BL Series Outdoor Mechanical Rooms with Boilers and Pumps Installation, Operation, & Maintenance WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death or property damage. Be sure to read and understand the installation, operation and service instructions in this manual. Improper installation, adjustment, alteration, service or maintenance can cause serious injury, death or property damage. A copy of this IOM should be kept with the unit.
Table of Contents Safety .............................................................................................................................................. 6 BL Base Model and Features Description ...................................................................................... 9 General Information ...................................................................................................................... 13 Codes and Ordinances ...................................................
Suction Guides .......................................................................................................................... 42 Glycol Auto Fill Unit ................................................................................................................ 43 Flo-Trex Combination Valve .................................................................................................... 45 BL Series Startup Form ...............................................................................
Index of Tables and Figures Tables: Table 1 - Service Clearances......................................................................................................... 17 Table 2 - Mounting Dimensions ................................................................................................... 18 Table 3 - Boiler Rated Input Capacity .......................................................................................... 20 Figures: Figure 1 - Backflow Preventer ...................................
Safety Attention should be paid to the following statements: NOTE - Notes are intended to clarify the unit installation, operation and maintenance. CAUTION - Caution statements are given to prevent actions that may result in equipment damage, property damage, or personal injury. WARNING - Warning statements are given to prevent actions that could result in equipment damage, property damage, personal injury or death.
WARNING Electric shock hazard. Before servicing, shut off all electrical power to the unit, including remote disconnects, to avoid shock hazard or injury from rotating parts. Follow proper Lockout-Tagout procedures. WARNING FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD Failure to replace proper controls could result in fire, explosion or carbon monoxide poisoning. Failure to follow safety warnings exactly could result in serious injury, death or property damage.
WARNING UNIT HANDLING To prevent injury or death lifting equipment capacity shall exceed unit weight by an adequate safety factor. Always test-lift unit not more than 24 inches high to verify proper center of gravity lift point to avoid unit damage, injury or death. WARNING Always use a pressure regulator, valves and gauges to control incoming pressures when pressure testing a system. Excessive pressure may cause line ruptures, equipment damage or an explosion which may result in injury or death.
BL Series Feature String Nomenclature 15 16 17 18 19 20 21 22 23 14A 14B 7 8 9 10 11 12 13 6A 6B 6C 5A 5B 5C 2 3 4 Unit Feature Options 1A 1B 1C 1D : B1 B2 B3 A1 A2 A3 A4 CONFIG VLT SIZE GEN Model Options B L – 0 5 0 – 3 – 0 – A 0 0 0 – A 1 A : 0 0 0 0 – 0 C 0 – 0 0 0 – K C C – B 0 0 0 F BG – 0 A – C AA 0 0 0 0 0 X BASE MODEL SERIES AND GENERATION BL UNIT SIZE 050 = 500 MBH Boiler Capacity 075 = 750 MBH Boiler Capacity 100 = 1,000 MBH Boiler Capacity 150 = 1,500 MBH Boiler Capacity 200 = 2,0
BL Series Feature String Nomenclature 15 16 17 18 19 20 21 22 23 14A 14B 7 8 9 10 11 12 13 6A 6B 6C 5A 5B 5C 2 3 4 Unit Feature Options 1A 1B 1C 1D : B1 B2 B3 A1 A2 A3 A4 CONFIG VLT SIZE GEN Model Options B L – 0 5 0 – 3 – 0 – A 0 0 0 – A 1 A : 0 0 0 0 – 0 C 0 – 0 0 0 – KCC – B 0 0 0 F BG – 0 A – C AA 0 0 0 0 0 X FEATURE 4: BLANK 0 = Standard FEATURE 5: BLANK 5A, 5B, 5C: BLANK 000 = Standard FEATURE 6: BOILER PUMP 6A: BUILDING PUMP CONFIGURATION 0=Standard, No Boiler Pump A = 1 Pump/Barrel
BL Series Feature String Nomenclature 15 16 17 18 19 20 21 22 23 14A 14B 7 8 9 10 11 12 13 6A 6B 6C 5A 5B 5C 2 3 4 Unit Feature Options 1A 1B 1C 1D : B1 B2 B3 A1 A2 A3 A4 CONFIG VLT SIZE GEN Model Options B L – 0 5 0 – 3 – 0 – A 0 0 0 – A 1 A : 0 0 0 0 – 0 C 0 – 0 0 0 – K C C – B 0 0 0 F BG – 0 A – CA A 0 0 0 0 0 X FEATURE 7: SERVICE OPTIONS FEATURE 14: COMPRESSION TANK 0 = Standard A = 115V Outlet, Factory Wired B = 115V Outlet, Field Wired 14A: BLANK 0 = Standard FEATURE 8: BLANK 0 = S
BL Series Feature String Nomenclature 15 16 17 18 19 20 21 22 23 14A 14B 7 8 9 10 11 12 13 6A 6B 6C 5A 5B 5C 2 3 4 Unit Feature Options 1A 1B 1C 1D : B1 B2 B3 A1 A2 A3 A4 CONFIG VLT SIZE GEN Model Options B L – 0 5 0 – 3 – 0 – A 0 0 0 – A 1 A : 0 0 0 0 – 0 C 0 – 0 0 0 – K C C – B 0 0 0 F BG – 0 A – C AA 0 0 0 0 0 X FEATURE 17: EXTERIOR CABINET OPTIONS 0 = Standard A = Access Door Windows FEATURE 18: CUSTOMER CODE 0 = Standard FEATURE 19: CODE OPTIONS 0 = Standard - ETL U.S.A.
General Information WARNING AAON BL Series boiler outdoor mechanical rooms are complete self contained liquid heating units. They are factory assembled, wired, and run-tested. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Startup and service must be performed by a Factory Trained Service Technician.
Wiring Diagrams A complete set of unit specific wiring diagrams in both ladder and point-to-point form are laminated in plastic and located inside the control compartment door. access. The strainer assembly is composed of two parts, the operational strainer, and the startup strainer, (located inside the operational strainer) which is to be removed 24 hours after startup.
See appendix for additional information on the installation, operation and maintenance of pumps. Makeup Water A city makeup water connection is provided to replace water that is lost from the system. Glycol units require a glycol feeder (optional factory installed or field installed) to replace fluid that is lost in the system. Water should not be added to glycol applications as this would dilute the glycol concentration and thereby increase the freezing temperature of the fluid.
pipe plug over the charging valve for protection. Purge air from system before placing tank into operation. All models have system water contained behind the diaphragm. It is recommended that the pre-charge be checked annually to ensure proper system protection and long life for the vessel. Pressure Relief Valve Required pressure relief valve is installed in the unit. This valve is set at 125 psig. Figure 2 shows inlet pressure versus capacity for this pressure relief valve.
Pipe Insulation The water piping and components on units with pumping packages are not insulated at the factory. Insulation should be installed on the water piping after the system has been checked for leaks. Units require rail support along all four sides of the unit base. Installation If unit is elevated a field supplied catwalk is recommended to allow access to unit service doors.
Do not push, pull or lift the unit from anything other than its base. Figure 4 - Steel Mounting Rail with Dimensions Table 2 - Mounting Dimensions Cabinet A B C D Style Standard 100” 96” 92” 97” Narrow Wide 142” 138” 134” 139” Lifting and Handling If cables or chains are used to hoist the unit they must be the same length and care should be taken to prevent damage to the cabinet. Before lifting unit, be sure that all shipping material has been removed from unit.
Figure 6 - BL, LL, RL, and CL Series Lifting Detail (General Configuration) Lifting slot locations are unit specific. Unit must be rigged at all marked lifting points.
Water Connection Connect the supply and return water lines. The connection size is listed on the unit rating sheet, along with the designed volumetric flow rate. The maximum operating pressure for AAON BL Series units is 125 psi. WARNING Boilers must be operated only with liquid flowing through boiler. CAUTION PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are vulnerable to attack by certain chemicals.
Figure 7 - Boiler Vent Shipping Covers Intake and exhaust covers are in place for shipping. These must be removed and external intake/exhaust components must be installed prior to boiler operation. Figure 8 - Boiler Vent Components Gaskets must be in proper position or flue gases could leak. WARNING Failure to follow proper joint connection procedure may result in carbon monoxide gas poisoning due to flue gas leakage.
Securely fasten the vent pipe joints according to the following procedure. 1. Insert the male end into the female section. Push the units together and turn them until the bead of the male end is seated against the flared end of the female section. This creates the necessary airtight seal. Align the seams on the vent lengths and orient them upward in all horizontal applications. 2. Tighten the locking band with a nut driver until snug plus 1/4 turn.
Verify the unit nameplate voltage agrees with the power supply. Connect power and control field wiring as shown on the unit specific wiring diagram provided with the unit. Size supply conductors based on the unit MCA rating. Supply conductors must be rated a minimum of 167°F (75°C). Route power and control wiring, separately, through the utility entry. Do not run power and signal wires in the same conduit. Protect the branch circuit in accordance with code requirements.
Startup (See back of the manual for startup form) Use the general check list at the top of the startup form to make a last check that all the components are in place, water flow is present, and the power supply is energized. WARNING Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
Maintenance General Qualified technicians must perform routine service checks and maintenance. Lubrication All original motors and bearings are furnished with an original factory charge of lubrication. Certain applications require bearings be re-lubricated periodically. The schedule will vary depending on operating duty, temperature variations, or severe atmospheric conditions. AAON Warranty, Service, and Parts Department 2424 S. Yukon Ave. Tulsa, OK 74107 Ph: 918-583-2266 Fax: 918-382-6364 www.aaon.
Appendix - Water Piping Component Information Water Pressure Reducing Valve Water Pressure Reducing Valves are designed to reduce incoming water pressure to protect plumbing system components and reduce water consumption. Overview Standard construction includes Z3 sealed spring cage and corrosion resistant adjusting cage screws for outdoor/waterworks pit installations.
Capacity Note: Use a pressure gauge downstream to adjust and verify the pressure setting. Maintenance Instructions To clean strainer remove the bottom plug and pull out strainer. Adjustment To adjust pressure setting, loosen the lock nut and turn the adjusting bolt clockwise to increase pressure, counter clockwise to decrease pressure.
Water Pressure Relief Valve Overview ASME Rated, Design Certified and Listed by C.S.A. Used for protection against excessive pressure on domestic storage tanks or tankless water heaters, the pressure relief valve has no temperature relieving element. Standard setting, 125 psi Size 3⁄4" x 3⁄4" (20mm x 20mm). ASME construction and is tested, listed and certified by the National Board of Boiler and Pressure Vessel Inspectors. ANSI Z21.22 “Relief Valves for Hot Water Supply Systems.
Operating Range Minimum working pressure: 1.45psi (10 kPa) Maximum working pressure: 150psi (10 bars) Temperature Range: 33°F – 240°F (5°C – 116°C) Performance: The figure below shows the installation of the vent valve for the venting of air while the fluid is circulating in the system and the required increase in pipe size in order to obtain proper separation of air from water. Performance curve details the quantity of air vented by the “Float Vent” according to the pressure in the system.
Maintenance No maintenance is normally necessary.
Where under normal operating conditions the limit of 68°C/155°F (Restricted Zone) for normal touch, or 80°C/176°F (Unrestricted Zone) for unintentional touch, may be experienced, steps should be taken to minimize contact or warn operators/users that normal operating conditions will be exceeded.
Pump Piping - General CAUTION Use Caution. Piping may carry high temperature fluid. CAUTION Discharge valve only is to be used to throttle pump flow. The discharge valve only is to be used to throttle pump flow, not the suction valve. Care must be taken in the suction line layout and installation, as it is usually the major source of concern in centrifugal pump applications Alignment Alignment is unnecessary on close-coupled pumps as there is no shaft coupling.
into the units of the pump head as stated on the pump nameplate and compare the values. Should the actual pump operating head be significantly less than the nameplate head value it is typically permissible to throttle the discharge isolation valve until the actual operating head is equal to the nameplate value. Any noise or vibration usually disappears.
Check the lubrication instructions supplied with the motor for the particular frame size indicated on the motor nameplate. Mechanical Seal Mechanical seals require no special attention. The mechanical seal is fitted with a flush line. The seal is flushed from discharge of the pump casing on splitcoupled pumps and is flushed/vented to the suction on close coupled pumps.
Noise Levels Estimated Pumping Unit Sound Power Level, Decibels, A-Weighted, at 1 m (3 ft.) from unit. Vibration Levels Vertical In-Line pumps are designed to meet vibration levels set by Hydraulic Institute Standard HI Pump Vibration 9.6.4.
2. Fill the dry casing with system fluid by opening the seal flush line interconnecting valve and the air vent fitting. 3. Allow the pressure to equalize in the two casings, if necessary, by opening seal flush line interconnected valve. 4. Unlock the discharge valve as per instructions below. 5. Unlock the suction valve as per instructions below. NOTE: Keep hands and tools away from locked suction valve arm, as the differential pressure may cause the arm to rotate quickly with force when unlocked. 6.
3. Loosen set screw (11) and lower locking handle (3) to the horizontal position, secure with set screw (11). 4. Rotate valve to center position so that the center pin of the locking arm (4) locates in the recess on the locking handle (3). 5. Loosen set screw (11) and raise locking arm (3) to the vertical position, locking the center pin in the locking arm recess, secure with set screw (11). 3. Rotate the suction valve towards the pump to be isolated.
WARNING Care should be taken when performing procedures 3 and 4. Read instructions carefully. Unlocking: 1. Open the interconnecting valve on the seal flush line to pressurize the serviced pump and vent air through bleeder valve on series 4302. Close these valves once the pressure is equalized and air removed. 2. Loosen set screw (11) and lower locking handle (3) to the horizontal position, secure with set screw (11).
Horizontal and Vertical Expansion Tanks ASME PRE-PRESSURIZED DIAPHRAGM EXPANSION TANKS FOR HEATING & COOLING SYSTEMS Vessel Description Tanks are ASME constructed and precharged. They are designed to absorb the expansion forces and control the pressure in heating/cooling systems. The system’s expanded water (is contained behind a heavy-duty diaphragm fully compatible with water/glycol mixtures) preventing tank corrosion and water logging problems.
Installation The Suction Guides may be installed in any arrangement feasible the arrangement of the pump flange bolt-holes. Suction Guides Introduction Suction Guides are designed for bolting directly onto the suction flange of horizontal or vertical shaft centrifugal pumps. Operating Limits The suction guide is designed to be a fourfunction fitting. Each Suction Guide is a 90º elbow, a Pipe Strainer and a Flow Stabilizer.
Temporary strainer must be removed following system clean up. After all debris has been removed from the system, or a maximum of 24 running hours, stop the pump and close the pump isolation valves. Drain the Suction Guide by removing the drain plug or opening the blowdown valve, if installed Remove the Suction Guide cover and remove the strainer assembly from the valve body. A temporary fine-mesh start-up strainer is tack-welded to the permanent stainless steel strainer.
The flow rates from the unit are designed for make-up rates. It is therefore suggested that the system is back-filled with due precautions taken to avoid contamination. Glycol is sometimes subject to bacterial attack and can become slimy as a result. AAON recommend the addition of a suitable biocide. The dosage should be calculated on the amount of water glycol mixture added and not the total tank contents.
6. 7. 8. 9. Repeat for standby pump (where fitted). Close the system-isolating valve. Open suction isolating valve. Switch on unit, initially both pumps will run. As the pressure reaches the pump control switch threshold, the pumps will switch off. 10. Check all piping for leaks following shipping. 11. Crack open system valve. The pressure will fall and the pump will start and maintain pressure. 3. Flow throttling valve Armgrip Flange Adapter Installation 1.
Table A1. Armgrip Flange Adapter Details 125 psi/150 psi 250 psi/300 psi Valve Size Ductile Iron Bolt Ductile Iron Bolt No. Size No. Size 2-1/2 4 5/8 8 3/4 3 4 5/8 8 3/4 4 8 5/8 8 3/4 5 8 3/4 8 3/4 6 8 3/4 12 3/4 8 8 3/4 12 7/8 10 12 7/8 16 1 12 12 7/8 16 1-1/8 The gasket cavity should face out to the adjoining flange. 5. Tighten remaining nuts evenly by following bolting instructions, so that the flange faces remain parallel (as shown in the figure labeled Recommended Bolt Tightening Procedure).
Flow Measurement with the valve in the Wide Open position Where approximate indication of flow is acceptable the Flo-Trex valve can be used. Note: The valve is shipped in closed position. The indicator on the plastic sleeve is aligned with the vertical scribed line on the stem. Step 1. Measure and record the differential pressure across the valve. Step 2. Record the size of the valve and stem position using the flow indicator scale.
From the Flo-Trex performance curve, a 4 in. valve with 5.4 ft of pressure drop represents a flow of 400 USgpm From the flow characteristic curve, a 4 inch valve at 50% open represents 34% of maximum flow. The approximate flow of a 4 inch valve with a 5.4 ft pressure drop when 50% throttled is: (400 x 34) = 136 USgpm 100 (25.2 x 34) =8.57 L/s 100 Note: To prevent premature valve failure it is not recommended that the valve operate in the throttled position with more than 25 ft pressure differential.
Step 4. Inspect and clean O ring cavity and install new O ring and seat. Valve disc stem should be inspected and replaced if worn. Valve stem O ring should be replaced at this time as discussed under Repacking of FloTrex section. Pressure-Temperature Limits Flo-Trex Cross Section 1. Body Main 2. Eye Bolt 3. Shaft 4. Spring 5. Spacer 6. Disc 7. Seat 8. O ring body 9. Body Suction 10. Capscrew 12.
BL Series Startup Form Job Name:_______________________________________________ Date:______________ Address:______________________________________________________________________ ______________________________________________________________________________ Model Number:_________________________________________________________________ Serial Number:_____________________________________________ Tag:_______________ Startup Contractor:______________________________________________________________ Address:___
Water/Glycol System 1. Has the entire system been flushed and pressure checked? Yes No 2. Have isolation valves to the boiler been installed? Yes No 3. Has the entire system been filled with fluid? Yes No 4. Has air been bled from the heat exchangers and piping? Yes No 5. Is there a minimum load of 50% of the design load? Yes No 6. Has the water piping been insulated? Yes No 7. Is the glycol the proper type and concentration (N/A if water)? Yes No 8.
Maintenance Log This log must be kept with the unit. It is the responsibility of the owner and/or maintenance/service contractor to document any service, repair or adjustments. AAON Service and Warranty Departments are available to advise and provide phone help for proper operation and replacement parts. The responsibility for proper start-up, maintenance and servicing of the equipment falls to the owner and qualified licensed technician. Entry Date 52 Action Taken Name/Tel.
Literature Change History June 2010 Revision of the IOM adding PVC and CPVC piping Caution. April 2012 Update of the IOM correcting the minimum inlet gas pressure for the 500 MBH boiler to 5” w.c and the 750, 1000, and 1500 MBH boiler to 7” w.c., adding the electronic startup form, adding the index of tables and figures, and updating the table of contents. July 2013 Update of the feature string nomenclature options.
AAON 2425 South Yukon Ave. Tulsa, OK 74107-2728 Phone: 918-583-2266 Fax: 918-583-6094 www.aaon.com BL Series Installation, Operation & Maintenance R53480 · Rev. A · 130725 It is the intent of AAON to provide accurate and current product information. However, in the interest of product improvement, AAON reserves the right to change pricing, specifications, and/or design of its product without notice, obligation, or liability. Copyright © AAON, all rights reserved throughout the world.
