SHANAGHAI HUAZHENG

SPECIAL BOILER
MANUFACTURE CO., LTD.

WNS SERIES FUEL（GAS）

STEAM BOILER

INSTALLING AND OPERATING

INSTURCTIONS

No2 lane 5235 Hunan Road, Pudong New Area, Shanghai

TEL：021-58147896 FAX：021-58147889
After service line：021-58147899 Zip code：201317
Dear user, thank you for using product of Shanghai Huazheng Special
Boiler Manufacture Co., LTD. For your safety and product using effect,
please do all the preparation work according to instructions when
installing and using this product.
Catalogue

Ⅰ Structure brief introduction、main specifications ………….. …（1）

Ⅱ Performance Characteristics ……………………………………..（2）

Ⅲ Boiler status out of factory ……………………………………....（2）

Ⅳ WNS Series fuel oil（gas）steam boiler main parameters ….. ....（3）

Ⅴ Installation illustration

(Ⅰ) Preparing work before installation …………………………（4）

(Ⅱ) Installation retirement ………………………………………（4）

(Ⅲ)Main function of electric control box ……………………（6）

(Ⅳ)Installation of pipe、instrument、valve and auxiliary parts ....（6）

Ⅵ、Direction for use

(Ⅰ) Heating and boiling …………………………………………....（7）

(Ⅱ) Ignition ………………………………………………………....（8）

(Ⅲ)Adjust safety valve …………………………………………......（9）

(Ⅳ)Steam supply ………………………………………………........（9）

(Ⅴ)Normal working ………………………………………………...（9）

(Ⅵ)Pollution discharge ……………………………………………...（11）

(Ⅶ)Maintenance …………………………………………………......（12）

(Ⅷ)Inspect of pressure parts and water pressure test………………..….（12）

Ⅶ、Cause and solution of common fault of fuel oil（gas）boiler .........（14）

Ⅰ、Structure brief introduction、main specification

WNS series fuel oil（gas）steam boiler is horizontal IC three-pass boiler. It
used underneath type furnace, fuel oil (gas) come in from here and
combustion in furnace of inner combustion chamber, then go through
reversal chamber. Height temperature will rush the second pass and third
pass smoke tube successively, then discharge from smoke box through
chimney. Most heat is absorbed by water; water turns to steam, and goes
out of boiler by steam pipe. On the boiler there are front and back smoke
cases, easy for check and repair. Burner installed on the front board of
combustion chamber, water feed device is installed on the base. Boiler has
a compact constructor; it is easy for installation and can start quickly, with
high heat efficiency and high automaticity. Each boiler adopts heat resistance
fiber and hermetic outer casing, with good heat-retaining properties. The
base is made of a whole steel structure, so it is very easy for installation and
location. It is widely used in textile、food、medicine、industry、currier and
hotel, such light industry and chemical industry and life use heating places.
Before boiler out of factory need to do strict quality check, at the same time
all the auxiliary parts and electric control devices are prepared, the boiler
should be completed fitted.
Main steam valve

Relief valve

Relief valve

Maximum security level

Normal water level
Connect to
Safe minimum level
the chimney

The thirdly return smokestacks

Smoke box
after

Smoke The second return smokestacks Reversal

box chamber
front
Furnace
bravery
Flame

Burner

Connect to
water softener
 Ⅱ、Performance Characteristics
WNS series fuel oil (gas) steam boiler has the below characteristics：
(Ⅰ)The structure of the boiler is compact and fitted with imported burner( optional
for user's requirement), the main part (for fuel oil) of burner, such as oil pump、
fan、magnetic valve、ignition device and air register are all installed together;
automatically feed water according to water level change, devices that
automatically adjust the fan and oil proportion in load change of boiler are all very
convenient to operate；
（Ⅱ）Boiler system has burn out protection and low limit water level protection,
steam overpressure protection and alarm light device, they are all easy to
manipulate and reliable；
（Ⅲ）The boiler is completed equipped with auxiliary parts, after the whole
installation of boiler go to field out of factory, it is only need to install water
treatment、pipeline、chimney and connecting water、electricity、fuel(gas) , with
a short installation period;
（Ⅳ）Compact structure with little coverage of land, this can save the land invest
of boiler, and easy for installation and movement.
(Ⅴ)All kinds of boiler can selected matching burners which are suitable to light
oil、heavy oil、natural gas、coal gas and liquefied petroleum gas, adaptable and
with wide selection range.

Ⅲ、Boiler status out of factory

WNS series fuel(gas)steam boiler is divided to types of hardware、software and
optional parts when out of factory：
（Ⅰ）Hardware：Boiler is consist of the whole body of boiler (including boiler
body、thermal insulation layer、front and back smoke box, ect), burner、electric
controlling box、water pump and various of valves and instruments；
（Ⅱ）Software：boiler installation and use instruction、pressure component
strength calculation sheet、product quality certificate、general drawing、boiler
body、tube valve instruments and electrical schematic diagram such technical
documents.
（Ⅲ）Optional parts：chimney、flue、points cylinder、 daily-use oil tank、oil
tank are packing and tie up separately.
 Ⅳ、WNS Series fuel oil（gas）steam boiler principle diagram

Put to outdoor safe place

Torching flame arrester DN40

Torching flame arrester DN40

Main steam valve

steam escape valve＞DN40

Relief valve
Connect to
Maximum security level the chimney
Normal water level
Total valve

Safe minimum level

Connect to
the gas
network

connect to
steam header Connect to water
pipe network

drainage
Oil-spill pipe
Drain pipe
Inlet tube

DN15
Outlet tube
Oil pointer

Daily-use Soft water tank

connect to

oil tank ＞2Q

Inlet and

Drains
＜1m3
drainage

outlet
Salt box
DN15

tubes
Drain contaminationDN40
Drains

Connect to
water softener

Oil tank
 Ⅴ、Installation illustration
（Ⅰ）Preparing work before installation
The design of boiler room should commit by qualified construction units, and
agreed by related institution in advance, the arrangement of boiler room should
meet the related requirement. After the boiler carried to field, in order to operation
quickly, need to do following preparing work：
1 、Staff preparation
The installation of boiler should undertake by the unit who get the boiler
installation license, installation unit should equip with plumber、fitter、electrician、
crane man、Cold welder and auxiliary worker；They should work with fireman
together.
2 、Organize related people study materials
Organize related people to familiar with 《 Steam boiler safety technical
inspection regulation 》 、 boiler drawing 、 this 《 Installing and operating
instructions》, these technical documents will help to know and master the
procedure of install crane operation.
3 、Locate the installation place.
A、The installation place is better to get close to steam using place. In order to
slow down the construction expense and low down the pipe heat loss；
B 、Prepare the supply voltage of 380V and 220V，power should conform to the
boiler's total volume；
C、Convenience of water supply and pollution discharge；
D 、The convenience of storage and transportation of fuel；
E、The arrangement of boiler should conform to the boiler regulations in chapter
8 of 《steam boiler safety technical inspection regulations》published by labor
ministry；
F、When boiler is in installation and transportation please make sure in a good
road；
4 、Foundation preparation
According to boiler general drawing of boiler，draw out the overall mounting base,
make it can bear the weight of boiler.
5、Device inspection and acceptance
A、After the boiler arrived，check all the things according our company out of
factory list. According to overall drawing, recheck the completeness and condition
of device；
B 、When unload the whole boiler, can put pipe under the side channel, use steel
rope to pull it, make the whole boiler move slowly on the rolling pipe, the place to
insert the steel rope should be the former or back hole of two sides channel on
the base，any part of the boiler body shouldn't broken.
C 、If the boiler body need to be hosting, the hosting ability of device shall not
lower than boiler's transporting weight. Hosting rope should be installed on the 2
groups (or front and back) of hosting ring on boiler roof, do not host on random
place.
（Ⅱ） Installation requirement
1、The installation of boiler whole body
After lay the boiler, the left and right side of water level, left and right side of
water level should keep horizontal, allowed water gauge elevation derivation
should not exceed ±5mm, or should block up the lower steel plate, boiler can be
higher in front and lower in back, the allowance of difference can be 0-50mm；
2 、Installation of water feed pipeline
Water feed should comfort to GB1576《Industry boiler water quality regulation》；
outlet of soft water box should install the steel filter，generally the high level of
water box is required to be lower than the boiler ordinary water level. This can
avoid the water flow back into boiler when boiler stops; make the result that when
in next start has to discharge much water.
3、Main steam pipeline installation
The straight section which stretches out main steam pipe should be longer than
0.5m, between the main steam pipe and section cylinder should set two bends,
the diameter of them should bigger than 3 times of pipe diameter, or should install
expansion section. The lowest of pipe should install drain valve，to prevent pipe
shock by water, main steam pipe should be warm.
4、Oil supply pipe installation
A 、 Oil tank should equip with water drain valve atmospheric valve, on the
atmospheric valve should install fire arrestor, on the pipe of oil inlet and outlet
should install filter. The installation place depends on concrete circumstances,
generally it will install on ground or underground, the total length should less than
5mm, when the oil tank is placed underground, should keep the height difference
of ground and oil pump center lower than 2.5cm.
B、Daily-use oil tank should set oil level auto-control system (by user), and
overflow pipe(diameter should be bigger thanDN32)、overflow oil will go back to
oil tank, oil outlet also should install filter, the installation place is better to higher
than burner, in order for the inhale oil of burner.
C、There are "oil in " and " oil return" two port, only need to connect the related
oil pipe and water-return oil pipe of daily-use oil tank and install the filter on the
oil port.
D、Oil pipeline should equip with filter. One of the fuels of boiler is light diesel oil.
After the oil supply distribution of light diesel oil should heat oil. So in all seasons
should use low grade diesel. If have condition, user should do frost protection
measure to avoid fuel oil frozen.
E、Daily-use oil tank and oil storage tank should conform to fire controlling
requirement.
5、Fuel gas pipeline installation
A、Boiler fuel gas should keep a "gas inlet" port，only need to connect the gas
supply pipe of boiler ；
B、Gas pipe including stop valve、filter、reducing valve、magnetic valve、leak
inspection device consisted of pressure control components and adjusting valve；
C、The most unsafe factor of fuel gas is leaking，so when during installing, make
sure to check the fuel gas pipeline strictly and especially the check of magnetic
valve，in order to prevent the explode and fire accident caused by fuel gas leaking.
6、Requirement of chimney
A、Requirement of chimney
Chimney should be installed vertically. The length between the chimney of boiler
commonly not be longer than 10m，bend not more than three and are not the
90℃ right angle bend. The height of the chimney usually is 15m and comfort for
requirement of environment protection. The outlet of chimney should better
installed rain hat，the distance between lower edge of chimney hat and chimney
outlet should longer than 0.7 times of chimney diameter. Chimney also should
have thunder-arresting measurement.
B、The chimney should have right angle bend, must use curve bend, this is to
prevent the resistance of smoke too big to deteriorate the combustion and smoke
flow situation.
C、Each boiler should have separate chimney, do not use a same chimney with
the other boiler, or it will make the combustion status get worse.
D、In west plateau area of China, because the atmosphere pressure is low, the
water steam bill be easy to change to dew and drop into back smoke box. This
will damage the smoke case and more easily to happen especially in the low load
of boiler and low temperature of atmosphere. To avoid this, installation unit can
install a ring and discharge the water in the ring. Detailed method: Install a steel
ring which is bent by 4.5/2.8 inequilaterally angle steel with on the 100mm upper
of chimney flange joint of chimney and boiler，weld the chimney in the inner
diameter, make it to be water storage plate， （also can use steel pipe withΦ50mm，
divide to 4 part along the diameter, then bend and weld it to a steel ring）make
the dew water receive by steel ring, then drill a little hole on the water plate，
install on socket and induct the dew water to ground.
7、Water pump installation
When install the vertical pump should be perpendicular to foundation plan.
（Ⅲ）Main function of electric control box
On the electric control box gathers boiler controlling(burner、water pump and
automatic control）switch button，user can use wire to connect burner、water
pump, and motor electrode water level controller and pressure regulator
according to "electric diagrams"，then get through external main power，the box
case should be protectively earthing ， detailed instruction should refer to
installation and use instructions of electric controlling box.
（Ⅳ）Installation of pipe、instrument、valve and auxiliary parts
l 、Install according to tube valve instrument drawing.
2 、The safety valve should installed after the water pressure test，safety valve
should install steam discharge pipe to discharge steam to safety place out of
boiler room. In the lowest of steam discharge pipe should install conduit pipe,
valve is not allowed to install on conduit pipe.
3 、Pollution discharge pipe connected to blow down tank or other safe place,
pipe should be firm, to avoid the movement of pipe and come to strike back and
scald accident
4 、The steam pipe of main steam valve should be connected by user, at least
should have 2 bends, or draw tube should be added, keep the warmness of pipe
outer face.
standard5 、 The elevation deviation of water gauge shall not
exceed±5mm,( boiler normal is the criterion), on the gauge should mark with
“highest level"|"lowest level" and ordinary level. The lower water drain pipe of
water gauge, must connected to a safety place，the gauge should be flexible
without leakage, lighting facility should be installed for inspection.
6 、When install pressure gauge and electric contact pressure，need to make
the dial vertical, mark red line on pressure gauge, display the permit highest
working pressure. The pressure surge pipe is forbidden to keep warm.
7 、The boiler is equipped with pressure regulator or electric connecting pressure
gauge，installation unit adjust the actual highest and lowest using pressure
according to user's requirement. In trial operation if pressure reach to this valve
will stop boiler automatically, restart the burner when pressure turn down back，
keep on trail operation , make working pressure always in an extent range.

Ⅵ、Direction for use

（Ⅰ）Heating and boiling

After installation , water pressure test and no load trail operation, verify that all
part get the condition to start then can begin heating and boiling，heating time
not less than 2 days and going in the same time with boiling
1 、The purpose of heating is the wall stick may dry slowly and will not crack
when using；The purpose of boiling is to clear the inner dirt and oil stain, need
to dose suitable medicine to make water change to alkaline water that can easily
remove oil stain.
2、Boiling can use Na2CO3 or Na3PO4·12H2O such medicine，the dosing
volume calculate by m3，former is 5 kg／m3，latter is 3 kg／m3。 Below medicine
is should matched to well mixed solution with concentration of 20%, do not doing
the solid medicine directly
3、In addition to the water valve， all the valve and water table valve shut
off，water table communicating pipe connect to the boiler; Open manhole，put
the treated water softener into the boiler，inlet water temperature is not higher
than average 40℃，let the boiler water level rose to water table 2/3 place，
turn off the pump！Stay in the pot after water stability，observe whether water
reduction and check the boiler flange joints and drain valve are leakage
appearance，if leakage tighten bolts，also check whether the drain valve tight
and without leakage；Then join pot from manhole place prepared solution，
close the manhole，open the main steam valve and points of cylinder total
valve，open a cylinder in points as exhausting valve valve，put the tube and
air valve connectivity，put steam tube diameter should be greater
thanφ45mm，to outdoor safe place。
4、Put the burner button on the manual switch place，start burner to say the
burner is running or not, oil pressure is in range of（0.8-1.0Mpa）or not，if oil
pressure is too low, should open the atmospheric valve of gear oil pump of burner，
do emptying with oil pump，when air are emptied, turn off it and adjust burner oil
pressure（detailed method see burner direction for use）， after burner started
for 1 minutes and oil is stable，start ignition button on burner，check the air shutter
is ok or not，if smoke is black mean the air volume is too small，it's better to turn
up it，if smoke is white means the air volume is too big, should turn down it（details
see direction for use of burner)，adjust it until can't see smoke in chimney，at
the same time should pay attention to the pressure of boiler.
5、When the burner debugging finished，burners combustion should turn to
single stage small fire state,in 12 hours before，boiler pressure kept zero
pressure condition，open points put valve cylinder，boiler exhaust temperature
rise 5℃/h，burning off when state too open state；In 12 ~ 24 hours，boiler
pressure to keep 0～0.1 MPa，control points put valve cylinder，control boiler
exhaust temperature rise 3℃/h，burning off when state too open stat；At 24 ~
36 hours and 36 ~ 48 hours，Boiler pressure control in respectively 0.4 MPa
and 0.6 MPa，control points put valve cylinder，The boiler control to exhaust
temperature gradually 170℃，burning off when state too open state，observe
whether water reduction and check the boiler flange joints and drain valve are
leakage appearance，if leakage tighten bolts，also check whether the drain
valve tight and without leakage。In the oven and pot should pay attention to the
water level changes，when water levels fall should immediately start pump
filling water，maintain boiler water is there。In the oven and pot 12 ~ 48
hours，should make the water In boiling state。By 48 hours after the boiler，
otop burning let the pressure gradually reduced to 0.1 MPa below，Water
temperature below 70℃，open drain valve，will pan of water all release。
6 、After the cooling of boiler, open the manhole, wash it with clean water and
do inspection， if still find oil stain, should do again as above method.
（Ⅱ）Ignition
l 、Before ignition the boiler should do overall inspect （Including related auxiliary、
tube）before feed water， and must close drain valve and open a safety valve
to let the air get out of the boiler drum；
2 、When using fuel gas(oil)，should start fan to blow away combustible gas may
stayed in the hearth to avoid blow up. When it is hard to ignition ， should
discharge inner combustible gas promptly；
3 、Inject treated water into drum，water inlet temperature commonly not higher
than 40℃ ，when water level rise up to the lowest of water gauge will close water
pump，waiting for the stable of water in boiler and check if level has declined；
4、When igniting should operation as《 electrical fundamental instruction》 ；
5 、The temperature should be rising to fact when in igniting, in order to generate
over strength heat stress result in the difference heat form all part，that will affect
the lifespan of boiler，time duration of ignition for first time from cold boiler to
rising to working pressure better to keep 2 hours， later when igniting cold boiler
should not less than 40 minutes，hot boiler not less than 20 munities：
6 、After ignition should pay attention to the water level timely，because there
will be water level rising，if exceed highest water level can discharge pollution；
7 、When steam come out of the first opened safety, should close safety valve
instantly and wash pressure bend tube and water gauge， when the steam
pressure rise to 0 . 2 or 0.3 MPa ，check the leakage of manhole and hand hole，
if have leakage should screw manhole and nuts of hand hole，meantime check
the leakage of drain valve.
8 、The vapor pressure rising gradually, notice parts of boiler if there is any
special sound，if have should check instantly, and shut down boiler if necessary，
debug the fault before keep running.
（Ⅲ）Adjust safety valve
1、Safety valve should adjust in the first ignition；
2 、Rated steam pressure of boiler P ≤0 . 8MPa，the one of the rated pressure
adjust to（working pressre+0.03MPa )，another to(+0.05MPa ) ；
Rated steam pressure of boiler 0.8＜P ≤5.9MPa，the one of the rated pressure
adjust to（1.04 times working pressre)，another to(1.06 times working pressre) ；
3 、When need to re-adjust the safety valve, the rated pressure should adjust
according to list 7-2 of item143 from 《 Safety Technical and Supervisory
Specification of Steam Boiler》which is issued by China State Bureau of Quality
and Technical Supervision. The adjusting sequence is open the highest pressure
first, then adjust the lower，make the pressure gauge of boiler as the criterion.
After adjust the safety valve，should add seal，forbid to raise the rated pressure
arbitrarily by using heavy things seizure valve plug or make safety valve out of
use.
（Ⅳ）Steam supply
1 、When steam pressure get close to working pressure and be ready to provide
steam out，the water level in boiler should exceed the normal level，and burning
should be stable；
2 、When supplying steam should open main steam valve ajar，use little steam
to warm tube ， meantime open water escape valve of pipeline ， escape
condensate water，warm time should judge by pipe length、diameter、temperature
of steam，commonly not less than 10 minutes，pay attention to the expansion
and flaw of pipe. After get warm and decrease of condensate water, main steam
valve can be totally opened; should open slowly and notice if there is special
noise of all parts，if there is should check as soon as possible，if necessary
should stop the boiler，after main valve is totally opened, should turn back the
main valve for a half circle to avoid immobility after warm expansion. After steam
supply should check the leakage and working status of auxiliary parts、valve or
instrument，in order to avoid steam carrying water，do not let water flow over
plastic board in any case, meanwhile do not open main valve too fast. Then will
reach to rated power in normal and stable condition of burning.
（Ⅴ）Normal working
Need to do when boiler in normal working: water level should be normal, pressure
of steam is stable and enough, keep boiler room clean and tidy, staff hand over
perfectly，strengthen inspection of all machinery devices and instruments. Make
sure the safety and reliability to avoid accidents. Fireman should summarize
working experiences regularly，improve operation ability continuously.
1、Fuel requirement： Fuel for boiler should be regulated fuel for burner. Do not
allow to change variety of fuel arbitrarily. The fuel oil burner is not allowed to use
petrol、megilp、sump oil、 mixed oil with above kinds of oil and opaque oil as
fuel. Burner oil pump is forbid to fuel-lean，oil return and block pipeline. After
installation completed, should wash the pipe，if oil pump damaged caused by
this will not regard for warranty scope.
2、Water feed requirement：water feed should conform to GB1576 《Industry
boiler water quality》criterion.
3 、Water gauge：
On one shift should wash water gauge once to make the gauge glass clean and
clear for watch；If find glass washer is leaking should screw bolts tightly (or
change for new one). The highest and lowest water level should have obvious
mark.
4、 Water level in boiler：
The level should be in the ordinary range displays in water gauge. In order for
the ordinary working for automatic control system, the water alarm and
transducer should be cleaned and washed on every shift. If for electrode
transducer the frequency is check one time per 3-6 months, and measure the
insulate resistance between electrode and flange, make the resistance to be
infinite.
Warning：When the water level of boiler decline to the place that cannot observed
by water gauge，make sure don't inject water into boiler but cut off power first to
stop burning. If fireman inject water into boiler will make boiler exploding! It will
cause grave consequences.
5 、Feed water device：
Check all the feed pump is ok or not, should start and check when turning over，
if have problem should repair it promptly.
6、 Pressure gauge：
Should check pressure gauge periodically, if there is any problem should repair
it instantly and change for it. In order to make sure the precision of gauge, need
to do calibration once half a year.
7 、Safety valve：
Notice the working status of safety valve. To prevent valve disk stick with valve
seat，should do exhaust test by pull lifting handle of safety valve periodically,
should raise air pressure for every 2~4 weeks as automatic exhaust test, this can
verify the safety of valve. The safety valve needs to do annual check.
8 、Insulation of boiler body and tube：
In order to reduce boiler heat loss，it better to do maintenance for boiler and tube
insulation layer.
9 、Clean water scale and dirt：
A 、Periodically check the dirty and coking status of heated place on boiler, such
as smoke tube and furnace. If have should clean it instantly, make it keep the
best heat transfer condition, will be benefit for increase coefficient of heat transfer；
B、Periodically check the dirt of inside of boiler drum and clean it instantly.
10、 Maintenance of boiler：
Periodically check the running status of main parts of boiler, if find leaking of air
and smoke should block it, keep the good condition of boiler.
11 、Clean of boiler room：
Boiler room should keep clean, do not pile up other things in room, and make the
room illuminated, especially for water level gauge and pressure gauge. Often
check the surroundings of boiler, check the auxiliary part to make sure they are
in good condition.
12、Shift turnover ：
Ensure every shift can working efficiently, fireman should do following things
when turning over:
A 、Fireman who receive the shift should arrive boiler room in regulated time for
preparation：
B 、Fireman who transfer work to the other one should：
（1）Make sure burning system is in good working；
（2）All machinery devices are in good working；
（3）All auxiliary parts(including tube、valve、instruments）are good，boiler room
is clean and tidy, room illuminated；
（4）Both party of shift should be responsible, and records of running status in
running record book
（Ⅵ）Pollution discharge
There will be more or less mineral materials in ordinary feed water, after the water
come into boiler, when concreted in an extent it will be sediment, the more volume
of steam vaporization, the long time of running, there will be more sediment, in
order for protection of boiler, need to make sure the water quality. The basicity
should not exceed 26 mol／L，if exceed this range should discharge pollution
instantly.
When discharging please notice following items：
1、If two sets or more boiler should the same main discharge tube should notice：
A、Forbid to discharge at the same time；
B 、If one boiler is in repairing, when discharging should close all discharge
valves of this boiler and block it discharge tube.
2 、Pollution discharge should in low load and high water level，watch closely
the water lever of boiler，better to decline 25~50mm each time when discharging.
3 、Operation details：
Open full of first pollution discharge valve（one near the boiler）then open ajar
the second in order for preheating tube，after tube preheated，open wide pollution
valve slowly，after completed close the third discharge valve first，then close the
first. If there is rushing noise in discharge tube，should turn down the valve until
noise vanished. Then open wide, do not discharge for a long time, for it may
affect water circulation.
4 、After discharge completed, should check the tightness of discharge valve,
the method is: After closed the pollution discharged for a while, touch the tube by
hand, if not cool three maybe leakage. It can be remained to require or change
some days later when boiler stops.
（Ⅶ）Maintenance
l 、Maintenance in boiler's normal working
A 、Periodically check the water gauge、valve、tube and flange are leaking or
not；
B、Keep burner clean and adjust system to be flexible；
C 、Periodically clean water scale and smoke scale；
D 、Check boiler thoroughly，if find the cracks and erosion of welding line of
pressure part、steel plate、tube，should be repair if very serious, if not can remain
to next time when stop boiler . If find any other problem and not affect running,
this can be record for next repair；
E 、If necessary, outer casing and insulation layer can be tear down to check
thoroughly. If find serious problem, should repair it soon and write down the
checking and repairing records in boiler safety technology register book；
F 、At least paint the base、front and back panel once every year.
2 、Maintenance methods for unused for longtime: Dry and wet. Unused for more
than one month should adopt dry method；Not more than one month use the wet
method.
A、Dry method:
Drain water out after shut down boiler , clean up dirt thoroughly and dry it with
fan, then put 10~30mm quicklime blocks in cases and put them in boiler shell.
Do not let the quicklime touch with metal surface. The dosage of quicklime
calculates by 8kg/m3 of boiler shell volume. Then close the manhole and valve.
Check one time per 3 months, if the quicklime block breaks into powder, need to
change it. When restart the boiler, take out the quicklime and plate.
B 、Wet method:
Drain water out after shut down and clean up dirt thoroughly. Fill soft water into
boiler , and heat water to 100℃，make the gas of water out of boiler, and close
all valves. In winter or cold places or temperature lower than 0 ℃，don't use dry
methods, or water will freeze and may damage boiler.
3 、To prevent boiler erosion by oxygen，steam and hot water boiler for supply
heat can install deaerator if have condition，this will increase the boiler's life span.
If have no deaerator, will cause dimples or leakage on smoke tube、welding line
and boiler. In order to decrease the chance of erosion, must choose one of below
two methods:
A、Close the water pump after boiler stops supply heat, open roof valve, heat
water of boiler into 100℃， 5 minutes later，close valve.
B、After the water closed supply heat, close water pump，open roof valve，
discharge water from discharge valve to sewage trench, then close all valves.
（Ⅷ）Pressure component test and water pressure test
1、If there are any case of blow，need to do pressure component test and water
test and do water pressure test.
A 、After newly fitting、refitting and move fitting,
B、Need to restart when stopped for more than one year,
C、After overhaul of pressure component；
D 、When must do checking because not sure of the condition of boiler running
and device .
2、 Before check should stop the boiler completely，clean water scale、outside
smoke dirt thoroughly, tear down wall、out casing and insulate materials，check
point as below:
A 、Make sure no crack on weld line and no leakage on boiler drum；
B、There is no crack on round bar steel stay parts of boiler drum；
C、There is no erosion、grooving or distortion on inside of boiler steel plate；
D、The is no distortion of smoke tube，no crack on weld line between end of
smoke tube and tube sheet；
E 、 No flaw on connecting between drum and feed water pipe 、 pollution
discharge pipe；
F 、No corrosion damage on tube sheet. If seriously damaged, should measure
its thickness and do strength calculate to confirm its allowance working pressure.
Do not use water pressure test method to confirm working pressure or do
overpressure test instead.
3、Test pressure：when working pressure＜0. 8MPa，test pressure is 1.5 times
of working pressure，but not less than 0 . 2MPa。
when working pressure=0 .8～1.6MPa，(test pressre+0.4MPa)
4、Water pressure test procedure
A 、 Do water pressure test ， inlet water temperature should maintain about
20~70℃，If temperature is two low will make outside wall dew mixed with leakage，
this will increase difficulty for check，if temperature two high will cause water drop
evaporation make it difficult to find leaking place. Water pressure test should do
when temperature higher than 5℃ ，when lower than 5℃ need to have anti-
freezing measurement；
B、Water into for full，pressure will rise slowly，speed better not to exceed 0.15
MPa, when reach to working pressure，should stop boost up pressure and do a
hermetic check，if necessary can slow down the pressure to normal and screw
bolt，then increase pressure to test pressure and keep it for 20 minutes， if
pressure is not declined means already in working pressure；
C 、Any leakage in water pressure test will should be marked, and repair it after
water drained, and take a record；
D 、The decline speed of pressure should be slowly，not exceed 0 . 3MPa per
minutes ;
E 、Safety precautions and notice：
（1）After completed installation，please check all the connecting of flanges、
valves and instruments are tight or not, and screw all the solid parts：
（2）Forbid to crew flange bolt when the pressure exceed 0.4MPa；
（3）There should be special mark when do water testing, don't do this when
noisy and there a so many people；
（4）Do not stand in straightly ahead weld line、flange and valve if there is
pressure；
（5）Forbid to do test under the pressure of more than 20 minutes or even exceed
the test pressure；
F、When the water pressure conform to below circumstances，it can be regard
qualified:
（1）No water drop or mist on pressure component wall and weld line；
（2）No distortion found after water pressure test；
（3）No leakage after the pressure decline to working pressure。

Ⅶ、Cause and solution of common fault of fuel oil（gas）boiler

When malfunction is happened, at first should check if the precondition confirm

to the normal running or not:
1、Whether there is electricity？
2 、The fuel gas pressure of gas supply is write of wrong，and if the ball valve
is opened or not？
3、Whether there is oil in tank？
 4、All regulators such as boiler pressure regulator、water level oil level are all
adjusted correctly?
5、The volume of air and fuel gas pass through are changed or not when burning？
If confirm the obstacle are not caused by above reason，then must do functional
test related with burner.
For example burner stops by cause of fault. If we need to find fault out should
remove interlocking and connect burner. We should observe the following
working procedure. The problems probably occur should be checked and
debugged. Need to install micro ammeter and U-shaped tube barometer.
Detailed fault status、reason and solution please see below form.（Refer to
direction for use of burner ）

Cause and solution of common fault of fuel oil（gas）boiler ：

Fault condition Cause Solution
1、 Check power fuse、wire、switch,
Control red light is etc；
not bright after 2、 The power is connected to the right
power on，burner No power supply to burner position of burner junction box;
is not running 3、 If installed other thermostat should
check if is affected by it
4、 Check contact of controller and
junction box
After power on, 1、 Motor short-circuited； 1、 Repair
motor of burner can 2、 Bearing of motor can't move； 2、 Repair or change for new one
move but after a 3、 Capacitor of motor is broken； 3、 Change for new one
while fault red light 4、 Oil pump spindle can't move; 4、 Repair
on 5、 Controller is broken； 5、 Repair or change for new one

After power on ， 1、 Lack of oil；fuel gas transfer
burner motor stops；
remove，after blow 2、 Oil pump get air in it；
procedure ， fuel
oil(gas) spurt out of 3、 Magnetic valve short-circuit；
nozzle ， then burn 4、 Oil pump is broken；
stops and red fault 5、 Coupling between connection
light is bright motor and oil pump is
disconnected, oil pump can't
remove with motor；
6、 Controller or magic eye is
broken；
7、 It's two bright in combustion
room（firebrick is burn to red or
carbon residue is still burning，
magic eye is abnormal）；
8、 Switch of air pressure is in
failure、dirty，tube is blocked
1、 Inject oil into oil tank； inform fuel
gas
management department；
2、 Exhaust air of tube according to
exhaust procedure;
3、 Change for new one；
4、 Tear down or change for new
one；
5、 Change for new one；
6、 Dismounting or change for new
one；
7、 If have carbon deposit，should
open
furnace end to clean it
8、 change、clean；

1、Change for new one；

1、 Transformer for ignition is
After power on，
broken；
motor of burn 2、Change or repair；
2、 High tension cable between
starts，after blow
connection transformer and
procedure，fuel
ignition cable is broken or
oil(gas) spurt out of 3、Change insulating porcelain
loose；
nozzle，after a stick；
3、 Insulating porcelain stick of
while burn stop, red 4、Adjustment of gap is about
ignition cable is broken；
fault light on 4~5mm；
4、 The gap of fire rod is to wide or
5、The distance between
no gap
adjustment and
5、 Fire rod touched flame
flame holder；
holder；
6、Clear it；
 6、 Carbon residue is exist in fire 7、Adjustment distance of leading
rod gap； edge
7、 The distance between fire rod of nozzle is about 3~4mm
end and oil nozzle is not
suitable (too salient or 8、Change it and clear moisture；
retract)； 9、Gradually turn down fan air door
8、 Oil contains moisture； and
9、 Angle of air door is too big, try again;
It is extinguished; 10、Clean(degreasing）、Change
10、Flameout protector probe is it
dirty and failure;
1、 Controller is in failure；
1、 Change and repair；
2、 The sensitization part of magic
2、 Clean it；
Burner often stops eye is not clean；
and fault light on 3、 Burner surrounding
3、 Improve boiler surrounding,
temperature is too high that will
low down room temperature；
affect operation of video
Controller
4、 Boiler stop for repair，make
4、 Spindle gap of pump is too
rotate
close or motor gear is too tight,
spindle run freely；
they will increase the load of
motor, affect controller
operation.
5、Make sure running in rated
5、 Overload running，or water
power,
level fluctuations，when get to
adjust load equilibrium；
limit water level，will stop
boiler automatically
6、 Filter is blocked, open
6、Clean and change
magnetic valve, when fuel gas
passes through the pressure
decline.

1、 Magic eye is dirty or broken； 1、 Clean it and change for new

one；
Extinguish after 2、 Oil nozzle is dirty or broken； 2、 Clean it and change for new
ignition for 10 one；
seconds 3、 Air door is to low without air； 3、 Open wider the air door；
 4、 Pressure switch contact point is 4、 Adjust pressure switch
not in running place(air pressure correctly，
is too low） if necessary it should be
changed
1、 Gradually reduce it；
1、 The air volume of air door of
The first flame is
second fire set too big
normal, when 2、 Clean it and change for new
2、The oil nozzle of second fire is
changed to second one；
dirty and broken；
will extinguish, or
3、Oil viscosity is too high, not easy
flame flick 3、 Dilute it with diesel oil；
to atomization；
4、Distance of flame holder and
4、 Adjust to range between
nozzle is not suitable
0~10mm；
5、Oil temperature too high, make pump
vaporization, cause influent of oil
5、 Appropriately slowing down oil
transport；
temperature and readjust；
6、Oil contains moisture( volume is
6、 After changed oil, clear
not high).
moisture than try again.
1、 Oil inlet volume is not enough or 1、 Check tube valve and filter
Squeaking when oil filter is blocked； then wash filter
pump rotating 2、 Oil inlet temperature too high； 2、 Reduce the oil inlet
3、 Temperature of oil inlet is too low, temperature；
viscosity is too high. 3、 Warming or dilute it with diesel
1、 Fuse broken；
Time
2、 Add control power supply； Check and repair
controller(computer
3、 Interlocking line is not working
)stop
Black smoke get out
of chimney, and still Oil nozzle is worn and cannot
Change a oil nozzle
the same after atomization
adjust the air door
1、 Air door is to open； 1、 Turn down air door；
White smoke get 2、 Oil contains moisture（volume is 2、 Improve the oil quality；
out of chimney not high).
1、 The screw in nozzle which is for
1、 Tighten the screw again and
press atomization part is loose or
clean greasy ；
there is oil dirt in oil pipe of
When burning there atomizer which will affect oil mist
is black smoke quality；
2、 Change or repair oil pump；
2、 Oil pump is broken and output oil
pressure is too high；
3、 Check filter、inside filter of oil
3、 Water supply system is stocked
pump、oil pipe、oil tank and
by oil dirt；
clean them；
4、 Air volume of air door is two small
4、 Open air door wide；
5、 Fan blade of burner is smeary、
5、 Clean greasy of fan blade
affected output wind power