass, it is imperative that the
water gauge valves be in near perfect alignment to
prevent stress on the glass. DANGER Never attempt
to replace the gauge glass on a boiler that is operating
under pressure unless qualified to do so. Always wear
safety glasses when working around gauge glass.
12. The trycock is a back up valve for verifying water level
in the boiler and should be used only when the gauge
glass is temporarily inoperable or if the boiler operator
suspects that the water level in the gauge glass might not
be reading true. Constant leakage out the trycock can
eventually cause it to plug up with scale and become
inoperable.
13. CAUTION The equalizing piping that connects the
steam column to the boiler must be kept free of mud and
Sludge. To access and clean, remove pipe plugs in the
crosses that connect the column to the boiler and rod out
with a stiff wire bottle brush. The bottom equalizing pipe
is generally the most susceptible to mud accumulation.
The steam column itself should be checked at least once
a year. Mud or sludge in the steam column is an indica-
tion that the column is not being blown down often
enough and/or the water softener is not working properly.
14. On steam boilers, sometimes the feed pump is on but the
water level won't rise in the sight glass until the s t e a m
pressure drops. If this happens, chances are the check
valve(s) between the boiler and the pump have failed.
For this reason Rite recommends two spring loaded
check valves piped in series in the boiler feed line
(See page 48).
15. A steam boiler that is shut off and cooling down will
eventually draw a vacuum. Usually this vacuum is broken
by air seeping in through the gauge glass gasket. If not,
the vacuum can be strong enough to pull water out of the
condensate return tank and flood the boiler. A full gauge
glass in the morning is an indication of this. If this causes
more water carry-over than the steam main's trap can
handle on restart, here are a few suggestions: 1. Install a
larger capacity float & thermostatic trap at the end of the
steam main. 2. Leave boiler "on" during off hours with
the steam supply valve closed and operating pressuretroll
in night set -back mode. 3. A vacuum breaker of the
proper rating can be installed by adding a tee in the
boiler's control piping, but be aware that this will intro-
duce the same unwanted oxygen into the boiler as the
seepage through the gauge glass gasket and may require
a modification to the chemical treatment program.
16. Check steam traps regularly. Steam loss through traps
that are stuck open can waste vast amounts of steam
to atmosphere without notice. If the end of the vent pipe
from the condensate return tank to outdoors is blowing a
continuous plume of steam, chances are one or more
traps have failed open.
Water Boilers
For closed hot water heating systems the most important
thing to avoid is losing system water. At least once a
month check the discharge piping from the boiler relief
valve(s) and the drain valve for any sign of leaks as well
as around the boiler head gaskets, pump seal(s), valve
packing(s), piping, etc. A water meter installed in the
fresh water make-up line is a very cheap and simple way
to tell whether or not the heating loop is losing (and
therefore making -up) water.
2. On hot water heating boilers, verify the following when the
system is at or near operating temperature: The boiler pres-
sure gauge should read well below the boiler's relief valve
set pressure. The boiler supply temperature gauge should
not read below 155° F for systems operating with delta T's
of 20° F or less. Return water temperature should be 135"
to 140° F or above to avoid the possibility of condensing.
3. On hot water heating boilers check the low water cut-off
operation once a month. If you have a float type low
water cut-off installed with Test 'N' Check valves, open
the drain valve beneath it while the burner is firing. The
burner should turn off. Close the drain valve and rnanu-
ally reset the low water cut-off if required. The burner
should attempt to relight. If you have a probe type low
water cut-off, hold in the "test" button for about six
seconds while the boiler is firing. The burner should go
off during this time and not attempt to relight until you
push the reset button.
PG 19 OPERATION, MAINTENANCE AND SERVICE
DAILY MAINTENANCE SCHEDULE:
1. Check the water level in the boiler gauge glass. Steam
RESPONSE
Operator Immediate if the water level
is unusually low or not visible.
On
2. Blow -down boiler and steam column per water treatment Steam
Operator Immediate if any of the water
On
program recommendations. Confirm that both low water
level controls fail to respond
during
cut-offs and the pump control function properly.
properly or if the blow -down
low
9.
valves or piping seem
demand.
Operator
restricted or blocked.
On
3. Check condensate return/feedwater tank for: (1) water Steam
Operator Immediate if no water in tank
6. Confirm that boiler is drafting properly by checking for a
level (2) overflow (3) water make-up valve operation from
or float valve rod linkage hangs
Immediate if there is any
high level (make-up off tight) to low level (make-up keeping
up when water level in tank
Water
up with pump demand) (4) feedwater temperature (5)
drops. Otherwise A.S.A.P.
High
constant steam plume coming out of the vent oioe.
Check boiler draft gauge.
Steam
4. Check chemical feed and softener systems.
Steam
Operator
A.S.A.P, if not working.
On
5. Visually check main flame through the firebox view
Steam
Operator
Notify qualified service company
On
port at the rear of the boiler.
Water
9.
if flame is too rich (all yellow), too
Steam
Operator
Immediate or A.S.A.P. if pressure
On
lean or unstable (pulsating)
Immediate or A.S.A.P. if actual
6. Confirm that boiler is drafting properly by checking for a
Steam
Operator
Immediate if there is any
On
slight negative draft entering the front firebox view port
Water
indication of back pressure
High
cover (A small amount of smoke is one way to do this).
Check boiler draft gauge.
Steam
in the firebox.
Fire
7. Check for residual flame in the firebox after the burner
Steam
Operator
Immediate if gas valves
At the end
has cycled off.
Water
11.
fail to close.
of a burner
Operator
A.S.A.P. if baseline stack temp-
On
"on" cvcle
8.
Check for simmering or discharging relief valves.
Steam
Operator
Immediate if boiler pressure is
On
or bellows to force the float ball down (simulating low
off or if the float fails to bounce
Water
water) and then releasing in order to confirm that the float
within 10% of relief valve setting.
9.
Check boiler pressure gauge.
Steam
Operator
Immediate or A.S.A.P. if pressure
On
22. Check one complete sequence of operation Steam Operator
Immediate or A.S.A.P. if actual
Water
(see page 16). Water
is above normal or closer than
there is a
written description.
call for
10-15% of relief valve set pressure
heat.
10.
Check boiler draft gauge.
Steam
Operator
A.S.A.P. if the draft reading
On
Water
is in the red zone.
11.
Check boiler stack thermometer.
Steam
Operator
A.S.A.P. if baseline stack temp-
On
Water
erature goes up by 40' or more.
12.
Check for water leakage: (1) under boiler (2) around
Steam
Operator
Immediate or A.S.A.P.
On
boiler headplate gaskets (3) low water cut-off gaskets
Water
(4) pump seals (5) system piping.
13.
Continue to eliminate entrained air from a new or
Water
Operator
Manually vent air from high
On or
freshly filled system.
points in the system.
Off
14.
Check boiler return water temperature.
Water
Operator
Immediate if return is less
On
than 135° F.
WEEKLY MAINTENANCE SCHEDULE:
15. Check make-up water meter and record the number Steam Operator Make sure your water treat- On or
of gallons in water treatment log or boiler log. ment company receives a Off
copy. Highlight any significant
changes in water usage
and investigate the cause.
16. Ditto Water Operator Immediate if you are making On or
up water. Off
17. Check water level in elevated compression type Water Operator Immediate if gauge glass is On
expansion tank. full of water.
MONTHLY:
TYPE OF BOILER BY WHOMBOILER
SERVICE REOUIRED TYPE RESPONSE
18. Slow steam evaporation test (see pages 18 and 19) Steam -Operator Immediate if level controls (See
•Boiler Tech fail to respond properly. page
18)
19. Probe low water cut-off test and reset check. Water Operator Immediate if control does On
not respond to test and reset Low
buttons Fire
20. Blow -down float low water cut-offs that are equipped Water Operator Immediate if low water cut-offs On
with McDonnell Miller Test 'N' Check valves. do not shut the burner off. Low
Fire
21. Check float low water cut-off that are not equipped with Water Operator
Immediate if the low water cut
On
Test 'N' Check valves by externally manipulating linkages
off does not shut the burner
Low
or bellows to force the float ball down (simulating low
off or if the float fails to bounce
Fire
water) and then releasing in order to confirm that the float
back up quickly (indicating
and linkages respond freely. This can be accomplished
that it is sticking to mud at
on most McDonnell Miller low water cut-offs except for #64.
the bottom of the float chamber).
22. Check one complete sequence of operation Steam Operator
Immediate or A.S.A.P. if actual
Start when
(see page 16). Water
sequence does not follow
there is a
written description.
call for
heat.
OPERATION, MAINTENANCE AND SERVICE PG 20
AFTER THE FIRST THREE MONTHS OF OPERATION:
23. Internal waterside inspection to check for scale, Steam -Operator Immediate or A.S.A.P. Off
corrosion, and electrolysis, the latter sometimes -Boiler Tech depending on condition of
indicated by reddish rust primer looking steel. -Water Treatment tubes and header boxes.
Company
Water" Reoresentative
24. Open the burner door if it is hinged, or the combustion Steam
-Operator Immediate or A.S.A.P. if:
Off
chamber access panel on side of boiler if it's not. Water
-Boiler Tech (1) Rust or water marks
Locked
Inspect bottom row of tubes (fireside) and slide
indicate chronic condensing
Out/
yardstick back and forth diagonally up between the
problems (2) Ceramic fiber or
Tagged
tubes to check for soot. Inspect entire combustion
refractory deterioration indicates
Out
chamber, including floor brick. for gaps, voids or
overheating due to draft or
If soot is found.
deterioration of the ceramic fiber panels or cast
overfiring problems (3) You
contacts for wear and replace
refractory.
discover any soot in the tube
as necessary.
open the valve. Leave open about 5 seconds and then
bundle (4) Any of the bottom
Steam
Operator
tubes are leaking, sagging. or
Off
return tanks. Twice a year is recommended.
have "blisters" or bulges.
Boiler Tech
25. Open drip/dirt legs to all vent lines. Disconnect vent Steam
-Operator
Immediate if water or moisture Off
lines at all diaphragm valves and switches as well as the Water
-Boiler Tech
is discovered. These lines
main gas pressure regulator and NOVV if supplied.
-Boiler Tech
must be completely dry and
38. Lubricate (if necessary) and do amperage test on all Steam
-Operator,
open to ntmosohere.
26. Inspect stack internally for soot near the draft Steam
-Operator
Immediate or A.S.A.P. Off
control and at the stack cap. Water
-Boiler Tech
If soot is found.
ANNUAL:
Immediate if valve fails to open or On
contacts for wear and replace
27. Follow step 23-26 above. See above See above See above Off
Locked Out/
Tagged Out
28. Inspect feedwater, blow -down and equalizing valves and Steam -Operator Clean or replace piping Off
piping for sludge restrictions or obstructions. -Boiler Tech and valves as necessary.
29. Check all wye strainer screens. Steam Operator Clean or replace as necessary. Off
Water
30. Check boiler water pH with sample pulled from boiler
Steam
-Operator
Adjust with chemical
Off
bbefor draining for internal inspection.
Water
-Boiler Tech
treatment as required to bring
38. Lubricate (if necessary) and do amperage test on all Steam
-Operator,
A.S.A.P. If full load amperage Off
-Water Treatment
into proper pH range.
draw is higher than motor name-
en off. Recheck draft when finished. Off
-Electrician
Company
Boiler Tech
Immediate if valve fails to open or On
contacts for wear and replace
Water
Representative
as necessary.
open the valve. Leave open about 5 seconds and then
31. Flush out and clean blow -down tanks and condensate
Steam
Operator
As required.
Off
return tanks. Twice a year is recommended.
reseat tightly, open a few more times
Boiler Tech
32. Open all float type low water cut-offs used on steam
Steam
-Operator
Immediate if float bowls
Off
boilers and McDonnell Miller #64 or 150 s (m) low
Water
-Boiler Tech
or float arm guides have
water cut-off on water boilers.
any mud or scale buildup.
33. Check for electrolysis due to stray electrical currents or
Steam
-Electrician
See pages 7 and 34
On
improper boiler -to -copper pipe connections.
Water
•Operator
34. Check high limit control operation.
Steam
Operator
Immediate if lowering high
On
Water
limit setting to pressure or
low
temperature reading in boiler
fire
does not cause burner to
shutdown and high limit to lockout.
35. Check high limit control, operator control and
Steam
-Operator
Immediate if the controls and
On
pressure/temperature gauge for nominal accuracy.
Water
-Boiler Tech
pressure/temperature gauge
are not within reasonable
accuracy of each other.
36. Replace gauge glass and glass packing gaskets
Steam
-Operator
Off
on steam column.
-Boiler Tech
37. Replace gauge glass and glass packing gaskets Water
Operator
Do only if expansion tank has Off
on elevated compression type expansion tanks.
gas train for proper operation.
become waterlogged during
-Boiler Tech
open when boiler is firing.
the year.
38. Lubricate (if necessary) and do amperage test on all Steam
-Operator,
A.S.A.P. If full load amperage Off
pump and fan motors associated with boiler system. Water
-Boiler Tech
draw is higher than motor name-
en off. Recheck draft when finished. Off
-Electrician
plate rating, check motor starter
Boiler Tech
Immediate if valve fails to open or On
contacts for wear and replace
Water
as necessary.
39. If supplied, check normally open vent valve on boiler
Steam
-Operator
Immediate if NOW stays Firing
gas train for proper operation.
Water
-Boiler Tech
open when boiler is firing.
40. Check that washer weights have remained in place on
Steam
Operator
Replace weights if they have fall- On or
the barometric damper.
Water
en off. Recheck draft when finished. Off
41. Relief valve test: With boiler pressure at 75% of relief
Steam
Boiler Tech
Immediate if valve fails to open or On
valve set pressure- use relief valve lever to manually
Water
if water or steam is not discharged
open the valve. Leave open about 5 seconds and then
under pressure. If valve fails to
close again. Relief valve discharge piping
reseat tightly, open a few more times
must be piped to a safe point of discharge. Ear and
to dislodge any foreign material on the
eye protection is recommended for this test.
valve seat. Replace valve if it does
not reseat.
42. Check draft gauge calibration Steam Operator Temporarily remove the plastic On
tubing to the draft gauage. If red
* The 3 month internal inspection may be waived Water gauge oil does not return to "0", try
for water boilers provided they are opened up
after one year. Subsequent inspections are adjusting it with the zero set knob.
discretionary but should not be more than
5 years apart.
Add oil as needed. See page 3 Para 4
PG 21 OPERATION, NIAINTENANCE AND SERVICE
Outdoor Boilers
1. Weatherproof boilers for outdoor installation come with
sheet metal covers over the burner and gas train. Controls
are covered or installed in Nema 3R or 4 panels and sealt-
ite conduit is used.
2. A storm collar is provided around the vent connector.
Sheet metal seams are caulked to prevent rain fi•om
entering the jacket. The RTV caulking (Dow #732)
Should be inspected once a year and repaired or replaced
as necessary.
3. Barometric damper draft controls are not supplied with
outdoor boilers because they do not work properly in windy
conditions.
4. To maintain proper draft, gas fired boilers should use R to
10 feet of stack straight up from the top of the boiler the
same diameter as the vent connector. For #2 oil fired
boilers, the height should be increased to 13 to 15 feet
and the use of an in-line condensate drain trap is recom-
mended in the first stack section.
5. The stack must be guy wired to the boiler or adjacent
construction and terminated with a rain cap. hn areas with
moderate to strong winds, a breidert type cap - available
from Rite - should be used.
6. If stack height must be increased beyond the heights in
paragraph 4, it might be necessary to add a baffle across
the vent connector to slow the draft down. When tiring,
the overfire (firebox) pressure should be -.01" to -.03"
water column. The measurement can be taken through
the tapping located in the rear viewport pipe on boilers
manufactured after June 2007. Draft measurement can
also be taken at the vent connector. (below the stack
baffle if installed) and the range should be -.03" to -.09"
maximum w.c. when firing.
OUTDOOR BOILERS PG 22
TROUBLESHOOTING
DANGER TROUBLESHOOTING SHOULD BE CARRIED OUT BY
QUALIFIED PERSONNEL ONLY
HONEYWELL RM7800 SERIES SEEAPPROPRIATE FSG BULLETINFOR OTHER FLAVE
SECTION I. FLAME SAFEGUARD CONTROLS S.AFEGt ARD CONTROLSANDMORE COMPLETE
OPERATION'& TROUBLESHOOTI:N"GI.NFOR.IIITIO.\.
1. On FSG, the top light does not come on: 1. Circuit breaker or fuse to the boiler is off.
2. Boiler power switch is off.
2. FSG does not sequence to PTFI (Pilot Trial for
Ignition). The second light down does not come on
Honeywell FSG Run/Test switch
(On hailers over 2500 MBH)
3. The top two lights come on but there is no ignition
spark as seen through the boiler rear viewport.
1. One or more of the limit switches are not
"made" (closed). Correct problem and then
manually reset the switch(es).
2. The operator or low fire control is not calling
for heat.
3. Burner control circuit fuse is blown.
4. Building Automation System is not calling for heat.
5. Burner fan proving switch not made. Check blower
motor rotation, check fan wheel, check fan proving
switch adjustment.
6. "End" or proving switches attached to the
following devices may not be made: combustion
air damper, induced draft fan, supply air fan,
automatic stack damper.
1. Make sure primary side of ignition transformer is
getting 120 VAC during PTFI. If not, check wiring
to the primary side. If wiring is good, the Flame
Safeguard is probably bad.
2. To test the ignition transformer, temporarily
remove the high voltage wire from the output post.
Install a piece of insulated 16 awg wire long
enough to reach grounded bare metal. Strip a 1/4"
off the end of the wire and holding the wire with
insulated pliers, maintain a 1/4" gap between the
end of the wire and the bare metal as shown on the
next page. If a spark jumps when 120 VAC is
applied to the primary side, the ignition transform-
er is good.
Continued
PG 23
TROUBLESHOOTING
3. Honeywell "Pilot" light is on but there is no
ignition spark for the pilot (continued from
previous page):
High voltage ignition
wire connected to
ignition electrode
inside burner housing.
14' Crap
Higf Voltagt Jl
park ,/ ,
4. During PTFI there is ignition spark but no
pilot flame:
TROUBLESHOOTING
3. High voltage ignition wire could be defective. To
test temporarily replace with a piece of 12 or 14
gauge insulated wire, TFFN solid or stranded. The
wire may have to be manually held onto the igni-
tion electrodes point of connection. If spark occurs
when 120 VAC is supplied to the primary side,
replace defective ignition wire.
4. Locate ignition electrode. Check high voltage wire
connection for tightness and continuity. Check
ceramic insulator for defects. Replace insulator if
cracked or broken.
5. Check ignition electrode spark gap distance per
burner manufacturer's recommendations. The elec-
trode will not spark if it is in direct contact with
metal or too far away.
1. Make sure air has been bled from the gas line and
pilot tubing for all new installations.
2. Make sure the manual pilot gas cock (1) is open.
3. Check the gas pressure to the pilot line at the 1/4"
tee test port (2) and make sure it is within the
range specified by the burner manufacturer.
4. During PTFI, check for gas pressure downstrearn
of the pilot valve at a plugged tee port or by
disconnecting the pilot tubing (3).
If there is no gas flow:
a) Check to see if the pilot valve (4) is receiving
120 VAC (if not, the FSG may be bad or the wiring
from the FSG's pilot terminal sub base to the pilot
valve may be faulty).
b) The pilot valve may be defective
c) The pilot regulator (5) vent port may be plugged
which may prevent the regulator from opening.
5. Check the pilot tubing for kinks, breaks or
internal obstruction.
6. Check the pilot burner orifice opening for debris
blockage or reduced diameter due to corrosion. Do
not enlarge the orifice opening beyond original
size.
PG 24
5. During PTFI there is a pilot flame but the
third light down does not come on:
6. There is a pilot flame and the third light down
is on but the fourth light is not on.
The fourth light down comes on but the main
flame does not come on.
1. Put the F.S.G. run -test switch in test position.
2. Using a multimeter (or the FSG's optional key-
board display module) make sure the pilot flame
signal strength is in the proper range.
3. If there is no signal, UV scanner (or flame rod)
may not be sighting the flame. Scanner may be
mis-wired. The amplifier, scanner or flame rod
might be defective.
4. If the flame signal is too low, pilot gas pressure
might be too low, the boiler draft might be too high
or too much combustion air is affecting the pilot
flame.
1. F.S.G. run -test position is in the test position. Move
to run position.
2. F.S.G. chassis might be defective.
3. Install keyboard display module on F.S.G. to help
troubleshoot.
1. Upstream or downstream manual gas train shut-ofT
valves might be off.
2. Check that the electrically operated safety shut-ofY
valves are opening, either visually in the case of'
motorized valves or by listening for the click of the
solenoid or diaphragm gas valves when they open.
Gas pressure taps are also available on the
upstream and downstream side of most gas valve
bodies.
3. The main gas pressure regulator vent or vent line
may be plugged, blocked or corroded shut, causing
the regulator not to open.
4. The bleed vent port or vent line to diaphragm gas
valve might be plugged, blocked or corroded shut
and not allowing the valve to open
PG 25
TROUBLESHOOTING
6. Intermittent flame
reset of FSG:
H
O
N'
E
W
E
L
L
S
U
B
B
A
S
E
Poor electrical ground. Verify that a solid earth
ground wire has been brought to the F.S.G.'s
sub base earth grounding screw.
2. Wrong electrical polarity: Check that the 120 VAC
supply hot leg goes to the burner switch and that
the neutral leg (L2) has less than .5 VAC potential
to earth ground.
3. Transient voltage problems with the main power
supply. To verify, run a temporary ground wire
from the pilot burner to the F.S.G. sub base earth
grounding screw.
4. Power supply less than 102 VAC or greater
than 132 VAC.
5. Ambient temperature at the F.S.G. is over 140
degrees F or less than -40 degrees F.
6. Pilot valve is sticking open after a burner firing
cycle and creating a false flame signal during
standby. Honeywell's "MAIN" and "ALARM"
LED lights will be on.
7. Energy Management System's enable -disable
relay is "Triac" type (i.e., voltage leaks through
before relay contacts fully make). Replace with
"ice cube" or similar definite purpose relay.
8. VFD (variable frequency drive) motors are operat-
ing nearby. Install a power line "noise" filter (such
as Corcom IOVSI or Schaffner FN 660-16-03) at
the supply side of the boiler's power -on switch.
TROUBLESHOOTING PG 26
Intermittent flame failure requiring manual
reset of FSG (continued from previous page)
Honeywell Chassis
and Modules
i6rienri: a �, Purge
Amplifier Timing
Card
)RITE y
404
9. Fluttering draft proving switch. If an induced
draft fan is used, be sure the draft proving switch
is properly installed and calibrated so that the
switch does not "flutter" on and off.
/ 10. Gas pressure "droop". Make sure the gas supply
piping to the boiler is properly sized to prevent the
gas pressure from decreasing below minimum
supply requirements when the boiler and any other
gas burning equipment connected to the same
meter are on line. This can be checked by install-
ing a gas pressure gauge of the proper range at the
gas train's supply gas pressure test port and seeing
if the pressure drops appreciably between static
(burner not firing) and flow conditions.
11. Intermittent F.S.G. control component failure.
The best way to check this is if there is a second
boiler operating nearby with the exact same F.S.G.
control. Swap the controls and see if the problem
stays with the boiler or follows the control. If the
problem follows the control, you may then want
to swap the F.S.G.'s control modules to further
pinpoint the defective component. If you do not
have another F.S.G. to swap, check with a local
authorized distributor to see if they can bench test
the unit.
12. A poor main or pilot flame can lead to deteriora-
tion of flame ionization and thus a weak flame
signal. Typical causes of this are temporary
negative boiler room pressure conditions or
stack downdrafts.
13. Too high a draft can pull the flame away from the
UV scanner or flame rod. Check draft gauge and
draft control to assure that draft is not over —.1"
w.c., especially on boilers with vertical stacks over
40 feet tall or operating with an induced draft fan.
PG 27
TROUBLESHOOTING
6. Intermittent flame failure requiring manual
reset of FSG (continued from previous page)
SECTION II. MAIN FLAME
1. Main flame "pulsates":
Washer
Weights
Barometric Damper
14. F.S.G. control sub base is defective. In some rare
cases, there have been hidden defects in the
F.S.G. sub base. If all else fails, the F.S.G.
sub base should be changed out (see page 26).
15. The following F.S.G. plug-in diagnostic display
module will provide flame signal read-out as
well as other useful burner monitoring and
troubleshooting information: Honeywell:
S7800A1001 or S7800A1142.
16. Some Honeywell flame safeguards have a
"run -test" switch that holds the sequence in the
test position. This can be useful for checking
flame signals and troubleshooting the burner at
various stages of operation.
1. Too much draft. Check draft gauge on side of
boiler.
2. Barometric damper- not installed.
3. Barometric damper is installed too far away from
the boiler. Install damper in stack tee as close to
the boiler as possible (see page 4, figure 4).
4. Barometric damper is installed in a Tee or collar
that doesn't provide enough offset, causing the
bottom of the damper gate to get caught in the
stack's exhaust flow while operating.
5. Barometric damper gate is not opening up enough.
Remove some washer weights.
TROUBLESHOOTING PG 28
SECTION III. GAS VALVE AND BURNER OPERATION
1. Boiler cycles on/off too frequently: 1. On steam boilers, adjust the differential setpoint
higher.
2. Diaphragm gas valve does not open when
energized:
3. Solenoid gas valve does not open when
energized:
2. On water boilers, replace aquastats with fixed
differentials to adjustable type.
3. Check energy management system's remote
start/stop relay.
4. Check sequence of operation (see pages 16) to
make sure the burner has returned to low lire
long before a call for heat has been satisfied.
1. Coil defective. Replace with new coil (part
#116931) for all Honeywell V48A valves.
2. Bleed port is plugged, blocked or corroded shut.
3. Valve defective. Replace.
1. Coil defective. For Honeywell V4295A valves,
replace with new coil (see chart below).
Vahc Size
(inch)
TNpe
Coil Part Number
120 Vac, 50/60 Hz
2 psi
5 psi
3/8, 1/2
N.C.
BBA51302
BBA51302
3/4
N.C.
BBA51302
BBA51314
N.C.
BBA51302
BBA51309
1-1/4
N.C.
BBA51303
BBA51310
1-1/2
N.C.
BBA51301
BBA51310
2
N.C.
BBA51304
BBA51311
2-1/2
N.C.
BBA51305
N/A
3
N.C.
BBA51306
N/A
3/4, 1
N.C.
BBA51307
N/A
1-1/4
N.C.
1313A51308
N/A
\2. Valve defective. Replace.
PG 29
TROUBLESHOOTING
4. Motorized gas valve does not open when
energized:
Valve Body Only
5. Safety shut-off gas valves fail to close
completely when de -energized:
Valve
Body
Stem
Valve Leal( Test (see Figure 10 on next page)
This is a test for checking the closure tighmc„ of a gas
safety shutoff valve. It should be performed by qualified
personnel during the initial startup of a burner system, or
whenever the valve or valve bonnet is replaced. It is
recommended that this test also be included in the scheduled
inspection and maintenance procedures. For a periodic
inspection test, fellow steps 1-12 below and refer to figure 10
on page 31.
1. Shut the burner power switch off.
2. Close the downstream leak test cock "E"
3. Open manual gas shutoff cock "A"
4. Remove the plug from the petcock "F" and connect
the test apparatus.
5. Submerse the 1/4" tubing vertically 1/2" into ajar of
water.
6. Slowly open test petcock "F".
7. When the rate of bubbles coming through the water
stabilizes, count the number of bubbles appearing
during a ten second period. Each bubble appearing
during a ten second period represents a flow rate of
approximately .001 CFH (23.32 cc/hr).
8. If the leakage rate for the SSOV "B" does not exceed
the allowable rate, close the test petcock "F" and rein-
stall plug.
9. Temporary hot-wire SSOV "B" to the open position.
10. Use test petcock "G" to test SSOV "C" in the same
manner.
11. If the leakage rate for SSOV "C" does not exceed the
allowable rate, close the test petcock "G" and reinstall
plug.
12. Rewire all valves and wiring to pre-test conditions and
check the burner gas train operation for at least two
complete firing sequence.
TROUBLESHOOTING PG 30
1. Check actuator for leaking hydraulic oil fluid.
2. Remove actuator and snake sure valve body
stem is not jammed and can be forced down
against closing spring pressure.
3. Replace actuator or valve body as required.
To Meet U.S. requirements, leakage tnatst not exceed the
following values:
V48A
Pipe Size
(in)
Allowable
Leakage
(celllr NatGas)
Number of Bubbles
per 10sec
(Nat Gas)
3/4"
332.5
8
1 "
377.5
9
1-1/4" & 1-1/2"
552.5
13
2" & 2-1/2"
812.5
20
V5055
Pipe Size
(in)
Allowable
Leakage
(cc/hl)
Number of Bubbles
per I11See
(N it/ Gtm)
3/4, 1, 1-1/4, 1-1/2
573
14
2,2-1/2,3
940
24
4
1 1254
33
V4295 A
Allowable
Number of Bubbles
Pipe Size
Leakage
per 10sec
(111)
(CC/hr)
(Vat Gas)
3/8" & 1/2"
235
6
3/4" & 1"
241
6
1-1/4 & 1-1/2"
444
11
2"
532
1 14
2-1/2"
629
16
3
768
20
NOTE: For international leak test requirements, contact the
office of the appropriate approval agency.
Manifold Pressure Pilot Pilot Gas
Gau_e Port Solenoid PresSnrC
Valve Regulator
To Burner To Pilot
rSecondlary�OV hMain
SSOV
Main Gas
Pressure
Reun lator
C, n
Doxcnstream
Lek Test
� oek
„ E
I c,t
Test
I'ctcuck
* Petcock
a" Flexible
Tubin
%" Aluminum
Or Copper fubin,
NOTE
x Test Tappings 11cry Be
Y2" Min
Located In Body OJ'SSOV
Or Ia The Piping.
Figure 10
.lar Of Water
Cut At 45' Angle
Manual
Pilot
Val%c
Gas Supply
Manual Gas
Shutoff Vale
A,
SECTION IV. DRAFT OR HIGH STACK TEMPERATURE
PG 31 TROUBLI S1100I IN(.
2. Too much draft:
Gate Washer
Weights
1. Excess washer weights on Barometric Damper
keeps the gate from opening and lowering the
draft through the boiler.
2
F
`3
3. High stack temperature. Over 400" F net or
500" F gross - except high pressure steam or
high temperature hot water boilers which
will have higher stack temperatures due
to higher fluid saturation temperatures.
Stack is over 25' tall and with Barometric Damper
wide open, the draft is still too high. Increase the
damper size or add a second Barometric Damper
in the stack.
Induced draft fan (if used) R.P.M. too high.
Reduce fan speed.
1. Excessive draft.
2. Boiler tubes require internal waterside cleaning.
3. Boiler tubes sooted (external).
4. Boiler overfiring.
5. Glycol in system (water boilers only) will result
in higher operating stack temperatures than
systems without glycol (see page 9).
TROUBLESHOOTING PG 32
SECTION V. WATER LEAKS
1. Headplate gasket leak
Typical headplate cap screw markings, ASME SA
grade, and maximuin bolt torque values. Typical
bolt torque for Rite Boilers will be less than the
following values:
1. Make sure the boiler flange and headplate
gasket mating surfaces are clean and not
pitted or wire -drawn.
2. Use new authorized factory gaskets as supplied
without additional sealant.
3/4"-10 N.C. Thread
SA325-1
Maximum 160 foot pounds.
3/4"-10 N.C. Thread
SA354BD-1
Section IV Boilers: Maximum 180 foot-pounds.
Section I Boilers: Maxintuni 200 foot-pounds.
PG 33 TROUBLESIIOOTINC
3. Use new or like new cap screw bolts with
5/8"-11 N.C. Thread
undamaged threads, lubricated with anti -seize
SA 307B
rated for 1800° F.
Maximum 50 foot pounds.
4. Make sure threaded thru-holes in header box
flanges are not galled or damaged. To "chase"
a-
5/8"-I1 N.C. Thread
SA 325-1
threads, use 5/8"-11 or 3/4"-10 hand tap with H5
thread limits. Bolts in flnger
}
ground should go
s. ound
Maxinnun 100 foottig
tight ht until the bolt heads engage the headplates.
5. After finger tightening all the bolts, tighten the
5/8"-11 N.C. Thread
cap screws SNUGLY in an alternating pattern
SA 354BD-1
starting at the centers (top, bottom, left and right)
Maximum 100 foot pounds.
and work toward the corners. Repeat this pattern a
second time. The third time just start at one
center bolt and go around the headplate in one
3/4"-10 N.C. Thread
direction without alternating. All bolts should be
o
SA 307B
uniformly snug when finished.
Maximum 85 foot pounds.
(JP
6. After bringing boiler up to operating pressure/
temperature, snug all bolts one more time.
3/4"-10 N.C. Thread
SA325-1
Maximum 160 foot pounds.
3/4"-10 N.C. Thread
SA354BD-1
Section IV Boilers: Maximum 180 foot-pounds.
Section I Boilers: Maxintuni 200 foot-pounds.
PG 33 TROUBLESIIOOTINC
2. One or more boiler tubes leak at the
tubesheet(s):
3. One or more boiler tubes leak above the burner
bed, usually from the bottom or second row.
(External wastage from long term leakage is
usually visible):
4. Water Boiler: one or more tubes leak from
above the second row:
Sectioned boiler tube showing
underdeposit corrosion.
(Enlarged for clarity).
Boiler may have been dry -fired. Tubes that are
sagging or warped must be replaced. If tubesheets
are warped and cannot be re -straightened, the
entire heat exchanger may have to be replaced.
Identify and correct the cause of the dry -fire
before putting the boiler back into service.
Problem is usually a long term overheated area
of the tube caused by a buildup of mud or lime
deposits. Replacement of leaking tube(s) is
required. Find cause of the water makeup before
putting boiler back into service and make appro-
priate repairs.
2. For steam boilers operating with water make-up,
find out why the water treatment program - espe-
cially the bottom blow -down, water softener and
chemical treatment - has not been more successful
at reducing scale.
3. Consider installing an automatic timed surface
blow -down system to reduce scale.
1. The leak might be due to longterm overheating
from internal scale but the higher- up in the tube
bundle the less likely a tube burnout becomes.
Check the boiler water pH before you drain the
boiler. It should be at or near 8.5. If below 7, the
water is acidic and is eating the steel.
2. Test for electrolysis due to stray voltage and
correct as necessary (see page 7 paragraph 5).
TRO uIII, r?srrooTrNG PG 34
4. Water Boiler: one or more tubes leak from
above the second row (continued from previ-
ous page):
5. Steam Boiler: One or more tubes leak from
above the second row:
6. One or more tubes have "split" or ruptured
during cold weather shutdown:
3. If copper piping was used on unv of the lines to
the boiler, make sure dielectric flange kits (or
unions) are installed and working to keep the
copper (cathode) isolated fro►n the steel (anode).
Note that a copper ground rod used to fix stray
voltage electrolysis will not solve a galvanic
electrolysis (dissimilar metals) problem even
though galvanic electrolysis will also show up
as AC rnillivoltage.
The problem might be due to longterm overheating
from scale (easily confirmed by visual evidence)
but the higher up in the tube bundle the less likely
a tube burnout becomes. Check the boiler water
pH before draining the boiler. It should be
between 10.5 and 11.5. If below 7, the water is
acidic and corroding the steel.
2. Remove the leaking tube(s) and section the tube
near the failure. If the tube that failed came from
below the normal water line, it could be due to
oxygen corrosion or carbonic acid. Oxygen
corrosion will appear as pitting in the steel, while
carbonic acid attack will appear as channeling
or grooving.
3. If the tube failed above the water line, it is usually
the result of oxygen corrosion. Reasons include:
a) Not enough oxygen scavenger in the chemical
treatment. b) Boiler is frequently shut down at
night or over weekend - causing a vacuum as it
cools and sucking in oxygen laden air through the
gauge glass packing gaskets. c) Out -of service
oxygen corrosion due to improper boiler lay-up
(see page 40).
PG 35
Indicates that water in boiler reached freezing
temperature. To help prevent this from occurring
again: a) Install an automatic stack vent damper
in the stack. b) Maintain enough glycol in the
system (hot water boilers only) to stay above
the freeze point. c) Leave the boiler- and the
system pump(s) on.
TROUBLESHOOTING
SECTION VI - Miscellaneous Water Boiler Problems
1. Water boiler "Knocks or Bangs" when firing:
Automatic
.— air vent
Test
cock
Isolation
valve
Automatic Air Vent
Air Scparalor =
To S) stem Pump (s) E
CORRECT HOOK UP °
Typical elevated compression
expansion tank
Tank drain Airetroll
~' Svstem connection from boiler--+gj` fitting
(Pitch piping up to prevent air traps)
1. The cause is almost always air in the system.
When filling the system, or re -filling the boiler
after an internal inspection, always manually vent
air from high points and other natural air trap
locations before turning the system pump on.
3. Make sure automatic air vents are installed at
highpoints in the system and that they meet or
exceed the M.A.W.P. of the boiler.
4. Where compression type expansion tanks are used
and the boiler is turned off regularly during heat-
ing season, the air in the tank can migrate down to
the boiler when the water cools. To fix this, either
leave the boiler on or replace the tank with a larg-
er one (either compression or bladder) that has
more acceptance volume. Sizing a new tank will
require an engineering review.
Never mix compression tanks and bladder/
diaphragm tanks in the same system.
6. System pressure may be to low. If the operating
temperature is above the boiling point, make sure
the boiler pressure safely exceeds the equivalent
steam pressure at that temperature to avoid
flashing to steam.
2. Boiler pressure goes up higher than normal. 1. If the system pressure rises when the boiler is not
firing there might be dirt under the seat of the
-" pressure reducing make-up valve, allowing city
'` water pressure to continue entering the boiler
SECTION VII - Miscellaneous Steam Boiler Problems
1. Flooded gauge glass:
Gauge G
Packing
1. If this occurs only after the boiler has been turned
off and cooled down, it's due to the boiler drawing
a vacuum and pulling water out of the condensate
return/feedwater tank. Adding a vacuum breaker
on to the boiler external piping can solve this
problem, but also creates another problem as
well: by introducing air into the boiler, you are
introducing oxygen into the boiler which will
require more chemical treatment (especially
oxygen scavengers) to compensate. As an alterna-
tive, consider leaving the boiler "on" in a night or
weekend "set back" mode (1-2 psi) with the boiler
\\ Pump "OFF" Probe stop valve closed.
Pump "ON" Probe
2. If flooded glass occurs when the boiler is
Manual Reset Low operating, see if the boiler feed pump is running.
Water Cut -Off Probe
3. If the feed pump system is designed to run
continuously and multiple boilers are fed by
individual electrically operated valves, see if
the valves are energized open. In either case,
if there is a call for water when there shouldn't
gh Water Alarm be, you will have to troubleshoot the feed pump
obe Tapping
circuit until you find the problem. If solenoid feed
Overflow Trap valves are used, there might be foreign material
Connection under the seat preventing a tight shut-off.
4. If two or more boilers are piped in battery, make
sure that the swing check valve (low pressure
steam only) is closing tightly to prevent steam in
the main header from condensing back into the
boilers that are off line. On high pressure steam
boilers piped in battery, the same thing can occur
through the spring loaded check valves or the
stop/check valves from each boiler's steam
supply. On low pressure steam boilers piped in
battery, it might be just as effective to install a
steam trap just above the level in the boiler where
the feed pump normally cuts off in lieu of install-
ing a large swing check valve. See page 48 for
recommended steam boiler battery piping.
PG 37 TROUBLESHOOTING
2. Steam boiler off on low water:
1. Follow steps in slow steam evaporation test
(see page 18).
2. If water level in boiler rapidly drops when feed
water pump comes on, the gpm rate might be too
high, the feedwater temperature too low or a both.
See page 6 for recommended feed rates. Ideal
feedwater temperature is 180° to 190" F.
3. "Slow" feedwater pump. Water level in gauge l . Check valve(s) in feed water line have failed and
glass starts to rise only after pressure in boiler boiler water has reached pump volute where it's
drops: flashing to steam. Replace or repair check valves
(see page 48 for recommended check valve type
and location).
4. Feedwater pump sluggish under most
operating conditions:
Overflow '
Port
2. Check feed pump discharge pressure with a
gauge and make sure it is above boiler operating
pressure. If not, on Burks pumps only, try
adjusting impeller clearance.
3. Feedwater tank temperatures over 200° F may be
causing steam vapor lock in pump volute. Lower
feedwater temperature to 180° - 190° F.
Make -Up water level
® adjustment valve
4 Wye strainer
Triplex Feedwater System
shown
TROUBLESHOOTING PG 38
1. Feed pump wye strainer screen is clogged.
2. Feedwater inlet port at the boiler is partially
blocked by scale or sludge.
3. Feedwater pumps "vortexing" due to low Net
Suction Positive Head (NSPH). Raise
make-up water level in tank before it reaches
the 1" overflow port.
5. Water carryover ("wet steam"):
5. Not enough steam:
Reducing the steam stop valve size and associated
piping from the steam outlet nozzle can raise
steam exit velocities out of the boiler and cause
water lift. The exception to this is on larger high
pressure steam boilers where stop/check valves
are almost always sized smaller than the boiler
outlet nozzle.
2. Instantaneous high steam demand. Correct by
using slower opening valves such as motorized
ball type in lieu of solenoid snap -acting type
valves to feed steam equipment.
3. Boiler water T.D.S. levels above 2600 ppm will
promote water carry-over. Lower T.D.S. level.
4. Make sure the steam main is properly pitched and
trapped at the end. Make sure the risers li-om the
steam main come off at or near the top of the pipe.
1. Boiler not sequencing to high fire
(see page 16).
2. One or more steam traps have failed open, causing
steam to continually blow by the traps. A steady
plume of steam coming out of the condensate
return tank vent line is a telltale sign of this,
normal trap operation will be indicated by wisps
of steam corning out the vent as various traps
open intermittently.
3. Boiler is undersized for the load. Fix this problem
by purchasing another Rite Boiler.
PG 39
TROUBLESHOOTING
Removing Boilers From Service (Lay. -up)
I here are two types of lay-ups: short term and long term.
A short term lay-up could be considered anywhere from a
few weeks up to the 3 to 6 month warm season that
comfort heating boilers are off-line. A long term lay-up
could be considered any time period longer that 6 months.
The two maingoals of short and long term lay-ups is to
prevent corrosion (oxygen or acidic) from attacking the
boilers waterside steel surfaces and to prevent freeze -ups
if the boiler is layed-up wet (full of water).
2. A water boiler wet lay-up is generally recommended for
short term removal from service for two reasons: the boiler
can be brought back on-line relatively quickly and it is also
less labor intensive than a "dry" (no water in the boiler)
lay-up. If the boiler to be layed-up wet in potentially fi-eez-
ing weather, add glycol to the boiler and system
in concentrations recommended on page 9, or consider lay-
ing the boiler up dry instead. To combat corrosion in a wet
lay-up, it is common to add a blend of oxygen scavenging
and corrosion inhibiting chemicals to the boiler and system,
but it is highly recommended that you do so under the
guidance of your water treatment specialist.
3. While wet lay-ups of water boilers are fairly straight
forward because the boiler and system are full of water
and all the air has been vented out of the system, steam
boilers are another matter. Steam boilers normally
operate with a water line approximately 2/3 full. Steam
boilers must not be layed-up in this manner because the
air in the upper portion of the boiler will attack the
exposed steel above the water line. Steam boilers must
therefore be completely flooded up to the steam outlet's
stop valve. The water used to flood the boiler should be
softened and chemically treated. Returned condensate
from the system is ideal for this purpose. The boiler
Should also be kept under slight pressure (3 to 5 p.s.i.) to
REMOVAL. FROM SERVICE (LAYUP) PG 40
prevent air (oxygen) from entering the boiler. Again, it is
Prudent to follow recommendations from your water
treatment specialist when laying up a steam boiler wet.
Their recommendations may include weekly testing of
the water for maintaining pH levels above 8 and sulfite
(oxygen scavenging) residual. Test results should be a
minimum of 20 ppm sodium sulfite (as S03) and 400
ppm phenolphthalein alkalinity (as CaCO3). In some
cases they may recommend nitrogen blankets for your
particular installation.
4. In a dry lay-up, you must be sure that the water is not
only drained from the boiler, but from all external boiler
piping as well. This includes low water cut-off float
bowls and the anti -siphon line to the steam boiler
pressuretrolls. After draining all the water out of the
boiler with the water temperature between 120-135°F,
remove the headplates. Next, the boiler tubes should be
thoroughly brushed clean to remove any mud or sludge
that could promote underdeposit corrosion (see page 17
and the bottom of page 34). Thoroughly dry all waterside
surfaces using a warm air fan, towels, etc. Place quick
lime (not hydrated) or commercial grade silica gel on
elevated non-metallic trays inside each header box. If
you are in an area subject to warm humid air, reinstall the
headplates. Consult your desiccant supplier or water
treatment company regarding the best type and amount
of desiccant to use for your area. Generally, 5 lbs. of
quick time or 8 lbs. of silica gel should be used for every
30 BHP. Open the headplates up every 1-2 weeks to
check results. In some cases, nitrogen blankets are used
in dry lay-ups but always exercise caution when working
nitrogen in confined spaces as pure nitrogen does not
support life.
PG 41
GLOSSARY
ABMA
American Boiler
Manufacturers Association
Air Handler
A system consisting of heating and
cooling coils with large fans
blowing air across the coils for
HGPS
heating and cooling buildings.
Aquastat
A water temperature controller.
ASME
American Society of
High Pressure Steam
Mechanical Engineers
BAS
Building Automation System (same
as EMS)
BIIP
Boiler Horsepower
(I BHP = 33,500 BTUH Output)
BT'UII
British Thermal Unit per hour (input
or output)
CAD
Combustion Air Damper
Category 1
Vent stack not pressurized and
Appliance
non -condensing.
Category 2
Vent stack not pressurized and
Appliance
condensing.
Category 3
Vent stack pressurized and
Appliance
non -condensing.
Category 4
Vent stack pressurized and condensing.
Appliance
CSD -1
Controls and safety devices rules for
boilers per AMSE code.
DDC
Direct Digital Control
Delta T
Temperature difference between inlet
or AT
and outlet of a hot water boiler
Differential
The difference between a boiler
operators cut-out pressure or
temperature and restart pressure
or temperature.
Efficiency AFUE
Annual Fuel Use Efficiency is the
average fuel efficiency of a boiler
over one year.
Efficiency Combustion
100% of fuel burned less °/0 of heat
loss out stack. Also called stack
efficiency as determined by a stack
analyzer.
Efficiency Thermal
100°/o of fuel binned less %, of heat
loss out stack plus 'Yo of heat
radiation loss from boilerjacket.
Also called true efficiency or
fuel -to -water (or steam) efficiency.
EMS
Energy Management System (same
as BAS)
FGR
Flue Gas Recirculation (as in piping
or duct used to return flue gasses to
the burner to lower NOx)
FSG
Flame Safeguard Control. Also
called burner management system.
FM
Factory Mutual Insurance that
recommends and approves various
boiler controls and gas valves.
HGPS
High Gas Pressure Switch
HTHW
High Temperature Hot Water boilers
built to Section I of ASME Code.
High Pressure Steam
A boiler designed for making steam
Boiler
over 15 psi. A Section I Steam
Boiler
Indirect Heating Heating surfaces in a boiler that do
Surface not directly see visible flame. Also
called convective heating surface.
IRI Industrial Risk Insurers (formerly
FIA). Now called GE GAP. Accepts
CSD -1 requirements.
LGPS Low gas pressure switch.
Low Pressure Steam
LWCO
MANVP
MBH or MBTU11
Motorized Gas Valve
MR
NB
NBBI
NOVV
NOx
PFEP
P11
Steam pressure at or less than 15
psi. A Section IV Steam Boiler.
Low Water Cut -Off: probe
(conductance) or mechanical float
type.
Maximum Allowable Working Pressure
(of boiler, stamped on ASME
nameplate).
1000 BTU per hour input or output.
A fluid powered or hydromotor
SSOV consisting of an actuator and
separate valve body.
Manual Reset
National Board: agency responsible
for boilers and other pressure
vessels in service.
National Board of Boiler and
Pressure Vessel Inspectors
Normally Open Vent Valve -
required on IRI gas trains between
2 motorized SSOV.
Oxides of nitrogen in exhaust gasses
usually expressed in ppm. Caused
by fusion of oxygen and nitrogen
molecules dining combustion
process. A component of smog and
acid rain.
Pilot Flame Establishing Period
The measure of the alkalinity or
acidity of a liquid.
PG 41 CLOSSARY
GLOSSARY
PID
Proportion Integral Derivative - A
SSOV
Safety shut-off gas or oil valve that
temperature or pressure control with
is electically operated.
the ability to anticipate load swings
and modulate the burner so it cycles
TDS
Total Dissolved Solids in water
on and off less frequently.
Thermal Shock
Metallurgical stresses inside a
PPNI
Parts Per Million
boiler created by heating
(expansion) and cooling
Pressuretroll
A steam pressure controller.
(contraction). Also known as
thermal stress cycling.
PSI (G)
Pounds Per Square Inch (Gauge
pressure)
Throttling Range
The number of degrees (or pounds
of pressure) below a modulation
PTFI
Pilot Trial For Ignition
control setpoint that the control will
Radiant Heating
Boiler heating surfaces that are
begin to modulate at.
Surface
exposed to visible flame.
UL 726
Underwriters Laboratories code for
Reheat
System using hot water to raise the
oil fired burners.
temperature of dehumidified chilled
UL 795
Underwriters Laboratories code for
air up to human comfort level.
boilers.
Section I Boiler
An ASME Code Boiler stamped for
VAN'
Variable Air Volume boxes for
over 15 psi steam, or over 160 psi
disseminating heat inside a building.
or 250° F water.
VAC
Voltage Alternating Current
L-
Section 1N' Boiler
An ASME Code Boiler stamped for
a maximum 15 psi steam, or up to
VDC
Voltage Direct Current
160 psi and/or 250° F water.
QVC
Inches of Water Column pressure
Short Cycling
Burner fires and then turns off after
28" = 1 psi
a short run time.
WSHP
Water Source Heat Pump
Static Pressure
The pressure inside a boiler caused
by the height of the water in the
piping above it.
Every 2.3 feet = 1 psi.
GLOSSARY PG 42
■
c
c
To System Pump (s) -a ---
Fresh Water Make-up
LEGEND:
G Water meter
[34 Ball Valve
lIJ
Pressure reducing till
Rite Hot Water Boilers
Suggested Piping Diagram For Closed Hydronic Heating System
Featuring Conventional 135° To 235° F Return Water Temperature
r1
Thermometer
u Threaded Pipe Cap Or Plug
Union or Flange
Reduced Principal (R.P.)
Backflow Preventer
Floor
Drain
Figure 11
GENERAL NOTE:
Natural Gas
Supply
Automatic
Air Vent
Gas Rated
Shutoff Valve
To Floor Drain
Drip Leg
This system may be used with a ftctory installed
boiler indoor/outdoor temperature reset control
provided the control is programmed to never return
less than 135° F to the boiler.
RITE HOT WATER BOILERS
SUGGESTED PIPING DIAGRAM FOR CLOSED LOOPED HYDRONIC HEATING SYSTEM
FEATURING 3 -WAY VALVE FOR BOILER PROTECTION
IMPORTANT
THESE ARE CONCEPT DRAWINGS ONLY - NOT ENGINEERED DRAWINGS. SPACE LIMITATIONS PRECLUDE
SHOWING VALVES, CONTROL SYSTEM DETAILS AND OTHER APPURTENANCES. PIPING CONFIGURATION FOR
REFERENCE ONLY AND PUMPING SYSTEM SHALL BE DESIGNED FOR THE PROPER APPLICATION.
AUTOMATIC AIR VENT
FRESH
WATER
MAKE-UP
BALL VALVE
7
STRAINER
III
A
A
I�I
WATER LEVEL
O
CONTROL
i
BOILER RETURN
°
WATER ISOLATION
VALVE
PRESSURE
RELIEF
VALVE
BOILER DRAIN
RSR
AIR SEPARATOR T
TRIPLE DUTY VALVE
(IF REQUIRED)
GENERAL NOTES:
1. THE 3 -WAY VALVE ACTUATOR SHOULD REMAIN IN FULL SYSTEM BYPASS POSITION UNTIL
BOILER LOOP TEMPERATURE REACHES 1907.
2. AFTER THE 3 -WAY VALVE IS RELEASED TO PROVIDE THE SYSTEM HOT WATER, THE 3 -WAY
VALVE SHALL MAINTAIN A MINIMUM HOT WATER RETURN TEMPERATURE TO THE BOILER OF
1357.
3. "CONDENSING" FLOW THROUGH A STANDBY BOILER CAN BE PREVENTED BY CLOSING EITHER
THE SUPPLY OR RETURN VALVE (SEE ISOLATION VALVES SHOWN ON BOILER).
OPTIONAL
DIVERTING
VALVE
TO
SYSTEM
FROM
SYSTEM
LEGEND:
7
STRAINER
III
BUTTERFLY VALVE
I�I
BALL VALVE
O
WATER METER
PRESSURE REDUCING
FILL VALVE
THERMOMETER
PRESSURE GAUGE
REDUCED PRINCIPLE
(R.P.) BACKFLOW
PREVENTER
® FLEXIBLE CONNECTOR
FD VARIABLE FREQUENCY DRIVE
Figure 12
n
n
cn
2 -WAY
VALVE
(TYPICAL)
OPTIONAL
VARIABLE
FREQUENCY
DRIVE
F\ FD,
CLOSELY
L J
SPACED
T
TEES
MINIMUM
135"F RETURN
(TYP.)
BOILER #1
BOILER #2
Rite Hot Water Boilers
Suggested Piping Examples for Closed Looped Hydronic Heating System
Featuring Primary -Secondary Piping with 2 -way and/or 3 -way Control Valves
IMPORTANT
These Are Concept Drawings Only - Not Engineered Drawings. Space Limitations
Preclude Showing Valves, Control System Details and Other Appurtenances. Piping
Configuration for Reference Only and Pumping System Shall Be Designed for The
Proper Application.
\ CIRCULATOR FOR EACH BOILER LOOP
SHOULD BE SIZED FOR FLOW THROUGH
3 -WAY BOILER AND PIPING. (WITHIN DASHED BOX)
MIXING
VALVE
BOILER RETURN
SENSOR
SECONDARYLOOP
3 -WAY MIXING'
VALVE ITYPICAL) I I
7 I I
I I
---------- -----� --
FAN FAN COIL I TC I
COIL END OF MIN 135'F
(TYPICAL) LINE
I R S I
I I
BOILER #1
L-------------------------
TC
MIN 1357
AIR SEPARATOR
BOILER #2
MIN 135°F
CLOSELY
SPACED
TEES
CLOSELY
SPACED
TEES
TCO)
T%/ CLOSELY
\> SPACED
TEES
BOILER #3 _ _r
I I
MIN 135°F
BOILER #4 J
LEGEND L
® PUMP ALTERNATE DIVERTING
VALVE LOCATION METHOD FOR
O BOILER SUPPLY BOILER PROTECTION
® BOILER RETURN (MINIMUM 135'F)
TC 3 -WAY MIXING VALVE TO PROTECT BOILER
FROM CONDENSING
CLOSELY SPACED TEES = MAXIMUM DISTANCE BETWEEN TEE
OUTLETS SHOULD NOT EXCEED 4X PIPE DIAMETER
Figure 13
/ CLOSELY
%\? SPACED
TEES
SECONDARYLOOP
SENSOR
CONTROLLER
OUTDOOR
AIR SENSOR
FOR RESET
(IF USED)
CIRCULATOR
SIZED FOR
ENTIRE SYSTEM
EXCLUDING THE
BOILER LOOPS
AIR SEPARATOR
0
Rite Water Heating Boilers Heat Pump Package
Suggested Piping For 60° To 90° F Water Source Heat Pump SystemsOnly
To Heat Keep Tees Closely From I Icat
Pump Loop Mininnum 4xd Spaced (Max. 4xd) Minimum 8xd Pump Loop
Loop Straight To Minimize Straieht
Pump pipe Common Pipe AP Pipc i
1 ,
� v �
---- C�onunon Pj,_
®--------- j No Valve !--------------
t ,
Note that reduction in pipe ;
diumeterfronr the nozzle 180° to 190° F ' ••V.
outlet to p►nnp" E" is standard
This arrangement is not intended for �� �� Aquastat (by others)
"Q' , I] With 60 90 F
use wheugh thful! iter is
flow � � � � Midscalc Range
through the holler lc required �\
(SPST, Break On Rise)
LEGEND: ::U
d = Internal Pipe Diameter
------ By Others
All other piping shown is factory supply and hydrotestcd
as part of Ritz's "Heat Pump Package Option"
4 or 8xd = Minimum straight run length of pipe
multiplied by the internal diameter of the pipe (in inches). 0
a
0
0
SET-UP INSTRUCTIONS
0 0
1. Provide aquastat in heat pump loop piping where shown ^° ° o ° o
to energize boiler and boiler loop pump "E" when heat is required.
0
2. Set up boiler aquastat to supply 180° to 190° F. d
3. Throttle butterfly valve "A" to approximately 80°/< closed.
4. Make additional fine tune adjustments of butterfly valves "A"
and "B" ("B" will be mostly open) until water temperature at
thermometer "D" holds between 140° and 150° F. Do not reset F
valves even if'heat pump loop tcn,perature is reset. p
5. Mark position of handle on butterfly valve "A". To isolate \ O N a
the boiler for summer cooling mode (or to service the boiler)
simply close valves "A" and "C". To restore to heat mode. return
"A" to marked position and open "C" fully.
Figure 14
Rite Steam Boilers
Suggested Piping for High Pressure Steam Boilers (150 psi)
Featuring Blowdown & Safety Relief Valve Piping
DANGER
To SAFE Termination
LA
Schedule 80 Pipe
& 300# Malleable Iron
Forged Steel Fittings
Figure 15
Full Size Vent
Outdoor To SAFE
Termination
A.S.M.E.
Blowdown Tank
or Separator
TO APPROVED
FLOOR DRAIN
Aftercooler Controls
(For Separators or When
Discharge to Sewer Is
greater Than 135" F)
Flashing
Steam
Sleeve Piping
Roof
Supply
Probe Low Water
Cutoff
/
9" T. 0. E.
I"
Nipple
Sleeve Piping Support
Safety
(NO Weight Allowed
On Safety Valve)
/Valve
Drip Pan
f
Elbow
o
"High Water Overflow
Trap Connection For
0
0
Boilers In Battery
0
0 0
0
\-.,e"
u
(On Steam Column)
0
Na
Gi TO APPROVED
a
0
0
200 WSP Rated
A FLOOR DRAIN
0
Ball Valve
4
0
0
200 WSP Rated
Quick Opening
1" Surface Blowdown Connection
0
Rear Bottom
0 0
0
Blowdown Valve
2" Front Header Drum0
0
Drain & Inspection Opening
o
0
0
0
200 WSP Rated Slow
u
Opening Y-Blowdown Valve
/Blowdown Sampling
Valve
LA
Schedule 80 Pipe
& 300# Malleable Iron
Forged Steel Fittings
Figure 15
Full Size Vent
Outdoor To SAFE
Termination
A.S.M.E.
Blowdown Tank
or Separator
TO APPROVED
FLOOR DRAIN
Aftercooler Controls
(For Separators or When
Discharge to Sewer Is
greater Than 135" F)
G)
A
00
Rite Steam Boilers
Suggested Piping For Low & High Pressure Steam Boilers
Featuring Steam Supply, Condensate Return Tank & Feedwater Piping
Install A I estcd At 200 VVSP Sluing Loaded
Low Pressure hon 110d\ Check Vahe._Or
Swing Chcck \ :ih c I [ere Or Install UT Trap OIT Install FST Trap Off Steam —�
__-1 Steam Column High \Vater Column I IiLdl Water ovetilo"
Overflow Connection Connection Class 25(1 :Angle -
c Y -Pattern Slop
Check valve �
Class 125 Cla," 125 Class 2;(1 OS&Y '0o \\ SI'
OS&)' OSSI' (or Rated Ball Valve Ball Or
Cate V'ulvc 200 \V'SP
�4valve Aaloe „� Or Smaller) Ball A'ulcc
5 PSI Low Pressure 15 PSI Low Pressure 150 PSI High Pressure 150 PSI High Pressure ISO PSI IInd
Steam Boiler Steam Boilers Steam Boiler Steam Boilers In Battery For 2" Stearn Boilers In Battery
Single Installation In Battery Installation Single Installation II
And Smaller Steam Supply Valves For 2 1" And Larger
Steam Supple ValceS
Option #1 Option #2 Option #3 Option #4 Option #5
Bottom Blowdowr
Metering P
Wired In S
With Feed
LEGEND: Mi
O
Water meter
74
Ball valve
QPressure
gauge
u
Threaded pipe cap, plug
or blind flange
illi
Union or flange
See ^`I ��P h Steam Mait�L�own " per 10 n n — —
Ontinnc tt In Direction Of Steatn Flow.
WE&w hm�l
Condensate Rettu-n --J'
Vent To Outside
Air Gap I lore
Or
R.P. Backflow
Preventer Here
oft Water —
lake -up
( lass'50 OS&Y Valve
200 \1'SP Ball
OrOate Vale
Flow/Lift Requirements
Limits Of Usc Of'I'his
Valve To 11150 dirt P250
Ilcat User
Equipment
F&T Steam Trap
g Loaded Checks
enc Seats <15 psig) C'ondcn,atc
in Seats X15 psig) Relnrn Tank
(Surge Tank)
Condensate
Rettll'll
Sampling Port
Boiler Feed
Pump
r.
1
z
n
Rite Steam Boilers
Suggested Piping For Low Pressure Steam Boilers (15 psi )
Featuring Blowdown & High Water Overflow Valve Piping
DANCER
To jaL Termination Flashim_
Sleeve Piping
Sleeve Piping Support
(No Weight Allowed
On Safety Valves)
LEGEND:
I)< 150 WSP Rated Ball Valve
u Threaded Pipe Cap Or Plug
----- Boiler Normal Water Line
Schedule 80 Pipe
& 300# Malleable Or
Forged Steel Fittings
1111 Union or Flange
A.
Safety Relief Valve
Drip Pan Glbw
+" Surface
Blowdown
Connection
Front He
Ph.
Roof
fill � n is xl;_.i_
Figure 17
Overflow Trap
Boilers In Battery
Lu -nn)
Bottom Blowdown
� Blowdown Tank
Blowdown Sampling Port
T
0
cn
0
Reduced principle (R.f
backflow preventer
Soft Water Make-up
LEGEND:
Rite Steam Boilers
Suggested Piping of 15 PSI Low Pressure Steam Boilers
For One Pipe Systems, Wet Gravity Return, Hartford Loop, Operating at 2 PSI or less
Heat Heat Heat
User(s) User(s) Usens�
To Floor Drain To Floor Drain
— "A" Dimension should be minimum 28"
Combination water feeder/low water cut-off
0 — Water meter
— 150 WSP rated ball valve
— 125 WSP rated OS&Y stop valve
LJ — Threaded pipe cap or plug
Union or flange
F, 3 — Boiler pressure gauge
Figure 18
T1
T
Reduced principle (R.I
backflow preventer
Soft Water Make-up
LEGEND:
u -
Rite Steam Boilers
Suggested Piping of 15 PSI Low Pressure Steam Boilers
For Two Pipe Systems, Wet Gravity Return, Hartford Loop, Operating at 2 PSI or less
HeatHeat Heat
Userls) Userts) User(s) From Thermostatic
Trine of W—f 11ec
To Floor Drain
Combination water feeder/low water cut-off
Water meter
150 WSP rated ball valve
125 WSP rated OS&Y stop valve
Threaded pipe cap or plug
Union or flange
Boiler pressure gauge
To Floor Drain
Figure 19
NOTE:
"B" Dimension should be 30" for every 1 PSI of Boiler
Operating Pressure.
NOTES
PG 52
25 Year
Pro -rated Thermaf
Warranty
Rite engineering & Manufacturing Corp. warrants its Boilers against pressure
vessel cracks and broken welds caused by thermal stress cycling ("thermal shock")
for a period of 25 years from the date of manufacture. The Warranty - non pro -rated
- is limited to the replacement or repair of the pressure vessel when such damage
is determined by Rite Engineering or an authorized Rite Representative to have
occurred during normal operation. The Warranty shall not cover damage due to
freezing, dry firing, or excessive scale build-up. The Warranty is limited to damage
to the boiler itself and expressly excludes all other consequential damage.
25 Year
Pro -rated
Erosion
Warranty
Rite Engineering & Manufacturing Corp. warrants its Boilers against waterside
tube erosion for a period of 25 years from the date of manufacture. Waterside tube
erosion - defined as the result of scrubbing action caused by high velocity water
flow through a limited number of boiler tubes such as copper finned - will not occur
to Rite Boilers because of our greater number of tubes and low pressure drop heat
exchanger construction. The Warranty shall not cover damage due to oxygen,
electrolysis or acidic corrosion. The Warranty is limited to damage to the boiler itself
and expressly excludes all other consequential damage.
Addition.( Warranty Coverage
Rite Engineering & Manufacturing Corp. warrants its Boilers against defective
parts and poor workmanship for a period of 18 months from date of shipment or
12 months from date of start-up - whichever occurs first. Controls, valves and
instruments made by other manufacturers and installed on Rite Boilers are generally
covered by the same warranty period. Misuse, neglect or exposure shall not be
considered grounds for warranty claims. In no case shall Rite Engineering be held
liable for any consequential damage including product loss, freight or replacement
labor.
"Operating instructions specific to limiting thermal stress cyc
►��emay be found on page 8 of this instructional manual ~,
v