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Permit M94-0001 - MUSEUM OF FLIGHT - FOUNDATION
3 -1 0-: A ' . e .z....., . ' . „, , ,:. ''....."''''” ' ' ' • '*' .. ';?fl., • 4, -Bers' City of nth wid ' Community Development / Public Works • 6300 Southcenter Boulevard, Suite 100 • Tukwila, Washington 98188 Permit No: M94 -0001 Type: B -MECH Category: NRES UMC Edition: 1991 Center Author ed Signature MECHANICAL PERMIT Address: 9404 EAST MARGINAL WY S Location: Parcel #: 332404 -9019 Contractor License No: INSTALL THREE NATURAL GAS FIRED MODULAR BOILERS, PIPING TO CONNECT TO EXISTING HEATING SYSTEM, ADDITION OF EXPANSION TANK, AIR ELIMINATOR, CONTROLS AND FLUE PIPING. Valuation: Total Permit Fee: Date Date: i/ /.9/)q (206) 431-3670 Status: ISSUED Issued: 01/19/1994 Expires: 07/18/1994 Suite: TENANT MUSEUM OF FLIGHT FOUNDATION 9404 E MARGINAL WAY S, 07024 -00, SEATTLE WA 98108 OWNER MUSEUM OF FLIGHT FOUNDATIO 9404 E MARGINAL WAY S, 07024 -00, SEATTLE WA 98108 CONTACT FENTON KRAFT Phone: 206 764 -5700 9404 EAST MARGINAL WY S, SEATTLE, WA 981084097 r******************************************* * * ** * * * * * * * * * ** * * * ** * * * * * * * * *** Permit Description: 50,000.00 103.13 ******************************************** * * * * * * * * * * * * * * * * * * * ** * * * * * *** ** I hereby certify that I have read and examined this permit and know the same to be true and correct. All provisions of law and ordinances governing this work will be complied with, whether specified herein or not. The granting of this permit does not presume to give authority to violate or cancel the provisions of any other state or local laws regulating construction or the performance of work. I am authorized to sign for and obtain this building permit. Signature:1444 Print Name: FQ4161 kv`ai'1 Ti t l e: /7y' ttuu.cr This permit shall become null and void if the work is not commenced within 180 days from the date of issuance, or if the work is suspended or abandoned for a period of 180 days from the last inspection. DEPARTMENT .. DATE IN `:. DATE 'APPROVED R EQUIREMENTS / COMMENTS OBUILDING - initial review 1._(L{ (ROUTED)' CONSULTANT: Date Sent - Date Approved - � F IRE { &I; 2nd NOTIFICATION ' FIRE PROTECTION: U Sprinklers U Detectors ON /A FIRE DEPT. LETTER DATED: INSPECTOR: INIT: O PLANNING ZONING: BAR/LAND USE CONDITIONS? U Yes O No SCREENING REQUIRED? O Yes O No INIT: REFERENCE FILE NOS.: 0 OTHER INIT: UILDING - final review I —1 Lj ci:� UMC EDITION (year): (Cl et INIT: 0C-c-4... Q LD I NG OFFICIAL ` _ c d MEM 1 `T INIT: Or AMOUNT OWING: 1(>3 I ,� V CONTACTED . 41. II a DATE NOTIFIED (� - 9 � BY: (ini { &I; 2nd NOTIFICATION ' �Y: ► (nit. 3RD NOTIFICATION 4 Y: Init.) PLAN CHECK NUMBER REVIEW COMPLETED CITY OF TUKI Department of Community Development — Permit Center 6300 Southcenter Boulevard - #100, Tukwila, WA 98188 (206) 431 -3670 Mechanical Permit Application Trackin PROJECT NAME IA I/1,5e It/iv) 01 Pi) jAt SITE ADD ESS SUITE NO. (=ILO rv ma ro nr.ul 10 3 . DEPARTMENTAL REVIEW "X" in box indicates which departments need to review the project. INSTRUCTIONS TO STAFF • Contacts with applicants or requests for information should be summarized in writing by staff so that the status of the project may be ascertained at any time. • Plan corrections shall be completed and approved prior to sending to the next department. • Any conditions or requirements for the permit shall be noted in the Sierra system or summarized concisely in the form of a formal letter or memo, which will be attached to the permit. • Please fill out your section of the tracking chart completely. Where information requested is not applicable, so note by using "N /A ", date and initial. SITE ADDRESS SUITE # 9 Li 09 EAsr rInGlU1i WA SokT1-1 VALU OF CONSTRUCTION - $ P rZ� � CO ASSESSOR # 3 3Z ij0 .)019 PROJECT NAME/TENANT riusEU1"i or Fi)61 - Jr POIL.r;R R ' TROF-1r TYPE OF WORK: 0 New /Addition 0 Modifications 0 Repair 0 Other: DESCRIBE WORK TO BE DONE: INSTALL 3 ivAroaAL GA....,.. naen 1`1 oout.,i Z Ro1CfR s /Pri,vo Ta CCN,V C T To �x /s r,Nc / - IFAT/Al6 5 y ;n i,Anmm1T /UN OF EAPAS /0N T)WK ft!RZ E L.11"1 /N/`Ir0R CoN7R02.i AND ,LUZ P1P /NG, :. ...:::::...,,.:::.t~tAT1NQtSt1.E' :. . TYPE :.: .:.:.::. ,.:::..:::: .,. ;. ,:: ;;;•<..; >:: :,.,.:<...,: :: . ;: .......... .:..:.. .., >< < $<; ftevc 000 000 /3i., I', ,uf 3 ZIPS'g108•- y0)T CONTRACTOR yT To lq p -rFJ 1" 11Nr•0 BUILDING USE (office, warehouse, etc.) 30iL ER 'ooh NATURE OF BUSINESS: rk64 ktV M(/scum WILL THERE BE A CHANGE IN USE? 0 No 0 Yes IF YES, EXPLAIN: WILL THERE BE STORAQE OR USE OF FLAMMABLE, COMBUSTIBLE OR HAZARDOUS MATERIALS IN THE BUILDING? IF YES, EXPLAINS No 11/_1 Yes IVAt ruxn L G14 F.two [ c„i, r1z wits or/ z: lzr f JJ C. W=ok mUTnNAL col go:,r /o,V IVo 01"/ /Ek 5 TO RAG L' OR (lc L' OP FLAr14 il'L13 1`14rrR/AL,S PROPERTY OWNER /`JUSFG,--/ OF tLIGNr 1 ciu17.41r/O/v :> O AIYI U T:.. N CPT :: ; R :. #:........ PHONE 76 L1 X7017 ADDRESS 91 -1041 P,4sr fJ4R6/NNL L4 y Soon. 5 Ala LtIA ZIPS'g108•- y0)T CONTRACTOR yT To lq p -rFJ 1" 11Nr•0 PHONE ADDRESS ZIP WA. ST. CONTRACTOR'S LICENSE # EXP. DATE PI.ON<::«:> € ; : V : <> :>D.ES.CRI T :> O AIYI U T:.. N CPT :: ; R :. #:........ : > €:.. �T < : DAT.R ::P < BAS C ERM IT FEE. 1 5 UN iT S Fl: PLAN K:F C ; : » : . »::. :g: OTHi~R: > ::: CITY OF TUKWILA Department of Community Development - Building Division 6300 Southcenter Boulevard, Tukwila WA 98188 , - (206) 1 - 36 0 43 7 - L PLAN CHECK • NUMBER r) )( f APPLICATION MUST BE FILLED OUT COMPLETELY BUILDING OWNER OR AUTHORIZED AGENT CONTACT PERSON :I HEREBY CERTIFY THAT 1:MAVE gEAO AN . AND. CORRECTAND t AM SIGNATURE 1 eV1T .kv`utiL PRINT NAME Ft =NTON V KRAFT` ADDRESS5L/0 / A.s r 9' (.4y ouy:4 APPLICATION SUBMITTAL In order to ensure that your application is accepted for plan review, please make sure to fill out the application completely and follow the plan submittal checklist on the reverse side of this form. Application and plans must be complete in order to be accepted for plan review. BUILDING OWNER/AUTHORIZED AGENT It the applicant is other than the owner, registered architect/engineer, or contractor licensed by the State of Washington, a notarized letter from the property owner authorizing the agent to submit this permit application and obtain the permit will be required as part of this submittal. VALUATION OF CONSTRUCTION The valuation is for the work covered by this permit and must be filled in by the applicant. This figure is used for budget reporting purposes only and not to calculate your fees. EXPIRAT1C ;I OF PLAN REVIEW Applications for which no permit is issued within 180 days following the date of application shall expire by limitation. The Building Official may extend the time for action by the applicant for a period not exceeding 180 days upon written reque ^t by the applicant as defined in Section 304(d) of the Uniform Mechanical Code (current edition). No application shall be extended more than once. If you have any LIVED DA please contac ' T ' Th' JN C AC T �,► � . _ �� E i_ N 3 193 Jai__ 3 . 19 ';it ,) 1 SA _..� MECHAN *.rAL PERMIT APPLICATION Mechanical Fee Worksheet must also be filled out and attached to this application. THIS PE DATE APPLICATION EXPIRES FEES (for staff use only) DATE //3 u = s about our process or plan submittal requirements, ± ent of Community Development at 431-3670. 5y PHONE •7 CITY/ZIP Se 4 LA. 99)Cg ° PHONE76t.. - 70D ov, '*O..O709 Projeap; �� v, /."—... �` Type of In �,� �,_` rn Date Called; Address: 7 AA, Date C: ed: Special Instructions: Special Instructions: 2/.::/ f h zr Date Wanted: - ,/%/ y ! am.. p.m. Requester: Phone No.: 7 6 q - ' 7co Phone No.: ro act; ,-- V1,SU�v, n Type of Inspection \ I N AB — Address: y0 r rn Date Called; ��— ^>—� Special Instructions: Date Wanted: 2/.::/ f h zr a p Requester: F cN o Phone No.: 7 6 q - ' 7co = INSPECTION RECORD Retain a copy with permit CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd., #100, Tukwila, WA 98188. ❑ Approved per applicable codes. COMMENTS:. • /, , 1T�., l a c .� � .�, �--� .. �,�i..�, ty � ! r s (-ifs P S'4- -� s f 44, i' ,4; /j f )7 ;F; , A A s 107A— 4 '�` l � - t /`�y i - j , !-14' � %" I Inspector: Corrections required prior to approval. Date: M9 (206) 431 -3670 ❑ $30.00 REINSPECTION FEE REQUIRED. Prior to reinspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. SPECTION O. nspector: Raraei nin_ )tom i INSPECTION RECORD • Retain a copy with permit CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd., #100, Tukwila, WA 981 Approved per applicable codes. ❑ Corrections required prior to approval. COMMENTS: Date: 2 ❑ $30.00 REINSPECTION FEE REQUIRED. Prior to reinspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. (206) 431 -3670 1 Data: PROJECT: /J ,c CONTACTED NAME: PHONE #: /4/(1,//7 LAST RECORDED INSPECTION: � y !y NO ONE THERE - NOTICE OF VISIT LEFT ON SITE PROJECT: /J ,c .+'i . PERMIT N0: A, 9 47,,,,,.(9/ ADDRESS : I CcioLI p , /4/(1,//7 LAST RECORDED INSPECTION: � y !y x s, LEFT MESSAGE WITH: 1...7;p4 7•L, �!�,44_ ANSWERING MACHINE CITY OF TUKWILA - BUILDING DIVISION 6300 SOUTIICENTER BOULEVARD, SUITE 100 TUKWILA, WA 98188 (206) 431 -3670 PERMIT INSPECTION STATUS REPORT SHONE CALL : PHONE # ; C.0 C l `' ` 700 TIME : SITE VISIT: COMMENTS: /" �• 419 c -e 4-h5 Ci de.1.0e A LvD�GL- INSPECTORS SIGNATURE: " DATE : / /ae c.✓ fr*kk***********kk*k*******k ***** ****** ** *k*k* ********** * **kkkkk CITY OF. TUKWILA, WA TRAN$MI T . GENERA 20.63 *** hkk• kkk k * ** ******* ****kkkA***** *k*h** A*kk*A** A ** *k•kkkkk * **A* GENERA 82.50 TRANSMIT Number : 94000082 Amount: 103.13 OJ :/13/34 15:54 TOTAL 103.13. Permit No: M34•- .0001 Type: B• -MCCH MECHANICAL PERMIT CHECK 103.13 Parcel No: 3 -901.5 CHANGE 0.00 Site Address: 404 EAST MARGINAL WY .S O1/20/94 82610000 16 :16 ' Payment: Method: CHECK Notation: FENTON KRAF1' ]:nit: SRO **k******W*kkk********** **** k k*** k*** **•k* *k•* *•**** *k * *k **** Account Code Description Paid 000/345.830 PLAN CHECK NONRES 20.63 000/322.100 MECHANICAL - NONRES 82.50 Total (This Payment): 103.13. Total Fees: Total All Payments: Balance: .103.13 10,3.13• ..00 C. Address: '9404 EAST MARGINAL WY S Suite: TenAnt: MUSEUMHOF FLIGHT FOUNDATIO B-MECH Parcel #: 332404-9019 CITY OF TUKWILA Permit No: M94-0001 Status: ISSUED Applied: 01/03/1994 Issued: 01/19/1994 **********Aft,*********************44************Ig*****************4****** Permit Conditions: .....,::::73';*-- - I 1. No changes will be ma d„e, by the Arch i tect and the Tukwila ,, 1Building DT■ils)on_., 2. Plumbing permi tsicaU- obtained through tii 1 e-King County DepartTedf Public Fe.,elth: 0Plumbing will be 4 , . , , , ■ 4 , 1; ., Inspected by4,:thaf agency, 4 Including tiding all gas/p tpingv,!:$,.'1,; (296-4722).44v4 t: 'c ,0,4-5',/ ■''' S ,i. ,: e , , i 3. Electrical i,permit shall be4, obtained through the%,,Wastlingp State DIAS 1 ,. on of Labort and Industries es anda,11 elle01cal ,•••. work wlaybe by th4 \agfreicy (248-6630) .1 ' 4 . 4. All paWts, in rt.,aprirps, aki;,,approved p b lans, 1 1 maintOpeVayailable atk hal'iob site ' prior to the,,,s'tarVbf v,,,k\ - any c99.struOpon Thee docup)emt are to be ma i n t a i ne d . .,: 't?‘ ava 04 1 e i nal - aillspectOn - approval is granted. *,„,,,, .1 S. Any exposed )0 1 a tion material shall have A flame Spread Rating of 25 or leis ,1arld materl*Hsha bear °: i den ii - -,...., f i 441 on showing the f ir.,0 O 1 rating , thereof 6. All con!tru to be done 1n taqqrillOce #4 th approVed plans aWd#- remeni ;+5T':‘.,‘,Un i fprm Bui 1:dlbg Code (1991 .' * ;1 Ed ql'on) a e aliien6eb by r140 1 ngt'ol Sfiieg ‘il Wash i ngtp En , •- • -,,z-• 7 the i i .-0•••,\I = • - 1 iBui 1 d i n Code , , Unifo m Wan i ca Ve d / 19p4 \Ed i et644-, and Washington St N # t q) ir a ..,„,,,, e 1 Code (1T91 se on,,Edition,. S' ,. ;. . V i '' 1. 13 ' ---. i i. ,,,,.....__ t.,,,1 , $ 60 - 11 ''' 6 n, * s.c. 0 ,,,:21: av,i1, 4 Y a 0 ‘ -*at 4 6 0 . 4 4 44 ' M.mu, Aca Dear Fenton. The RICE Group Consulting Engineers RICE Group inoerely, Chris Wrlgh 144 Railroad Atro., Mello 212 t?acrena■. Washington OAOaf 20e/774.31129 Fax 20d/672.200e Fenton Kraft Museum of Flight 9404 E, Marginal Way South Seattle, WA 98108 RE; New Holler Room - Combustion Air p fietifioti 1 Sc� � YnatS-craoJ ax ; - 3666 - ram e Gaol, Please Coll me ,wilow you've kaej cl,awce 3o re Vie'I T hooks whuch Ft1Oh 7e1Qjohoie 7611-5700 S6 – 0709 This letter is meant to serve as documentation that the combustion air openings for the new boiler room at the above project are a designed installation complying with Sec. 607 (b) of the Uniform Mechanical Cods. The throe installed boilers are Aerco model KC - 1000, with 1,000 MBH gas Input, These boilers are (breed draft boilers designed fbr ducted (4 ") combustion air inlets. The forced draft fan provides the power to pull air directly through a 4" duct to the combustion chamber which is not possible on standard atmospheric boilers. However, a duct is not required and actually reduces the penlbimance of the boiler by making the forced draft fin work harder, Thus, all that is required to operate the boiler is a 4" diameter opening per boiler to the outside. In this case the Museum has installed (4) 18" X 16" openings with SO% free area which is far in excess of the (3) 4" diameter openings required. If you have any questions regarding this matter please do not hesitate to call. — V ?Om .13610 dalra corm's+. - Co eICts Poet -rte hex Note Awns 1 104" S•7O7 PhunI NOV 1 5 1994 Q� fit~ p p 1 . ENT (� To: Mr. Duane Griffin To: From: From: Fenton Kraft Mr. Duane Griffin Building Official City of Tukwila - Permit Center Department of Community Development Fenton Kraft. HVAC Manager Museum of Flight Foundation Project: Museum of Flight Boiler Retrofit Building Permit Number B93 -0475 IMMACOOLIROMMOVROMOZIP Re: Request for Extension of Building and Mechanical Permits Museum of Flight 9404 East Marginal Way South Seattle, WA 98108 -4097 Tel: (206) 764 -5700 Fax: (206) 764 -5707 sEcea November 5, 1994 Recently I received a letter from Shelly Bates notifying me that our permits were about to expire due to the amount of time that had passed since our last inspection. I called Shelly and she recommended that I contact you and request an extension of our permits for the boiler project. Although we are nearing completion with this project there are several items still remaining to be resolved or completed prior to being ready for the mechanical and building final inspections. During the last two weeks we have had the factory representative calibrate and test the boiler operation, obtained certification from the State licensed boiler inspector, and activated and tested the automation system. Next week System Control is scheduled to complete the installation and testing of the boiler room heat detector as part of our existing fire protection system. Once this is complete we will be ready for the fire final inspection. The following week we will call for the electrical final inspection. Among the items still outstanding are the completion of roof flashing and gutters, sealing of conduit penetrations within the museum, fabrication and installation of escutcheon plates, and the installation of a differential pressure transmitter. With the above items in mind as well as the time required by other museum projects, I anticipate that it will take a little more than a month to complete the items remaining. Thus if possible, it would be a great help if you could grant an extension of the building and mechanical permits until the end of the year. I do appreciate you're consideration of this matter and look forward to hearing from you. Sincerely, Fenton Kraft q;w.rra . ss'�rr.»F'w`�r.�:rvr.. + = 11 -4 -94 2:23pm p. 1 of 1 101 0 4 190 0 0Mm PM G�lT 1_ � c245- /O ?7 7/ � � p ✓ i''.e � p� S pe i171 / 0 I z f dl�,,r �� y � ;a t/ r / s, 7,74. /w . u .. n �l I A i [H �t•�.J Oct 03, 1994 981084097 FENTON KRAFT 9404 EAST MARGINAL WY S SEATTLE, WA RE: MUSEUM OF FLIGHT FOUNDATIO Dear Permit Holder: Our records indicate that on Nov 09, 1994 one hundred -and eighty days will have passed with no inspections having been called for under Tukwila Mechnical Permit Number M94 -0001. Unless you call for an inspection, or obtain a written extension from the Tukwila Building Official prior to that date, your above referenced permit will become null and void on Nov 09, 1994. If your project is complete please call for final inspection. If you are actively working on your project please contact our office. If you have any questions or need further information to obtain an extension on your permit please call the Tukwila Building Divison at 431 -3670. City of Tukwila Department of Community Development Rick Beeler, Director Lv Shel ie Bates /Sylvia Osby Permit Technicians Department of Community Development John W. Rants, Mayor V M To: Re: Dear Mr. Larson, Tel: 764-5700 Fax: 784 -5707 Dave Larson City of Tukwila Building Division 6300 Southcenter Blvd., # 100 Tukwila, WA 98188 From: Fenton Kraft HVAC Manager Museum of Flight 9404 East Marginal Way So. Seattle, WA 98108 -4097 Noted corm Plan Che ns and requ # M 94 -0001 ted engineering Information, First I wanted to thank you for all of your help and advice during your last inspection. I em sending two additional sheets along for your review. The first addresses the area in the basement storage area where the anchors that previously supported only ductwork were utilized for pipe support as well. I have drawn up a possible solution where two additional anchors would be installed at each pipe support bracket assembly. These anchors would be of known embedment and as supplementary supports should eliminate our concerns about the load bearing capacity of the existing anchors. The second sheet is a detail that was done by 3M and provided to me by Natkin Service (the mechanical contractor). It details fire stopping in an annular penetration involving fiberglass insulated Sch -40 steel pipe passing through a concrete or concrete block wall. This assembly is rated at two hours and thus appears to exceed the requirements (Type 2 one hour) that we discussed. Please review the above items and let me know If they are satisfactory approaches to take and if any changes or improvements would be necessary. Again thank you very much for your time and help on this project. I hope to see you soon. Sincerely, '"r onion Kraft HVAC Manager Museum of Flight June 7, 1994 RECEIVED ,j"!J 0 71994 COMMUNITY DEVELOPMENT 3 /2" MINIMUM EMBEDMENT Ii 3/8" ROD COUPLING 3/8" AL7:-.READ TWO ADDI T IONA_ AT EAC- ?PE SUPPORT ASSEMBLY NOTE: DRAWN( NOT TO SCA_E 'NSTALL TWO ADDITIONAL 3/8" PARA.BOC TYPE CONRETE M CHCRS AT EACH EXISTING ANCI -OR FLINT. CNE NEW ANCI -OR SHALL BE INSTALLED ON EACH S.DE OF EXISTING ANChOR AND SHALL BE LOCATED NOT LESS THAN j FROM EXISTING ANCHOR_ SPACING OF NEW ANCHORS SP ALL MATCH FOLE SPACING OF NEW STRUT CHANNEL LENG:rl = 14" APX. NEW SUPERSTRLT SERIES 1203 CHANNEL OR EQUI NCTE: \EW MEAL CnANP E_ SHALL BE E \TRAP ?ED EXISTING ALL T -READ RCD / NUT ASSEMBLY OR SHALL BE 4 MIEC- A MCALLY CONNECTED TO - -E EX:S ING MEAL CI-L &\h 4" SCI - -43 STEEL P PES IRS ALLED AS PART 0= BOILER RETROFT PROJEC EXISTIt. G 3/5" ALL THREAD EXIS " -NG SI-EET MEAL SJ ?P.Y DUCT _X.S NG ANCHOR 3CLT r TYPE AND LEi \ AS OF 6/5/14. j I • �•::, -5rPI i t* aIu.Ni,t.o< LLIj n•i a i r IC SY4k.T_�? AL YCATIOILQ .�rF _ An.S Pd.:S /..J 1. Drawing No.: 5300- IPW10.02 ' 2. System Yustificadon: UL Through - Penetration Piresiop System No. 91, Configuration A, per • ASTM E 814 (ANSI/UL 1479) Fire Test. 3. Assembly: Minimum thickness of solid concrete wall Is 4 1/2 in. or may be constructed of LIG classified blocky. 4. Ratings F - 2 hr„ '1' -1 1/2 hr. 5. Penetrating Item(s): Nominal 4 -in. diameter (or smaller) Sch. 40 (or heavier) steel pipe with nominal 2 in. thick glass fiber pipe Insulation. 1. Install the firestop symmetrically on both sides of the wall assembly, 2. Minimutn annular space requirement Is 3/4 in. Maximum annular space allowable is 17/8 In, 3. Recess a nominal 1 in. thickness of tightly packed micteral wool sating, 1 In from the wall surface. 4, Fill the annular space around the insulated pipe with a minimum 2 -in. depth of 3M Fire Barrier CP 25 Caulk. 3300•IPW10.02 Page 2 of 2 . STEEL PIPE. 2" MAXIMUM GLASS FIBER INSULATION. • UL SYSTEM 1 91(A) All /Ht/set"l . stinks% It rrnsUen, sal 1 /$UP DATI hleeda\ssalIMu sestets* halls halls s it asset es 11111 vigil. is Wino Is Walk 1 Ilsvner, Anse the uIdl11Me el u11 NI saNlblle ere bjsn• 1 eselrsl, I I shill net lie tbh Io rs ' lump, .,I sr ssstq "entld, fa,YlUs Seem Ile "a el RN 1111 tid erlel Sr er ekT 111& WI OMNI, O ISM be Is 'whet as, of evr Mdse. Iws/ le It &Whe, 31111/ St Paul IREST. P run MAX i IA II Dwo, I.D. 4 -01 -r: 5300 IPW 10.02 $UPERI DI'9 err PI MINERAL -WOOL PACKING. 4 I/2" SOLID CONCRETE WALL OR UL CLASSIFIED BLOCK WALL, IIf1V. OH. Lrn t)" J, 3/4 MIN. 10 1-7/8 MAX. ANNULAR SPACE, E WA PENETRATION, fIRESTOP INSULATED STEEL PIPE THROUGH A CONCRETE WALL CP 250 CAULK 2 NOUN 11A1NlQ sew t . Ll $ , T" DEPTH 3M FIRE BARRIER CP 25N\S CAULK. I:• MUSEUM OF FLIGHT Project: Museum of Flight Boiler Retrofit To: City of Tukwila Building Department Re: Mechanical Permit Application The Museum of Flight will be acting as the general contractor and primary mechanical contractor of this project. The purchasing and installation of all major equipment such as boilers, boiler controller, expansion tank, circulating pump, and controls linking the boiler controller to the museums existing energy management system shall be done by the Museum of Flight staff. A mechanical subcontractor with a current Washington State contractors license will be selected to assist with the installation of piping, pipe supports, valves, and pipe insulation. Please let us know if any further information or documentation is required. Sincerely, 9404 East Marginal Way South • Seattle, Washington • 98108 January 18, 1994 Fenton Kraft HVAC Manager Museum of Flight RECEIVED CITY. OF TUKWILA JAN 1 9 1994, PIRMIT CENTER . RE C KC -1000 Features • Natural Gas Fired • 14:1 Turndown Ratio • Direct Vent or Conventional Flue Capabilities • ASME 150 PSIG Working Pressure Certified • U/L Listed, FM Approved, ASME Coded • U/L Listed for Alcove Installation on Combustible Flooring KC-1000 Specifications BTU Input 1,000,000 BTU /Hrt Net Output @ full input 860,000- 915,000 BTU /Hr * ASME Working Pressure 150 PSIG Electrical Requirement 120/1/60 20 Amp Gas Requirements 8.5" W.C. Minimum @ Full Load 14" W.C. Maximum Flue Size 6" Diameter Water Connections 4" Flanged 150 lb. ANSI Gas Connection 1- 1 /4 "NPT FILE C OPY .MODEL KC -1000 GFB PRODUCT SPECIFICATION AERCO KC Gas Fired Hot Water Boiler System The AERCO KC Hot Water Boiler is a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, it re- lates energy Input directly to fluctuating system load. The boiler can be used singly or in modular arrangements for inherent standby with minimum space requirements. Venting flexibility permits installation without normal restrictions. The advanced electronics of each boiler module offer selectable modes of operation. The options available Include: Constant Temperature Internal Setpoint Indoor /Outdoor Reset 4.20ma Linear Signal Response AERCO Boiler Management System Integration AERCO Combination Domestic Water /Boiler Plant Regardless of the mode of operation, the load tracking capability of every unit delivers the ultimate in energy control through energy input modulation with a 14:1 ratio while meeting all load demands. With condensing capability, the KC Boiler is ideally suited for modern low temperature as well as conventional heating systems. Because of the compact design with direct or chimney venting, the KC Boller system is applicable to either new construction or retrofit application with the same excellent results. Efficiency, reliability, and longevity make the KC Boiler System a true step for- ward in heating system design. • Quiet Operation throughout Firing Range • Internal Low Water Cutoff and Dual Over Temperature Protection • Compact Space Efficient Design • Single or Modular Applications • Precise Temperature Control +/- 2F • Optional Sealed Combustion *Output is dependent upon return water temp. and tiring rate— tUp to 2000' Altitude. see efficiency curves on reverse. Minimum Water Flow 25 GPM Maximum Water Flow 150 GPM Water Pressure Drop 0.23 Ft. @ 100 GPM Water Volume 23 Gallons Control Range 50F to 220F Standard Listings & Approvals U /L, FM, ASME Optional Approval IRI Weight, Installed 1200 lbs. Cw• F -GOO. o pt 0 3 0 0 pow at GFB -1 CITY OF TUKWILA APPROVED J A 1 4 1994 t i C' Modules Model Mbh input Mbh Output Length Depth Height Weight Remote Signal ' / (a) (b) (b) (c) e s 4 -20mo Signal 20 One (1) KC -1000 1000mbh 860mbh- 915mbh 1'10" 4'9" 6'8" 1200lbs. Two (2) KC- 1000 -2 2000mbh 1720mbh- 1830mbh 5'10" 4'9" 6'8" 24001bs. Three (3) KC-1000-3 3000mbh 2580mbh- 2745mbh 9'8" 4'9" 6'8" 36001bs. Four (4) KC- 1000 -4 4000mbh 3440mbh- 3660mbh 13'6" 4'9" 6'8" 4800Ibs. Five (5) KC- 1000.5 5000mbh 4300mbh- 4575mbh 17'4" 4'9" 6'8" 6000lbs. Six (6) KC- 1000 -6 6000mbh 5160mbh- 5490mbh 21'2" 4'9" 6'8" 72001bs. Seven(7) KC- 1000 -7 7000mbh 6020mbh- 6405mbh 25' 4'9" 6'8" 8400lbs• Eight (8) KC- 1000.8 8000mbh 6880mbh- 7320mbh 28'10" 4'9" 6'8" 96001bs. Constant 220F point s•tpo nt 50F Temp Setpoint Indoor 220E Supply Temp 70F /Outdoor Reset / / / / / i /j 1''' 0 Load : 100 70F Outdoor OF Temperature 4 - 20mo 220E 50F Remote Signal ' / Boiler Management System BMS ra a 1 e s 4 -20mo Signal 20 ,'0 CO Dimensions KC -1000 Boiler 09 ALL DINEN91GN5 AND SECS DINLNSIWS ARE Su6JCCT TO CHANGE CCR11rIrn WANINGS ARE AVAILASLC W KA/MST SROVN ARC IN INCHES RRC SURE RCL Cf VALVE AC SERVICE CONNECTION ® b 77 I/A OVERALL NE WT1 68 1/! 69 -7/• r TA 1/� NP1 AIR INLET \ y /R I.D IMLC 105[ S 1N0C1 C 45CNSATC GRAIN ' DRAIN VALVE Aerco KC - WOO Boiler Basic Dimensions Ratings and Dimensions Efficiency Curves 102 100 98 96 6 94 . 92 6 90 88 86 84 82 80 50 100% FRE Represented By: 70 90 110 130 150 170 190 RETURN WATER TEMPERATURE PERCENT FIRE 76% FIRE AV0 26 ! 50X l � - VATCA IWTLCI �• - 1500 riot VATCR 110[1 / CGNTRq 4 l T r--- -- 35 (a) Style to be Determined by Individual Application Requirement. o• r Overall Length Typical Modular Boiler Dimensions (KC- 1000 -3) (b) Alti ude below 2,000'. Apply Altitude Correction Factor above 2,000'. (c) Ou put dependent upon application -see efficiency curves. Programmable Modes of Operation HEAT EXCHANGERS • WATER HEATERS • BOILERS CONTROL VALVES • STEAM GENERATORS AERCO HOT WATER SYSTEMS AERCO INTERNATIONAI IM( • 1 s PARIS AVE.. PO. BOX'128 • NORTHVALE. N.J. 07847-0128 ARC ✓Powerful Main Mode Selections ✓Powerful Internal Programmable Software • ✓Completely Operator Controlled & Responsive ✓Full Information LCD Display ✓Controls up to Eight KC Series Boilers ✓ "Bumpless" Energy Transfer MODEL 168 PRODUCT SPECIFICATION BMS -1 AERCO KC Gas Fired Hot Water Boiler Management System C ✓Boiler Plant AFUE Equivalent over 95% ✓Maximizes Efficiency of KC Boiler Modules ✓Easy Installation & Automatic Operation ✓Complete Control of Auxiliary Equipment A Complete Control System ... - For the Most Efficient Boiler Operation Attainable!! 0 0 8 Ei AERCO DOILER MA AGEMEN bows, N e•. err Mw. Mrw Term, 1 w.p S. .r weer Y f711D ♦AS HDDL LL4 'or Irn/lw 4M .bN N,..tw. b Crop run .rr N.— rro YT .. . _ [tl-,. CAM, Now w S. T..r - ww,r CMq -N. Irrr fir•. / f °�.W. M TwF (New ) Pa.. wn OM-CI E Noble id. HDR TEMP AIR TEMP LOAD SYS MT TEMP SET POINT REF TEMP HOR 'HIGH OMIT PROP BAND CONF�G The AERCO Boiler Management System Model 168 is a flex- ible control center designed to stage and modulate AERCO KC style boilers. A single Model 168 BMS panel gives total control and indication of a modular boiler plant of up to eight KC style units. Utilizing advanced Pulse Width Modulation with PID logic, the Model 168 maximizes the condensing ability and efficiency of each boiler module and regulates the output of the boiler plant with precise accuracy. A boiler plant with + / -2 °F header temperature variation is assured under normal load conditions. Standard functions of the Model 168 include equalization of module run time and con- tinual monitoring of module operation. Staging can be ac- complished either sequentially or in parallel operation. With user programmable modes of operation, the Model 168 al- Main Mode Selections • External Setpoint — A change in the Auxiliary Sensor Condition results in a proportionate change in Header Temperature — a function of the Adjustable Reset Ratio (.3- 3.0:1). Typical Applications: Indoor /Outdoor Reset Hydronic Heating Process Application. Snow Melting • internal Setpoint — Delivers Constant Supply Water Tem- perature at setpoints of 50 °- 220 °F. Typical Applications: Water Source Heat Pump Domestic Water Generation Supplementing Heat Recovery Equipment Swimming Pool Heating • 4.20ma Signal — Header Temperature responds Linearly to an External 4 -20ma Control Signal Typical Applications: Computer Controlled Building Management Industrial Process Greenhouse Applications woe wr ...Tnw .c..nTm.«t w. 0 0 • Boiler Plant AFUE Equivalent over 95% • Powerful Main Mode Selections • Powerful Internal Programmable Software • Completely Operator Controlled & Responsive • Full Information LCD Display • Maximizes Efficiency of KC Boiler Modules • Easy Installation & Automatic Operation lows easy changes of plant performance In the field. The Model 168 panel is a rugged control designed for easy installation and operation. The advanced electronic features of the BMS system allow it to be easily integrated to building management systems. The Model 168 can take building ref- erence temperatures to allow a shift in output of the boiler plant. Setback can easily be accomplished with a simple ex- ternal time clock. Easy installation is made with low voltage twisted wires between the panel and boiler modules. Fault Alarm contacts, automatic system start, two interlock circuits, and the ability to start an auxiliary piece of equipment at both start and 100% load integrate all functions around the boiler • plant into one reliable control center. Bumpless Energy Transfer When modules are added or deleted, the energy delivered is automatically adjusted to prevent fluctuations in the header temperature. This 'Bumpless Transfer' maximizes the effi- ciency of the individual modules and the total system. The boilers are brought on as illustrated in the chart below. Typical 3 Module Boiler Plant 100% Staging Sequence 75% 50% 33% 25X 7% 0 Mod #1&2 Mod )1,2,3 Mod #1 0 10% 33% 50% 75% Total •Heating Load 100% THE AERCO BOILER MANAGEMENT SYSTEM MODEL 168 Our UNIQUE DESIGN provides these Features and Benefits: • Application Flexibility —Three different configurations are selectable in the field to provide application versatility to meet the needs of any closed loop system. The BMS con- troller allows the user to configure the BMS to produce Boiler Plant performance in conjunction with all ancillary equipment and Building Management controls. • Continuous Communication —Using Pulse Width Modula- tion the BMS control continually sends information to each one of the KC modules in operation and receives informa- tion from sensors in the supply header, outdoor air, or other inputs. Eliminating external electrical 'noise', the re- sponse to changes In operating conditions or loads Is in- stantaneous for maximum performance. The ultimate ben- efit is that the BMS runs the plant at optimum efficiency, modulating boiler units to their individual and system max- imum performance. • Accuracy —The BMS control system uses PID (Propor- tional +Integral +Derivative) control algorithm to provide a dynamic response to all changes in plant operation. Header temperatures as well as percentage of module input are precisely controlled, with virtually no overshoot or short cycling of equipment. A header temperature of +/- 2°F is assured during continual plant operation. • Building Reference Temperature Inputs —The BMS con- trol system can accept reference temperatures either di- rect from a sensor or from an external 4 -20ma signal. This allows for adjustments in the operation of the entire plant to compensate for varying conditions. The BMS responds to the needs of the system. • Sequential or Parallel Operation — Modular Boiler Plant operation can be selected to either sequence modules on or to run all modules in parallel, as the application re- quires. Mode of operation can be changed by simple key- board selection. • Bumpless Transfer Operation —The BMS system, when in the sequential mode of staging boiler modules, can bring additional modules online at adjustable percentage of input. The user can select at what boiler input percentage modules will be either added or deleted to support the se- lected main program configuration. This allows for the maximum benefit from the individual module's ability to condense and run at maximum efficiency. • Automatic System Start—The BMS 168 System has auto- matic system start contacts that can be selected to close between 32 °F and 100 °F. This eliminates the need for the plant operator to turn auxiliary equipment on and off. • Programmable Maximum & Building Reference Tempera- tures— Boilers can be clamped at a maximum high tem- perature. The reference temperature (desired building temp.) can be adjusted to provide a minimum header tem- perature. These features allow a wide range of boiler water temperature responses to outside air changes re- sulting in maximum comfort. • Equalizes Module Runtime —The panel sequences mod- ules on a First On -First Off basis. This automatically equal- izes the running time of all modules in the boiler plant. It keeps all modules in operating condition and does not overtax any one unit. • Random Lead Module —The BMS 168 has a random start of the lead boiler module to help equalize runtime between modules — to insure all modules are operative and avail- able for operation as required. • Automatic Allowance for Maintenance —The BMS Model 168 system continuously monitors the number of modules that are available for operation. When modules are elimi- nated for maintenance, the panel will automatically operate the next module as needed. In case of malfunction, a lack of response from any unit to the control system signal will automatically be compensated for as the BMS brings the next available module on to satisfy the demand. • Time Delay Between Module Start —A fixed, thirty- second time delay between module starts allows for a smooth en- ergy input without spikes in electrical, gas, or venting con- ditions. • Two Interlock Circuits —The BMS contains two standard interlock circuits that must be completed from external dry contacts before plant operation begins. These can be used to monitor pumps, combustion air dampers, or other equipment. • Adjustable Off Set — Through simple time clock contacts, the BMS control system can off set the boiler output pro- gram as desired. Whether for night setback, daily setback periods, or some other controlling factor, the BMS shifts the plant output an adjustable shift from the original setpoint, either to higher or lower temperature. • 100% Control of Auxiliary Equipment— Contacts are avail- able within the BMS to operate auxiliary equipment when the boiler plant is at 100% load. This can easily be used to control an auxiliary input (boiler), notify a building man- agement system of full load condition, or close outside air dampers if desired. Contacts turn -off is adjustable through the keyboard to any percentage of the boiler plant input. • Fault Alarm Surveillance —The BMS Control system con- tinually monitors its own sensors and interlock circuits for fault, and provides an alarm closure contact in the event of a problem. It can easily be used to notify a remote station of boiler plant operation difficulties. • Expandable —For Boiler plants larger than eight modules, Model 168 Control Panels can be easily inter- connected to operate up to 32 modules. Each individual BMS panel con- tinues to modulate and operate each boiler module with the same level of accuracy as with one panel. • Simple Installation —The BMS Control System operates on standard 115/1/60 power supply. Uses only 22ga twisted pair wires between the individual modules for both control and monitoring functions. Lead wiring can be up to 200 ft away from the panel. • Rugged & Reliable —The BMS Control System is encased In a NEMA 13 grade enclosure and can operate in an am- bient temperature of 55 °C (131°F). Built to withstand the normal conditions of a commercial boiler room, the BMS is rugged and reliable in operation. • Power Off Memory—By using non volatile memory, pro- grams are retained through shut down of over two years. Batteries are not required. • i n 4 I zme f YTB 9+ t ale s ms In; c�— D ifis tt+ �� s ll n- Y1B ctr 5 511111-.1 4'144140w © OW Ot- oz-ti .+ 01H5 U z1N! •tI ct SR ht • liras E r S1S • sr nw 111 c4 E • NW W } 4 Q 1 1 1 w • REQUIRED RECOMMENDED OPTIONAL MAIN MODE SELECTION EXTERNAL SET POINT © OA (© or ©) QH OE OF OG 10 INTERNAL SET POINT © OH ®000 4 to 20 mA SIGNAL ©O QH OE 0 ©O TYPICAL INSTALLATION OUTSIDE AIR AA TEMPERATURE SENSOR BOILER OUTPUTS JP2 BOILERS 3 THROUGH 8 HEADER © SENSOR A£REO C>CD SPECIFICATIONS: Dimensions 10" X 11.6" X 4.7" Weight 12 lbs. Electrical Requirements 115/1/60 1AMP Enclosure NEMA13 For custom programming of BMS Model 168 contact AERCO Engineering Department • Dry contacts —see AERCO wiring diagrams for details. Represented By: DOIL£R MANAGEMENT JP3 JP4 C BUILDING REFERENCE TEMPERATURE SENSOR lel PWR INPUT FAULT ALARM O INTERLOCKS O 4-20 mA [] REMOTE INPUT ❑1 AIRCO MAT WATER SYSTEM SERVICE SWITCH 115/1 /60 1AMP L SYSTEM START Accessories Available: • Supply Header Sensor Kit • Outdoor Air Sensor Kit • Building Reference Sensor • RS -232 -C Computer Interface • Combination Control Panel AUXILIARY BOILER PUMP COMBUSTION AIR DAMPERS HEAT EXCHANGERS • WATER HEATERS • BOILERS HEAT RECLAMATION SYSTEMS • CONTROL VALVES • STEAM GENERATORS / / / / / / / / / / 2' / (.6) MIN. / y //4 1 -6' (.452) MIN. 1 . NM CI 4' -9° ■ • 1' -10` — (.55.9) 2' (MIN.) l' -6 (.452) MIN. r 17° (43.18) MIN. REQ. HEAD CLEARANCE 6' -8' (2.032) ALL DIMENSIONS AND SIZES SHOWN ARE IN FEET AND INCHES. < ) ARE IN METERS. D AERCO hrrrizminay.44 rn►c NORTHVALE. NJ 07647 KC SERIES GAS FIRED BOILER MINIMUM SPACE REQUIREMENTS DVN. BYALDATEVA rEV. sCALEI. SUj, SD -B -427 A C►nca./Q - nt� 0 MATERIALS OF CONSTRUCTION PRESSURE VESSEL 1/4' CARTON STEEL SHET1. 5A-53 GRADE B .024' COPPER LDER AIM 1-12 1/4' CARIOM STEEL HEADS, SA -515 C I(IUSTAIN MR COPPER lam TUL LI-m Cu-ll UPPER FEATS S1 -42 CU-1Q LOVER WA 53 -402 COPPER NICKEL WALT. SI -402 TEAT EXCHANGER DESIGN STANDARDS >K MO th WORK ING PRE igi TEST SIDE 150 ' 200 225 APPEL( WEIGHT (LIS) DRY WET 1000 1200 ASIE CODE CERTIFICATMN STAMP I H 22 (50.8) (55.88) i 29 (74) 1 1 -1/4 (3.175) NPT GAS INLET f•-- -- 47 (11938) PRESSURE RELIEF VALVE SHELL CAP AC SERVICE CONNECTION 3/4 CONDUIT 120 VAC SINGLE PHASE 20 Anp. V /GRDIND 49 (124.46) 52 -1/2 (133.35) 57 (144.78) 0 13 62) 3/4 (1.90) DIA. 15 6 (15.24) I.D. FLUE CONNECTION 17 (43.18) 71 -5/8 (181.93) 80 (2032) (OVERALL HEIGHT) 78 -1/2 (19939) 70- 3/16 0179.86) 3 (762) DIA. AIR INLET \ `5 /B I.D. MALE HOSE CONDENSATE DRAIN SIDE AIR SENSOR CDNN. \ `1 C2.541 DRAIN VALVE MOTES. 1) DRAIN VALVE AND RELIEF VALVE ARE INCLUDED SEPARATELY IN SHIPMENT. 2) A 1/4' PER FOOT FLUE PITCH DAM TOWARDS TIE HEATER MUST DE MAINTAINED TO ALLOW THE FLOW CT ANY CONDENSATE FIRMED IN THE FLUE TO FLOW TO THE DRAIN. MODEL KC STYLE I+-- 35 (88.9) 1111) I'll 4 (1016) - 1501 FLG'D HOT WATER OUTLET 4 (10.16) - 1501 FLG'D COLD WATER INLET REMOTE ALARM L CONTROL CONNECTION 3/4 CONDUIT 23 (58.42) r 30 076.20) ALL DIMENSIONS AND c17EN' SHOWN ARE IN INCHES. C ) ARE IN CENTDETERS. 14E1?CO i1Fa7Rnur701.24 DM NORTHVALE, NJ 07647 KC SERIES GAS FIRED BOILER DIMENSIONAL DRAWING OWN. BY.DATE SCALER!. SIZEI AP —B -568 rA C*1Ca1SL'1M. APPD.Ak L Y S v 0 4` 150 FLG'D RETURN INLET GAS SUPPLY 4" 150 FLG'D SUPPLY &1TCJ HEATING SYSTEM RETURN LEGEND 0 COMB. BALANCING /STOP VALVE STOP VALVE CHECK VALVE PRESSURE /TEMP. GAUGE UNION Y STRAINER / / � I) DIRT TRAP REMOTE ALARM AND CONTROL CONNECTIONS (REFERENCE OF -1060) TYPICAL LOCATION OF MAKE —UP. ELIMINATION AND EXPANSION COMPONENTS APPLICATION NOTES: U A 1/4" PER FOOT FLUE PITCH BACK TOWARDS THE BOILER MUST BE MAINTAINS TO 6 . 3 ALLOV ANY CONDENSATE FORMED IN THE FLUE TO FLOW TO THE DRAIN. 2) FOR ACTUAL SIZES AND LOCATIONS IT PIPING AND OTHER COtdIECTIONS TO THE BOILER, SEE DIMENSIONAL DRAWING. 3) DELL DRAIN VALVE AND CONDENSATE HOSE SFUULD BE ARRANGED TO PERMIT THE FLUIDS TO DRAIN FREELY, BY GRAVITY, TO A CONVENIENT FLOOR DRAIN. RELIEF VALVE SHOULD BE PIPED VERTICALLY TO A HEIGHT 18" ABOVE FEDOR. 4) ALL (.) ITEMS ARE INCLUDED SEPARATELY IN SHIPMENT. 5) THIS IS A TYPICAL INSTALLATION DRAWING. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED. 6) LOCATE WATER INLET AND OUTLET FITTINGS (Le. UNIONS, ELBOWS, ETC.) AND ALL PIPING A MINIMUM OF 6" FROM BOILER FITTINGS TO PREVENT INTERFERENCE WITH REMOVAL OF BOILER PAELS AND COVERS. LOCATE GAS PRESSURE REGULATOR A MINIMUM OF 2' FROM BOILER. 7) SEE PRODUCT SPECIFICATION FOR PRESSURE DRIPS AT VARIOUS FUNS. � 4tAitizo q. DIRT TRAP AUTOMATIC AV WENS KR se WATER SUPPLY PRE 5JRE REDUCING Flu VALVE 1 -1/4" MANUAL SNUTDFT 31f GAS SUPPLY SEE Cif-1030 FOR GAS PIPING INSTALLATION UNE SIZE BYPASS--"' RACKFUX PREVDRER " ED. AERCO VENT ELIEF VALVE IIE TAP FOR OXYGEN ANALYZER / 4 4.444 1 =0 4 44g C ONNECT 5/8" I.D. HOSE TO CONDENSATE DRAIN ELL DRAIN VALVE �E SYS131 PUMP IR INLET LECTRIC POWER CONNECTION (120 VAC. 60 Hz, If, 20 Anp.) HEATING SYSTEM PLY INTAIN A REGULATED 8.5" V.C. PRESSURE AT MAXIMUM BTU/H INPUT (1" V.C. REGULATION MAXIMUM) AMATORY GAS PRESSURE REGULATOR (SUPPLIED BY OTHERS) KC SERIES GAS FIRED BOILER MULTIPLE UNITS IN PARALLEL AERCO iivrzmurwoxw4 lire NORTHVALE, NJ 07647 OWN. BYDATE REV. SCALEM. SIZEl I SD -B -439 B CHKn SI'Il APPri��C� General AERCO KC Series gas fired potable water heaters and boilers are modulating input devices that require an adequate volume and pressure of gas for proper opera- tion. Whether natural gas or propane, the gas require- ments of the equipment must be properly met to fire reliably. Designers and installers must adhere to the recommendations of AERCO and of the local authorities having jurisdiction. A thorough understanding and knowledge of these recommendations is required for a successful design and installation. Gas Train Components AERCO heaters come with a standard UL /FM approved gas train, factory tested and fired, with a minimum number of modular components. These components have been designed to operate at extremely high com- bustion and seasonal efficiencies by closely controlling both the volume and air /gas mixture to the burner. The major internal gas train components are: • SAFETY SHUT OFF VALVE (SSOV) —an electro- hydraulic double seated gas valve, containing proof of closure switch, is utilized to stop fuel from flowing into the gas train of the heater. This is a 100% tight shutoff device that has a visible window indicator of valve position. Reliable and a standard industry component, this valve is factory piped with a gas pressure switch on the inlet side of the valve. The gas pressure switch monitors the manifold pressure for minimum supply conditions. • GAS DIFFERENTIAL REGULATOR —a self- contained diaphragm type regulator is used to maintain a con- stant gas pressure differential across the air /fuel valve. This regulator, adjusted at startup only, is key to the proper, stable operation of the heater. • AIR /FUEL VALVE — controls both volume and proper air /gas mixture to the burner through two separate valve body /seat portions within a single housing and with a common shaft. The gas portion of the valve is a slide port type valve with linear proportion -to- position characteristics. The aluminum valve body and machined gas plug are closely matched to allow pre- cise gas flow as the ports of the seat are opened or closed. The driver of the valve is a precision stepping motor at the top of the shaft providing continuous positioning from full input to minimum fire. The opera- tion of the valve controls the volume and mixture of air and fuel in perfect proportion throughout the entire modulation from minimum to maximum. The air /fuel valve also contains two proof of position switches. • NOZZLE -MIX BURNER — provides the actual point of air /fuel contact and combustion into the cylindrical combustion /heat exchanger. Fabricated from stain- Gas Fired Equipment Guide Gas Components and Supply Design Guide GF -1030 less steel and Inconel, the burner is stable throughout the input range of the heater, and holds both the spark ignitor and flame rod for the combustion super- vision system. Easily removable from the heater, the burner porting and vane design bring the air and fuel together with high velocities for precise mixing and controlled combustion. Gas Pressure Requirements Though it is a modulating burner, every AERCO KC Series heater requires a stable pressure. For natural gas or propane, the inlet supply to the heater must be 8.5" W.C. min. when firing at maximum input. A Minimum Supply Gas Pressure Switch in each manifold prevents the heater from operating without sufficient pressure. Maximum gas pressure for natural gas and propane heaters is 14" W.C. Static gas pressure (when the units are not firing) may vary, but actual gas pressure should be measured when the unit is in operation with a ma- nometer at the 1 /8" NPT port provided in the inlet manifold. In a multiple heater installation, gas pressure should initially be set for a single heater in operation, and then additional heaters should be staged on, to be certain gas pressures do not droop more than 1 " W.C., but never below the minimum allowable pressure. Low gas pressures must be adjusted for proper operation. A fluctuating gas pressure can be indicative of either faulty fuel supply regulator operation or undersized gas supply piping. An external pressure regulator should be installed on each KC heater. The regulator must be installed with no less than 2 feet of pipe between the regulator and heater gas inlet. Regulator discharge range must be able to maintain 8.5" W.C. for natural gas or propane. For gas supply pressures exceeding 14" W.C., a lockup type regulator is required. Gas regulators are self- contained with diaphragm vent holes to allow diaphragms to change position. These vents normally require escape piping to the outside from the heater location. The differential pressure regulator in the gas train is factory piped and does not require any vent piping. Individual Heater Supply Gas Lines Every heater is factory supplied with a 1 -1 /4" NPT plug type gas cock Intended to be installed close to the Gas Train Inlet for use as a service valve. It also provides a positive shut -off to be used during gas pipe testing to isolate the heater. This cock may be installed on either vertical or horizontal piping into the heater. Refer to Diagram 1 for typical location of the gas shutoff to each heater. Gas piping should contain ground unions for removal of the gas piping to the heater for maintenance or service as required. Gas piping should never obstruct the removal of the side panels of the heater, and should not be supported from the heater itself. Gas piping should be supported properly from the floor or overhead as the installation allows. Custom Gas Trains Gas Piping Diagram 1 Typical Pipe Connection to an Individual Heater, T —f /4' LAB PRESS PEGUTAIOR - \ (SUPPLIED BY DINERS) I •t, MANUAL SHUTOFF• MANUAL, SHUTOFF (ALTERNATE: LOCAfO ) GAS SUnc; Drip legs are recommended on each heater to prevent any dirt, pipe chips, or debris from entering the heater Gas Train Inlet. When multiple heaters are installed, some utilities and local codes require a full size dirt leg on the gas main as well as on the individual units. The bottom of the gas drip leg should be removable without disassembling gas piping. The weight of the gas pipe should not be supported from the bottom of the drip leg. Some utilities, insurance carriers, and industrial cus- tomers have special requirement gas components on high input devices beyond that normally supplied with AERCO KC heaters. Secondary shutoffs, high or low pressure operators, and external regulators are typical of the requirements of gas utilities. It is mandatory that a designer or installer comply with these requirements. AERCO assumes no liability when these requirements are not satisfied for any location or installation. Contact your local gas utility for their specific requirements before installing AERCO equipment. Special gas trains for IRI and other standards are available. Please contact the AERCO factory with your specific requirements during design. All gas piping and components must comply with NFPA local codes, and utility requirement's minimum. Only gas approved fittings, valves, or pipe should be utilized. Standard industry practice for gas piping is Schedule 40 iron pipe and fittings. All high and low gas pressure piping systems must comply with local utility and building codes. Assembled piping should be clean of all debris, pipe chips, or foreign material to prevent any from entering the KC Series heater gas train. Piping should be tested as prescribed in NFPA. Equipment should be isolated before testing any piping system over the allowable pressure. DO NOT EXCEED 1/2 PSIG on the inlet side of the KC Heater at any time. Gas Supply Main Sizing Gas pipe sizing, for either a single or multiple heater installation, shall be sized to provide no more than a 0.3" W.C. drop from the source to the heater location. The fuel supplier or utility should be consulted to confirm that sufficient volume and normal pressure is provided to the building at the discharge side of the gas meter or supply pipe. For existing installations with gas equip- ment, gas pressure should be measured with a manom- eter to be certain sufficient pressure is available. Before sizing gas piping, a survey of all connected gas devices should be made. Gas piping supplying more than one gas device must be able to handle the total connected input within the allowable gas pressure drop. As well, the allowable minimum and maximum gas pressure for each device should be considered. Whenever the min- imum and maximum gas pressures vary between de- vices, gas pressure regulators at each unit should be Installed to allow regulation at any individual unit: Gas pressure must never exceed the maximum allowable of any connected device. The total length of gas piping as well as fitting pressure drop should be considered when sizing gas piping. Total equivalent length should be calculated from the meter or source location to the last heater connected. Gas piping tables 6.1, 6.2, 6.3, 6.4 from NFPA 54 should be used as a minimum. ( See Tables pages 3 and 4.) Gas pipe should be selected on a total equivalent length from the appropriate table. The gas volume for cfh flow will be the input divided by the calorific value of the fuel to be supplied. Gas Header Sizing Main supply gas pipe sizing should be developed for the total plant. Heater gas manifold piping should be sized based on the volume requirements and lengths between heaters and the fuel main. Multiple heater manifold sizing (Diagram 2) indicates the proper sizing for units placed on the factory standard 50" centers with 1 -1 /4" takeoffs for each unit. Header sizes can be either full size or stepped in size as units are connected. A typical gas piping header diagram for a 5- Module KC Heater Plant is illustrated in Diagram 3. Diagram 2 Multiple Heater Manifold Chart KC SERIES HEATER GAS HEADER SIZING No. of Heaters 1 2 3 4 5 6 7 8 Schedule 40 Iron Pipe" 1 2" 3" 4" 4" 4" 6" 6" 'Based on Natural Gas .60 specific gravity, 1000 BTU /Ft Propane Gas 1.6 specific gravity, 2520 BTU /Ft A single header gas manifold regulator should not be used. Each KC Series heater should have its own indi- vidual regulator. Header should be located above or behind heaters. Gas piping should not be installed di- rectly over top or front of any part of heater. Clearances for maintenance are required. Gas Piping Tables The following pipe and vent sizing tables have been taken from the National Fire Protection Association Article 54 (NFPA 54), 1984. Nominal Iron Pipe Internal Size Diameter (Inches) (Inches) Pipe Size of Schedule 40 Internal Standard Pipe Diameter (Inches) (Inches) G nn TABLE 6.1 Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0.5 Psig or Less and a Pressure Drop of 0.3 Inch Water Column (Based on a 0.60 Specific Gravity Gas) Length of Pipe, Feet 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1 1.380 1050 1 1.610 1600 1100 2 2.067 3050 2100 1650 1450 1270 1150 1050 — 21 2.469 4800 3300 2700 2300 2000 1850 1700 1600 1500 1400 1250 1130 1050 — 3 3.068 8500 5900 4700 4100 3600 3250 3000 2800 2600 2500 2200 2000 1850 1700 4 4.026 17500 12000 9700 8300 7400 6800 6200 5800 5400 5100 4500 4100 3800 3500 TABLE 6.2 Pipe Sizing Table for Pressures Under 1 Pound Approximate Capacity of Pipes of Different Diameters and Lengths in Cubic Feet per Hour With Pressure Drop of 0.3 Inch Water Column and 0.6 Specific Gravity 2.00 2.067 1275 — — 2.50 2.469 2033 1397 1122 3,00 3.068 3594 2470 1983 3.50 3.548 5262 3616 2904 4,00 4.026 7330 5038 4046 5.00 5.047 13261 9114 7319 50 100 150 200 250 300 400 500 nee n4 A711 I A - reo 44 tier Diagram 3 Typical Multiple Heater Manifold Construction MUN (Mt LEG 1 -1 / *' 01S PRESS. REGULATOR WIN ShUTOPT GAS SUPPLY 1 -1 /!' WNUAL SNUTOfT •. fW.UL SNUTOfT / (ALTERINTE LOU1/011) CAS SUPPLY PR/ POCTR Total Equivalent Length of Pipe in Feet 1698 2485 3462 6264 4 04 4 1505 1363 1167 1034 2203 1996 1708 1514 3069 2780 2380 2109 5552 5030 4305 3816 onen 04 •e &e94 c"••Te Pipe Size of Schedule 40 Internal Standard Pipe Diameter (Inches) (Inches) ITI 12/90 10M TABLE 6.3 Pipe Sizing Table for 5 Pounds Pressure Capacity of Pipes of Different Diameters and Lengths in Cubic Feet per Hour for an Initial Pressure of 5.0 Psig With a 10 Percent Pressure Drop and a Gas of 0.6 Specific Gravity Total Equivalent Length of Pipe in Feet 50 100 150 200 250 300 400 500 1000 1500 2000 1.25 1.380 4084 2807 2254 1929 1710 1549 1326 1175 1.50 1.610 6120 4206 3378 2891 2562 2321 1987 1761 1210 - - 2.00 2.067 11786 8101 6505 5567 4934 4471 3827 3391 2331 1872 1602 2.50 2.469 18785 12911 10368 8874 7865 7126 6099 5405 3715 2983 2553 3.00 3.068 33209 22824 18329 15687 13903 12597 10782 9556 6568 5274 4514 3.50 3.548 48623 33418 26836 22968 20356 18444 15786 13991 9616 7722 6609 4.00 4.026 67736 46555 37385 31997 28358 25694 21991 19490 13396 10757 9207 5.00 5.047 122544 84224 67635 57887 51304 46485 39785 35261 24235 19461 16656 6.00 6.065 198427 136378 109516 93732 83073 75270 64421 57095 39241 31512 26970 TABLE 6.4 Fitting Equivalent Length Pressure Drop in Feet HEAT EXCHANGERS • WATER HEATERS • BOILERS HEAT RECLAMATION SYSTEMS • CONTROL VALVES • STEAM GENERATORS 1ERC HOT WATER SYSTEMS AERCO INTERNATIONAL, INC. • 159 PARIS AVE, • NORTHVALE, N.J, 07647 (201) 768 -2400 • TELEX 135450 • FAX 201 -768 -7789 Screwed Fittings 90° Welding Elbows Welding Tees Valves (Screwed, Flanged, or Welded) Nominal 180° Pipe Close Size, Return R/d R/d Inches 45 °eII 90 °e1l Bends Tees = 1 = 11/2 Forged Miter Gate Globe Angle 1 1.61 3.45 7.66 6.90 1.84 1.38 5.17 6.90 0.81 38.3 19.1 11/2 1.88 4.02 8.95 8.04 2.14 1.61 6.04 8.04 0.94 44.7 22.4 2 2.41 5.17 11.5 10.3 2.76 2.07 7.75 10.3 1.21 57.4 28.7 21/2 2.88 6.16 13.7 12.3 3.29 2.47 9.25 12.3 1.44 68.5 34,3 3 3.58 7.67 17.1 15.3 4.09 3.07 11.5 15.3 1.79 85.2 42.6 4 4.70 10.1 22.4 20.2 5.37 4.03 15.1 20.2 2.35 112.0 56.0 5 5.88 12.6 28.0 25.2 6.72 5.05 18.9 25.2 2.94 140.0 70.0 6 7.07 15.2 33.8 30.4 8.09 6.07 22.8 30.4 3.54 168.0 84.1 Pipe Size of Schedule 40 Internal Standard Pipe Diameter (Inches) (Inches) ITI 12/90 10M TABLE 6.3 Pipe Sizing Table for 5 Pounds Pressure Capacity of Pipes of Different Diameters and Lengths in Cubic Feet per Hour for an Initial Pressure of 5.0 Psig With a 10 Percent Pressure Drop and a Gas of 0.6 Specific Gravity Total Equivalent Length of Pipe in Feet 50 100 150 200 250 300 400 500 1000 1500 2000 1.25 1.380 4084 2807 2254 1929 1710 1549 1326 1175 1.50 1.610 6120 4206 3378 2891 2562 2321 1987 1761 1210 - - 2.00 2.067 11786 8101 6505 5567 4934 4471 3827 3391 2331 1872 1602 2.50 2.469 18785 12911 10368 8874 7865 7126 6099 5405 3715 2983 2553 3.00 3.068 33209 22824 18329 15687 13903 12597 10782 9556 6568 5274 4514 3.50 3.548 48623 33418 26836 22968 20356 18444 15786 13991 9616 7722 6609 4.00 4.026 67736 46555 37385 31997 28358 25694 21991 19490 13396 10757 9207 5.00 5.047 122544 84224 67635 57887 51304 46485 39785 35261 24235 19461 16656 6.00 6.065 198427 136378 109516 93732 83073 75270 64421 57095 39241 31512 26970 TABLE 6.4 Fitting Equivalent Length Pressure Drop in Feet HEAT EXCHANGERS • WATER HEATERS • BOILERS HEAT RECLAMATION SYSTEMS • CONTROL VALVES • STEAM GENERATORS 1ERC HOT WATER SYSTEMS AERCO INTERNATIONAL, INC. • 159 PARIS AVE, • NORTHVALE, N.J, 07647 (201) 768 -2400 • TELEX 135450 • FAX 201 -768 -7789 Post -It'" brand fax transmittal memo 7671 10 of pages I. 1 2.. To f" /V , [' "-., tcwor From t t.... tO f a AAA Do. JVL 4e'?1Nf.0 ocAt' Co. T7-Le 1 D FihoAO M Nora. FAX # 0 .0 i . . . . . . . . 7 . 4 5 , . . . . _ 1 : 1 1 9 . 9 NOV 10 '93 05:50PM AERCO INT'L AIRCO Grassi 1.!■ 1 nnn I...,ai"... F ne nCm-iUQ UVU gas- TII "teo mouure is a high effi ciencyforced draft hydronictdomestio water heating unit with unique venting capabilities. Venting options, such as horizontal and vertical discharges, direct vent, and rnanifolded vent breeching, typically exceed those of other combustion equipment. The KC1000 is designed to provide extremely high thermal efficiencies and opti- mum temperature control under widely varying condi- tions. The design of the flue gas vent and combustion air system must maintain these objectives. The high efficiency is achieved through airtfuel modula- tion and the release of energy due to condensing of the moisture in the combustion products. Each KC unit is fitted with a condensate removal trap to discharge the condensate. Figure 1 Indicates the air inlet, vent con- nection and the condensate connection. Condensation is possible in the exhaust vent system and it must be designed to accommodate tfie moisture. This bulletin allows for broad design latitude while meet - ing the objectives of safely. longevity and optimum per- formance. MATERIALS AND APPROVALS The KC 1000 is a Category III and IV appliance and requires special attention to exhaust venting and com- bustion air details, The exhaust vent MUST be Ul. Listed for use with Category III and IV appliances: operating temperatures of up to 480" F, positive pressure, con- densing flue gas service. Currently, UL Listed vents of AL20 -4C stainless steel must be used with the KC 1000, Proper clearances to combustibles must be maintained per UL and the vent manufacturer. UL and NFPA 54 (National Fuel Gas Code ANSI Z223.1) guidelines are often the basis for state and local codes. AERCO's recommendations follow the guidelines of these recognized agencies unless there are codes applicable to the installation site that are more stringent. The venting and combustion air systems must meet all applicable code requirements, 1 P. 1/12 TECHNICAL BULLETIN and Cornbustion Air Guide GF -1 050 Code Required Vent Terminations: The guidelines below should be followed to comply with AERCO, UL, and NFPA S4 (National Fuel Gas Code ANSI 2223.1) recommendations and regulations: • Vent terminations should be at least 4 feet below, 1 foot above or 4 feet horizontally from any window, door or gravity air inlet of a building and should extend beyond the outside face of the wall by a minimum of 6 in. The bottom of the vent terminal should be at least 12 In. above both finished grade and any snow accu- mulation point. • The vent termination should be least 3 feet above any forced air building inlet within 10 feet. • Vents should not, terminate over public walkways or over an areawhere condensate or vapor could create a nuisance or be detrimental to the operation of regu- lators, meters, or other equipment. • Discharges should not be in wind blocked areas, cor- ners or directly behind vegetation. , • Wall and roof penetrations should follow all applicable codes and the vent manufacturer's instructions. The vent should never be installed at less than the required clearances to combustible materials per UL, NFPA, and local codes, "Double -wall" or "thimble" assemblies are required when penetrating combus- tible walls and roots. Combustion Air from Outside the Building The room should have two permanent louvered open- ings to the outdoors. Eaoh opening must have a mini- mum free area of 1 square in. for each 4000 Btuh of total input rating of all equipment in the space. When the air is supplied to the room via ducts, two ducts must be used. Vertical ducts and openings must have a minimum free area of 1 square inch for each 4000 Btuh of total equipment Input. Horizontal ducts and openings must have a minimum free area of 1 square in. for each 2000 Btuh of total input. The free area of the openings must take into account restrictions from louvers and screens. The louver manufacturer should be consulted for the percentage of free area available. Consult NFPA 54 if the free area is not known. Louvers should be fixed lathe open position or interlocked with the equipment so that they open automatically during equipment operation. The combustion air openings, whether ducted or open directly to the outdoors, should be located on the same wall and positioned so that one is high in the room and one low to assure good ventilation. Openings should never be placed directly in front of piping or other equip- ment that might freeze during cold weather. Combustion Air from within the Building Where combustion air is to be used from within the building, air must be provided into the equipment room via two per- manent openings to an interior room. Each opening must have a minimum free area of 1 square in. for each 1000 Bfuh of the total equipment input. The openings should be located on the same wall, one high and one low. There must be sufficient air infiltration into the building. Direct Vent/Sealed Combustion When room air Is insufficient or not suitable for combus- tion, the KC 1000 is approved for direct vent installation, i.e. draw all combustion air from the outdoors via a metal or PVC duct connected between the KC unit(s) and the outdoors. An Inlet air (sealed combustion) adapter is available as an accessory from AERCO. The minimum sealed combustion air duct size is b in. diameter for each KC unit. In many Instances, the combustion air duct can be manifolded for multiple unit applications. The length and restriction of the seated combustion duct has a direct effect on the size, length and restriction of the discharge venting. The direct vent air intake should be located at least 3 feet below any vent termination within 10 feet. / — P.2/12 ', NOV 10 '93 05:51PM AERCO INT'L Exhaust Vent and Combustion Air Systems The KC 1000 offers several venting and combustion air options, and although the application parameters may vary, there are some basic similarities for all systems. Tables 1 and 2 cover the pressure drop of most vent and duct fittings and sizes. The vent exit and air duct entrance losses are also included to allow fora correctly designed system. It should be noted that flow and vent or duct diameter have the most significant effect on overall system pressure drop. When using fittings or terminations not listed in the tables, consult the manufacturer for actual pressure drop values. If rectan- gular duct is to be used, consult Table 5 to select a round diameter duct that has the identical pressure drop per length of rectangular duct. The pressure drop values used in this bulletin are in equivalent feet of 6 in, dia. exhaust vent. Note that 1 eq. it of 8 in. dia. vent is equal to 0.00581 in. W.C. Flue gases have a lower density (lighter) than air and will rise, creating "gross natural draft". Gross natural draft is created when the flue gases exit the vent at some eleva- tion above the KC 1000. The amount of draft is depen- dent upon the height of the stack and the difference between the flue gas and the surrounding air tempera- tures (densities). Gross natural draft,values for stacks of various heights for the KC unit are located in Table 3, The draft values are based on a sea level installation site. Adding the gross natural draft (negative) to the vent and air system pressure drop (positive) determines if the total system will be positive pressure or negative pres- sure ('net natural draft"). As with most combustion equipment, negative pressure (net natural draft) sys- tems should be treated differently from positive pressure systems when the discharge vents are manifolded. Note that sidewall vent terminations, as well as some vertical terminations, are positive pressure systems. Table 4 indicates correction factors that should be applied to installations that are above sea level. The correction factors must be applied to both natural draft and pressure drops of vent and air duct The pressure drop through vents and combustion air ducts will increase with higher elevations, while the natural draft will decrease. Although individual discharge vents are recommended, in many instances it may be more practical to manifold multiple units. When multiple units are connected via a manifolded vent, the operation of a given unit can be affected by the others if the venting or combustion air system is not designed properly. Properly designed common vent and air supply systems can be installed 0 7 3 P.3/12 which will prevent "operational interaction" between units. The design parameters for marifotded vent sys- tems will differ from those of individually vented sys- tems. Manifolded vent design must assure that all flue gases flow towards the vent terminatkin at all firing rates by maintaining less pressure In the common vent than at the air Inlets of the KC 1000$. Exhaust Vent Systems • Positive Pressure- Positive pressure in the vent at all firing rates. Side wall and vertical discharges at an elevation less than 30 feet above the AERCO's exhaust manifold typically fall Into this category. • Natural Draft - Negative Pressure- If the vent termina- tion is 30 feet or more above the AERCO exhaust manifold, a reasonable "natural draft" may be gener- ated. The "natural draft" is dependent on the stack height, flue gas and ambient air temperatures, site elevation (atmospheric pressure) and the vent's resis- tance and exit loss. Combustion Air Supply Systems • Room Air- Air is supplied into the KC 1000 area via louvers or a make -up fan. Sealed Combustion: Sealed combustion air duct between the outdoors and the KC blower. 4 Forced Sealed Combustion: A supplemental air sup- ply fan installed In the sealed combustion duct. Select the fan to provide 250 SCFM per connected KC unit and maintain 17 to 43 equivalent feet (0.1 to 0.25 In. W.C.) of static pressure above the combined system pressure drop of all units when operated at their maxi- mum capacity. individually Vented Systems: Systems.wtth individual vents may be used with any of the combustion air systems listed above and in Figure 2. The maximum combined pressure drop of the vent and com- bustion air system must not exceed 140 equivalent feet of length. Calculate the pressure drop for the exhaust vent separately from the combustion air duct pressure drop. Divide the vent pressure drop by the altitude correction factor (CF), Table 5, to correct for installations above sea level. Determine the natural draft, if any, from Table 4 and multiply It by the altitude CF. Add the attitude NOV 10 '93 05:52PM AERCO INT'L comb. air total drop: 1131.55 ft 1 System OK; less than 140 equivalent feet. corrected vent pressure drop (positive) and the draft (negative) to get the total vent pressure drop. Add the total vent pressure drop to the altitude corrected com- bustion air duct pressure drop. The total system pres- sure drop must not exceed 140 equivalent feet. Example: Calculate max. pressure drop for an installation at 450 feet above sea level with a 6 in. dia. exhaust vent with 2-90° elbows, 2.45° elbows, 40 feet of horizontal run and 10 feet of vertical run and a 8 in. dia. sealed combus- tion air duct with 2 -90° elbows and 50 feet of run. 6 in. dia. exhaust vent pressure drop: 2 -90° elbows: 2 x 15 30 ft 2 -45° elbows: 2 x 8 z 16 ft 50 feet total run: 50 x 1 = 50 ft (40 horiz. + 10 vert.) exit loss: 1 x 22.03 22.03 ft vent drop subtotal: = 118.03 ft altitude correction: 118.03 = 120.19 ft 0.982 CF natural draft -10 feet: -4.68 altitude correction: 0.982CF -4.60 ft x (-4.68) vent total drop: _ 1 tt 8 in. dia. combo, air duct pressure drop: 2 -90° elbows: 2 x 2.82 5.64 ft 50 feet total run: 50 x 0.14 = 7 ft entrance toss: 1 x 3.06 = 3.06 It comb air drop subtotal: 15.7 ft altitude correction: 15. = 15.99 ft 0.982 CF 15.99 It I S ystem total pressure drop: =vent drop+alr duct drop = 115.56 + 15.99 For systems utilizing manifolded sealed combustion ductwork, use the longest length of common duct and the individual branch to the furthest KC air inlet for calcu- lating the pressure drop. 4 P.4/12 MANIF"OLDED SEALED C0MBU5tt0N FIGURE 2 INDIVIDUAL VENTS NOV 10 '93 05:52PM AERCO INT'L Common Vent Breeching (Manifolded) - Net Natural Draft Vent and combustion air systems that have a combined system pressure that is negative or neutral fall into this category. Do not Inducts the 6 in. die, branches between the common vent and each KC 1000 if each branch is equal in pressure drop (same length and number of fit- tings). The maximum combined pressure of the vent and the air system must be in the range of 0.0 to negative ( -) 43 equivalent feet (0.0 to -0.25 in. W.C.). Manitoided vent systems with pressures greater than 0.0 eq. feet must be treated as Positive Pressure systems. Net natural draft systems can use room air or sealed combustion (individ- ual or manifolded) air supply systems. See Figure 3. Add the vent pressure drop (altitude corrected), the com- bustion air pressure drop (altitude corrected) and the natural draft (altitude corrected). The total must be in the neutral to negative pressure range of 0.0 to -43 eq. feet. Example; Calculate system pressure drop for an installa- tion at 1000 feet above sea level. Two KC units are installed with a common 12 in. dia. vent breeching. The 12 In. dia. breeching runs 12 feet horizontally (includes distance between units), makes a 90' bend ant runs vertically 37 feet to termination. 6 in dia. vent, 6 feet long, connects into the 12 In. breeching above from each KC 1000. The KC units draw air from within the room. 12 in. dia exhaust vent pressure drop: 1-90' elbow: 1 x 3.75 49 feet total run: 49 x 0.12 (12 horiz. + 37 vert.) exit loss: vent drop subtotal: altitude correction: 6 in. dia. exhaust vent: same press. drop natural draft-12 in, vent -37 feet vert. altitude correction: total vent pressure: No combustion air drop. Total system pressure 15.14 = 0.964 CF 0.964x = (- 16.85) System OK; less than 0 equivalent feet. 3.75 It 6.88 ft = 5.51 ft 15.14 ft 1 15.71 ft I Oft 1 -16.24 ft I I -0.53 ft I = vent drop +air duct drop = I -0.63 eq. feet' 5 P.5/12 MAKE -UP LOUVERS AIR I INDIVIDUAL SEALED COMBUSTION 1 COMMON VENT 1I MANIFOLDED SEALED COMBUSTION OR AIR MR FIGURE 3 COMMON VENT — NATURAL DRAFT NOV 10 '93 05:53f'M AMC() INT'L Common Vent Breeching (Manifolded) Positive Pressure When the common vent breeching is positive pressure, forced sealed combusion air ducting is necessary. The supplemental combustion air supply fan can draw air directly from outdoors, or from within the room. See Figure 4. If room air is used, the louvers or make up air ducts to the outdoors must be sized, as described earlier. Add the altitude corrected pressure drops of the venting and combusion air system. If a supplemental air supply fan is required, it should deliver 250 SCFM per KC unit at 17 to 43 equivalent feet (0.1 to 0.25 In W.C.) above the combined system pressure drop. The static pressure of the fan should not exceed 140 eq feet (0.81 in. W.C.). The combined pressure drop of the combusion air and venting system (without the fan) should not exceed 123 eq feet (140 eq ft -17eq ft 123 eq ft). Combustion Air Fan Static Pressure Equivalents static pressure (in. W.C.) 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 static pressure (eq. feet) 17.21 34.42 51.63 68,84 86.04 103.25 120.46 137.67 The combustion air supply fan should be operated at all times when any manifolded unit is firing. Installation of a in. back draft in. damper in parallel with the fan to assure that air would be available if the fan is inoperative. Example: Site elevation is 1100 feet. Three KC units installed with a 12 in. die, vent with 25 feet of horizontal run and 7 feet of vertical run and 3 -90° elbows. A 6 in. dia. vent section rises 8 feet above the units and enters the breech- ing at a 45° angle. The combustion air duct is 10 in. dia. with 2 90° elbows and 25 feet of run. 8 in. duct, 8 feel long and 1 -90° elbow connect the manifolded air duct with each unit. Calculate the required fan size. 6 12 in. die. exhaust vent pressure drop: 3 -90° elbow: 32 feet total run: (25 horiz. + 7 vert.) exit loss: vent drop subtotal: altitude correction: 6 in. dia. exhaust vent: 5 feet of run natural draft-12 in. and 6 in. vent -12 feet vert. altitude correction: total vent pressure drop: 3 x 8.43 = 32 x 0.28= 46.64 = 0.964CF 5x1 -5.61 ft 0.964x (5.81) _ 10 in. dia. combustion air duct pressure drop: 2 -90° elbows: 25 feet total run: entrance loss: vent drop subtotal: altitude correction: 2x10.72 25x0.43 = 43.48 = 0.964CF dia. combustion air duct: 8 feet of run: 8 x 0.58 = 1 -90° elbow: 1 x 8.87 = comb. air subtotal: altitude correction: 13,31 = 0.964CF total comb. air duct drop: _ Combined vent and air duct drop: = Determine fan static pressure required: Combustion air fan should deliver 750 SCFM at 0.65 to 0.81 in. W.C. 25.29 ft 8.96 ft 12.39 it 46.64 ft P.6/12 48.38 ft I -5 ft I 1 -5.41 ft 47.97 ft 21.44 ft 10.75 ft 11.29 It 43.48 ft 45.10 ft 4.64 ft 8.67 ft 13.31 ft 1 13.81 ft 58.91 ft f 104.01ft I add 17 to 43 eq. ft. to 104.01 Do not exceed 140 equivalent feet. = 121.01 to 140 eq. ft. 0.65 to 0.81 in. W.C. • NOV 10 '93 05:53PM AoRRCCO INT'L Vent and Combustion Air System Design Requirements • The minimum exhaust vent and combustion air duct size 6 in. die. The exhaust manifold connection is designed to accommodate a 6 In. vent. A 6 In. x 3 In. reducer, shown in Figure 5, is included with the inlet air adapter to connect to 6 in. dia. galvanized, alumi- num or PVC sealed combustion air duct. • A 1/2 In. dia. combustion test hole should be provided in each unit's vent starter section about 12 in. to 16 in. above the exhaust manifold connection. A 6 in. length of straight vent should be provided downstream of this hole. See Figure 6. A means to securely seal the hole should be provided to prevent leakage following any testing. , ROOM AIR OUTSIDE AIR FIGURE 4 COMMON VENT -POSE 1VE PRESSURE 7 P.7/12 ' FIGURE 5 SEALED COMBUSTION AIR CONNECTION RECOMMENDED NOV 10 '93 05:54PM AERCO IN1'L a Connections to common vent breeching or duct work must be accomplished with a 45° elbow in the diectkin of flow in the main breeching. °Pees" should not be used to accomplish these connections. See Figure 7. FIGURE 7 RECOM MENDED • Interconnection of groups of units must never be accomplished via a 'Yee ". As shown in Figure 8, change the direction with one of the mains and then connect the second, 3 diameters (common section diameter) from this tum, via a 45° connection. • Figure 9 ilivatrateti the preferable like this "transition vent section" when making the 45° connection into a main. The main can also remain at one diameter, as long as it Is sized for the total number of units vented, 4� 8 P.8/10 and the 45• branch connection is retained. Use of the preferred °transition' assembly will reduce the overall system pressure drop. • The vent system should always be pitched up at least 1/4 In. per 1 foot of run towards the vent termination. This will allow condensate to drain back to the unit to be disposed of. Low spots in the vent must be avoided. Periodic inspection should be performed to assure for correct drainage. See Figure 10. • As shown in Figure 10, an "inspection end cap" should be provided on the end of the vent or duct main. • KC 1000 vents should not be interconnected to those of other manufacturers' equipment. .-) No. KO units Duct Dl.. 00 61nt9ht RuniFt. lea. N.1 90° abow (Da, rI.) 45 • Bbow Qi4 ILl &M. Lew (ott. 0.1 1 6 .58 8.67 4.62 9.68 e .14 2.82 1.5 3.06 10 .05 1.19 .64 1.25 2 8 .56 1128 6.01 12.25 10 .19 4.77 2.54 5.02 12 .07 2.07 .03 2.42 14 .03 1.14 .61 1.31 16 .02 .68 .36 .77 3 10 .43 10.72 5.72 11.29 12 .16 4.65 2.46 5.45 14 .07 2.57 1.37 2.94 16 .04 1.54 .92 1.72 4 12 .28 8.27 4.41 9.68 14 .13 4.57 2.43 5.23 16 .07 2.73 1.46 3.06 16 .04 1.61 .88 1.91 5 2.47 .2 20 3.8 8.16 1.66 .11 22 2.28 4.79 18 .06 2.51 1.34 2.99 20 .D3 . 1.68 .88 1.96 ' 6 16 .15 6.15 3.28 6.89 4 .39 .08 Mil I 1.93 4.9 3.1 06 20 1.29 2.82 3.25 .03 1.68 = 1.93 2.27 .02 1.13 .6 .8 t.336 7 4.22 .11 4.92 2.62 5.86 20 .07 3.28 1.75 3.84 22 .04 226 122 2.62 24 .03 1.02 8 20 .09 - 22.2 8 6.02 8.43 22 .05 2.98 1.69 24 .03 2.02 1.07 2.42 Nu. KO unlu Vont Dlo. (T) Stnlght DuniFL 1egr.1 90 13bow Oa, 1,) 1 45° Dtbaw (ha 8 rail Lou (t4. R.) 22.03 1 6 1 8 25 5.07 2.71 6.97 10 .09 2.19 1.17 2.86 2 10 .35 8.75 4.67 11.42 12 .12 3.75 2 5.51 14 .06 2.08 1.12 2.97 16 .03 1.27 .68 1.74 3 12 .28 8.43 4.5 1229 14 .13 4.71 2.51 6.89 16 .07 2.85 1.52 3.92 18 .04 1.66 .89 2.45 4 14 .24 8.38 4.47 11.89 16 .13 5.07 227 6.97 1D .07 2.98 1.58 4.35 20 .04 1.99 1.06 2.86 5 16 .2 7.92 4.22 10.89 18 .1 4.82 2.47 6.8 20 .06 3.11 1.66 4.48 22 .04 2.17 1.16 3.05 6 18 .15 6.66 3.55 9.79 6.43 20 .09 4.48 2.39 22 .06 3.12 1.67 4 .39 24 .04 2.11 1.12 3.1 7 20 .12 6.09 3.25 8.75 22 .08 4.25 2.27 5.97 24 .05 2.87 1.53 4.22 8 20 .16 7.96 4.24 11.42 22 .1 5.55 2.96 _ 7.8 24 .06 3.75 2 5.51 NO 1 10 ' 93 05:54PM AERCO INT'L • Horizontal vent and ductwork should be sup- ported every six feet of length. Vertical vent and duct- work should be supported to prevent esooessive weight on the horizontal runs. The exhaust manifold and inlet air adapter should never be utilized as a weight support- ing element. The supports should be arranged and the overall layout designed to assure that stresses on the vent and combustion air connections are minimized. • The vents and combustion air ducts may be insulated per the vent manufacturer's instructions and local codes. CONDENSATE REMOVAL: The exhaust vent system must be pitched up away from Table 1 Discharge Venting Pressure Drop P.9/12 the KC unit towards the vent termination a minimum of 1/4 in. per foot of length. This will allow condensate to drain back to the unit to be disposed. Low spots in the venting where condensate may collect should be avoided. The condensate trap assembly is located directly below the exhaust manifold. Plastic hose should be connected to the trap assembly and run to drain. Care should be taken to avoid kinks and from raising the tube above the trap assembly. Condensate should flow freely to drain. Do not hard pipe the condensate to drain, as the trap assem- bly needs to be removed for maintenance and service. if the condensate must be lifted above the trap assembly to a drain, it should be drained Into a sump, From there a pump can lift the condensate away. Table 2 Sealed Combustion Alr Duct Pressure Drop Stack Haight Draft (eq. ft.) 0 Mack Haight Dell (eq. II.) (111 1000 0.964 (ro 0.947 8 -3.73 2500 44 -20.57 10 -4.68 0.880 46 -21.51 12 - 5.61 5000 48 -22.46 14 -6.56 0.801 50 -23.39 18 -7.49 7500 55 -25.73 18 -8.42 0.729 60 -28.07 20 -9.36 10000 65 -30.41 22 -10.29 70 -32.75 24 -11.22 75 -35.09 26 -12,17 80 -37.43 28 - 13.10 85 , -39.75 30 - 14.03 90 -42.09 32 - 14.96 95 -44.43 34 -16.9 100 -46.77 36 -16.85 105 -49.11 38 -17.18 110 -51.45 40 -18.71 116 -53.79 42 -19.64 _ 120 -56.48 alle Elevation on Altitude Corm Hon Feclor tCpl 0 1 500 0.982 1000 0.964 1500 0.947 2000 ,_ 0.930 2500 0.913 3000 0.896 3500 0.880 4000 0.864 4500 0.848 5000 0.832 5500 0.817 6000 0.801 6500 0.787 7000 0.772 7500 0.758 8000 0.743 8500 0.729 9000 0.715 9500 0.701 10000 0.688 _ NOV 10 '93 05:55PM AERCO INT'L Table 3 Gross Natural Draft Table 4 Altitude Correction Adjacent Side of Duct )n. Side of Rectangular Duat (in.) 6 8 10 12 14 16 18 20 22 24 6 6.6 26.2 8 7.6 8.7 10 8.4 9.8 10.9 12 9.1 10,7 12 13.1 14 9.8.4 11.5 12.9 14.2 15.3 16 10.4 12.2 13.7 15.1 16.4 17.5 18 11 12.9 14.5 16 17.3 18.5 19.7 20 11.5 13.5 15.2 16.8 18.2 19.5 20.7 21.9 22 12 14.1 15.9 16.5 17.6 18.3 19.1 19.9 20.4 21.3 21.7 22.7 22.9 23.9 24 25.1 24 12.4 14.6 Table 6 Round Duct of Identical Pressure Drop to Rectangular Duct NOY 10 '93 ° " 05 :561:11 AERCO INT'L CORRECTIONS TO GF -1050 AERCO Gas Fired KC1000 Venting and Combustion Guide PLEASE INSERT THIS SHEET IN YOUR (iF- 14151 DOCUMENT AND REFER TO THE FOLLOWING CORRECTIONS, WHICH ARE llll;lllJC;!l713!) AND IN 173LICS. Page 4: Under example in left column: Example: Calculate max. pressure drop for an installation at 450 feet above sea level with a 6" dia. exhaust vent with 2 -90° elbows. 2.45 elbows, 40 feet of horizontal run and 10 feel of vertical run and a 8" dia. sealed combustion air duct with 240° elbows and 50 feet of run. 8" dia, exhaust vent pressure drop: 2 - 90° elbows: 2 x 15 2 - 45° elbows: 2 x 8 50 feet total run : 50 x 1 (40 hortz. + 10 vert,) exit loss. vent drop subtotal: altitude correction: natural draft - 10 feet: altitude correction: vent total drop: 1 x 22.03 = 22.03 ft _118.03 0.982 - 4.88 ft 0.982CF x ( -4.68) 30 ft = 16ft 50 ft = 118.03 ft 120,19 ft -d 80 ft = L11549_1 Page 6: Example at bottom of left column, the peconq sentence: Example: Site elevation is 1100 feet. Three KC units Installed with a 12" dia. vent with 25 feet of horizontal run and 7 feet of ,vertical run and 3.90° elbows. A 6" dia vent section rises 5 ' above the units and enters the breeching at a 45° angle. The combustion air duct 1s 10" die with 2 -90 elbows and 25 feet of run. 8" duct, 8 feet long and 140 elbow connect the manifotded air duct with each unit. Calculate the required fen size. Page 6: Formulas in right column: 12" dia. exhaust vent pressure droo: 3 - 90° elbows: 3 x 8.43 32 feet total run : 32 x 0.28 (25 hofiz. + 7 vert.) exit loss: vent drop subtotal: altitude correction: 46.54 = 0.964CF 8" dia. extigust vent: 5 feet ofrun 5x1 patt pI draft - 12" and 6" vent - 12 feet vert. altitude correction: total vent pressure dro ll: ombined vent and ajr duct droo: Determine fan static pressure required: 0.964 x = (- 5.61) Combugtlori air fan should deliver 75n sum At 0_70 tn, ( R1 in 25.29 ft = 8.98 ft = - 5.81 ft _ P.12'12 12.39 ft 46.64 ft 48.38 ft I 5ft 1 I - 5.41 ft 4797 ft add 17 to 43 eq. ft to 108.88 Do not exceed 140 equivalent feet. = 123.88 to 140 eq. ft. = 0.7010 0.81 in W.C. 240/1/60 Power Supply ITI 9 ian FiM H� Emergency Switch * • At Appropriate Location as required by Local Codes •• Break Glass Station, Firestat, etc. ••• Contactor Rating determined by Total Plant Load To Individual KC Heater Service Switch , Diagram 5 Multiple KC Heater Sub - Distribution Schematic Secondary Safety ** Control Circuit Fuse 0 Ground AEI Main Power Contactor * ** 115v Coil Sub — Distribution / Panel o Individual 20A Circuit Breakers HEAT EXCHANGERS • WATER HEATERS • BOILERS HEAT RECLAMATION SYSTEMS • CONTROL VALVES • STEAM GENERATORS HOT WATER SYSTEMS AERCO INTERNATIONAL, INC. • 159 PARIS AVE. • NORTHVALE, N.J. 07647 /91171 7Aa_9d1111 . Tel CV •Oe ArA _ •wV •n• see 77nn To Individual KC Heater Service Switch Multiple Unit Wiring Whenever multiple units are installed within the same mechanical spaces, electrical code requirements call for a single electrical shutoff for emergency use. There are many different configurations that can be used to comply with common devices. AERCO provides the following as samples of how this can be accomplished, but it is the responsibility of the electrical designer to comply with local codes and regulations affecting an individual installa- tion: Diagram 4 Multiple KC Unit Protected Circuit Schematic 115/1/60 N' Control Circuit H Emergency Switch • At Appropriate Location as required by Local Codes • ' Break Class Station, Firestat, etc. 615 Individual 115/1/60 20A Protected Circuits (One /Heater) Secondary Safety ** Control Circuit Fuse { Multiple Pole Single Throw Main Contactor 115v Coil 20A /pole minimum To Service Switch of Each Individual KC Heater Sub - Distribution Panel When power is supplied directly for the complete water heating or boiler plant from a larger power supply trans- former or building panel, a sub - distribution panel with individual protection for smaller circuits can be utilized. Diagram 5 illustrates this concept. A Main Power Con- Multiple Protected Circuits Depending on the available electrical service, an individual 20a electrical circuit may be allocated for each individual heater from an electrical supply panel. This is commonly used with installations of up to four heaters. For a common safety circuit, a multiple pole contactor can be used to provide power to the modules. Diagram 4 demonstrates how this is arranged with a separate 115v control circuit. Contactor pole ratings must be at least 20a per pole. Other electrical devices may be required other than those shown to comply with local requirements. tactor of sufficient current carrying capability must be used to break power to the entire sub - panel. This arrange- ment is normal for 3 or more units, or wherever individually protected circuits are not available for the individual heaters. Mi L:l,r +wi:w Sin Unit Wiring When a ;3ingle heater is to be installed, a dedicated pro- tected circuit should be provided from the power source for connection. No other electrical devices should be permanently wired on the same circuit. An emergency switch (electrical shutoff) must be in series with the power to the unit. Refer to Diagram 2 for proper field wiring of a typical single 115/1/60 N 20A Fused Circuit H C Emergency Switch * Secondary Safety ** Service Switch At KC Heater KC Water Heater Electrical Junction Box co\ H O GO N O * At Appropriate Location as required by Local Codes ** Break Glass Station, Firestat, etc. I Ground 115/1/60 Pump Fused Circuit H 115/1/60 (N 20A Boller Fused Circuit H Emergency Switch • • At Appropnate Location as required by Local Codes • • Break Glass Station, Firestat, etc. • • • Independent flow switch may be used in lieu of relay contacts to activate boiler. Diagram 2 Single Water Heater Electrical Schematic Diagram 3 Single Heating Boiler Schematic Secondary Safety ** Service Switch At KC Heater KC Boiler Electrical Junction Box water heater installation. See Diagram 3 for a single boiler space heating application. No shutoffs or electrical con- nections should be made in series between factory wired devices such as the high limit or low water cutoff controls. The factory wiring must not be altered or faults may be experienced. When used as a single unit, either water heating unit or a single boiler, control wiring other than external outdoor sensors or interlocks is integral to the unit. Ground 0-- System Starter __(Outdoor Air Stat, Manual Switch, etc.) DPST Contactor /or Relay Heating System Pump Interlock KC Boiler Control Interlock Terminals Box NIKO Gas Fired E General AERCO KC Gas Fired Water Heaters and Boilers are fully factory wired packaged units which require simple power wiring as part of the installation. This technical guide is intended to help designers provide electrical power wiring ( Line Voltage) to KC units. Control wiring details are in other publications depending upon application. This is intended as a guide only, and cannot include all alterna- tives, situations, or be totally inclusive. To comply with all codes and authorities having jurisdiction, designers and installers must plan the electrical wiring carefully and execute the installation completely. Emergency shutoffs, fusible fire switches, break glass stations, and other elec- trical requirements should be considered and installed whenever necessary. Individual Unit Electrical Requirements Each gas fired unit requires 115 /1 /60 power wiring to the factory mounted wiring box connection on the front right side of the chassis of the unit. The control circuit of each heater is fuse protected in accordance with NEC. All copper wiring should be used, and a proper ground wire must be connected to the terminal lug provided. Each gas fired unit in operation has an electrical require- ment of 8 amperes at full 1000 mbh input for a KC -1000. The electrical draw will decrease to approximately 4 amps ELECTRICAL NIPPLE uipment Electrical Power Wirin • Guide GF -1060 Diagram 1 Service Switch Typical Location at minimum input. AERCO recommends that electrical designers allow a minimum of 20a service for each AERCO KC unit to be installed. Wire size and type should be made per the National Electrical Code based on length and load. Provisions for Service Designers must provide emergency shutoffs and other devices to satisfy electrical codes. It is also recommended to provide an electrical shutoff Service Switch of suitable load carrying characteristic on or near each KC heater. No electrical boxes or field components should be mounted to the surface of the heater. The Service Switch should be mounted in an electrical box at least 3 -4 inches on a nipple directly off the unit as illustrated in Diagram 1. Wiring conduit, EMT, or other wiring paths should not be secured to the unit, but supported externally. Nothing should be installed to block the removal of either side cover for service. An electrical 115/1 /60 outlet in the same box as the service switch makes a convenient connection for combustion analyzers, drop lights, or other service tools that might be required for service. Electricians should be instructed as to where the wiring boxes should be located, such as away from relief valve discharge, drains, etc. Particularly on multiple unit installa- tions, it is important that no wiring blocks access between heaters. This should be stressed to avoid service problems later. SERVICE SWITCH CONVENIENCE OUTLET ALTERNATE LOCATION FOR SERVICE SWITCH ON WALL DO NOT BLOCK REMOVAL OF SIDE PANEL FLEXIBLE CONDUIT TECHNICAL BULLETIN AERCO Boiler Application Guide General AERCO KC Boilers are designed for use in any hydronic closed loop heating system application within the limita- tions of temperature and pressure ratings. Due to their extreme flexibility and precise control, they can be used to supplement any hot water system. This guide is intended to help designers apply AERCO boilers to the most common types of systems. If a special application is needed, please call your local AERCO Representative or the AERCO factory for specific application information. Single and Multiple Applications The AERCO KC Boiler can be applied either as a stand alone Single unit or as a Modular battery of boilers with unlimited input. KC multiple boiler systems provide in- herent standby, minimize floor space required, and, most importantly, modulate to match the changing re- quirements of the load under partial loads. Actual boiler sizing and selection are the responsibility of the de- signer. ASHRAE Standards recommend sizing equip- ment with a minimum of oversizing for maximum system efficiency. A multiple KC Boiler installation matches any load fluctuation from 0 to 100% without overshoot. AERCO subscribes to and recommends the methods utilized by ASHRAE and IBR to develop proper loads and sizes required. Combination plant sizing is recom- mended directly from the ASHRAE System Manual. Piping Pressure, Temperature, and Flow Restrictions KC Series units are ASME certified for working pressures of up to 150 psig. KC Boilers can not be used in applications where this pressure rating can be exceeded or irreparable damage may result. Individual Diagram 1 Proper Modular Boiler Piping TECHNICAL BULLETIN GF -1070 ASME pressure relief valves are supplied on each boiler in setpoints of 30, 50, 75, 100, or 150 psig as specified. AERCO KC Boilers require a minimum of 25 gpm flow per boiler for proper and stable boiler control operation. Maximum flows are limited to 150 gpm to prevent erosion of construction materials. Whenever KC boilers are employed into systems where ancillary flow devices (such as three -way valves) are used, minimum flows must be maintained for proper boiler operation. Due to excellent heat exchanger design, the water side pressure drop through KC boilers is negligible. KC units are applicable to systems with temperatures from 50F to 220F. Due to their condensing design, normal low temperature restrictions do not apply. While most common heating applications are designed with a 20F temperature drop, KC boilers are capable of 100F temperature drop through the heat exchanger without thermal stress. Primary vs. Secondary Flow The low pressure drop through the heat exchanger of AERCO KC boilers makes primary pumping of system water directly through the boiler shell by the system circulating pumps most efficient. Electrical and extra pump costs are eliminated. Standby losses suffered with common natural draft type boilers are not experienced with Aerco Boilers. KC units have tight air flow control when units are off. Due to their condensing nature, water temperature limitations restrictive to non - condensing boilers do not apply. KC boilers have a temperature range of 50F to 220F, providing a large application range. For low temperature systems such as water source heat pump or low temperature chiller supplement, system flows can directly interface with the boiler heat exchanger. Multiple Boiler Piping Design When more than one KC boiler is to be used in a system with common operating controls, a balanced flow piping design must be used. Each boiler must be fitted with an adjustable orifice balancing valve. The failure to balance flow evenly through boiler modules will prevent full delivery of boiler capability at design conditions. Valving and Service Provisions Each KC Boiler should be individually valved on supply and return from the system for maintenance and standby. As each is individually protected by safety controls, there are no extra controls or labeling required. System components, such as fill valves and air separation equipment, are not required for each individual boiler unless a condition of local code. Boilers should be properly spaced to allow for installation of valving and service between units. Piping should be located to allow free access between boilers. Each unit has an individual factory installed drain in the boiler shell so no field piping drain is required. Hydronic System Accessories AERCO KC Boilers must be used in conjunction- with appropriate hydronic accessories such as pumps, expansion tanks, air elimination equipment, etc. System design should be towards a minimum of operator maintenance required. Normal commercial and industrial systems employ constant -run pumping equipment. Controls should activate heating pumps whenever KC Boilers are in operation. Also, air elimination in conjunction with pre - charged diaphragm expansion tanks is preferable to air control. Compression tanks may be used but create a maintenance job for the operators. Make -up systems must be employed as required by codes. Fill valves must be used with backflow preventors as required. Pumps, three -way valves, or other flow devices should always provide the minimum flows required for a single or multiple boiler installation. Consult your local AERCO representative for proper application advice. Condensate Piping Each AERCO KC boiler has a separate indirect condensate drain that must be permanently piped as part of the installation. The condensate produced is less acidic than a carbonated soft drink, and is safe for all types of drainage systems. Condensate can be drained by gravity to a floor drain, or drained into a small condensate pump ( such as used with air conditioning equipment) and pumped to a convenient drain. Each unit will produce under 2 gallons per hour in the full condensing mode. In modular applications it is common to manifold these drains together in a plastic pipe manifold to a floor drain. Condensate manifolds must be large enough to handle the flow anticipated and be properly secured and protected. They are generally located behind the modules for short runs of plastic tubing into the manifold from the condensate drain. When each unit is individually drained, the drain line from the heater to the drain should be large enough to allow 9 air venting from the heater drain cup. Too small a drain line will cause backup and the cup to overflow. Controls Safety Controls KC Boilers are equipped with a high limit aquastat and a secondary safety high limit aquastat. Every KC Boiler has safety controls in accordance with ASME Section IV for low pressure heating boilers. These controls are factory wired and installed to simplify field installation. An internal electric probe type low water cutoff, and a manual reset high limit temperature device comply with ASME standards. Other local requirements for external safety devices (flow switches, pressuretrols, etc.) should be provided and installed locally. Designers should check with local authorities having jurisdiction to assure compliance with all applicable codes. Internal Boiler Operating Control Options KC boilers are complete with both combustion safeguard controls and operating controls in each unit. When applied in a single application, boiler control modes must be specified and ordered with: Order Code Description 3 Internal Setpoint 2 External Setpoint 4 4 -20ma Remote Signal Output — Constant Discharge Temp — Indoor /Outdoor Reset — Linear response to external applied signal Factory software and testing allow a simple installation, with minimum field wiring required. When more than one KC boiler is applied in a modular application with an AERCO Boiler Management System ( Model 168), the modules should be specified and ordered as 'BMS' compatible (Order Code 5). Simple field control wiring of two twisted wires connects the BMS Panel to the individual modules. For boiler plants that will both provide space heating and domestic water production of common modules, 'Com- bination' option (Order Code 6) should be specified. KC units with Order Code 6 are capable of firing to a constant temperature, such as an internal setpoint boiler would, and are also able to modulate in response to a BMS signal when transferred into the heating mode. These units MUST be piped in field to the hot water generator, and therefore must be identified before the installation is begun. For small applications it may be desirable to utilize boilers with individual operating controls. Particularly for modular installations of two modules, it may be prefer- able to set the two units up to operate in parallel. This will result in efficient operation without the expense of a central boiler management system. Field Sensor Location When a single KC Boiler is used, all water sensors are internal to the boiler unit and factory positioned. When multiple boilers are used, with common sensors such as the Header Sensor, the water sensor must be located in the field piping. It should be placed in the common supply at least 3 -5 feet downstream of the point where the last module connects into the supply header. All outdoor air sensors should be positioned on the North wall of the building served, and not in direct sunlight. A sunshield is provided as part of the outdoor air sensor kit. Modular Boiler Control For maximum efficiency and flexibility of operator control, an AERCO Boiler Management System (BMS) should be used with a modular KC application. The Model 168 BMS has the capability of controlling up to eight modules as well as auxiliary equipment. Refer to BMS -1 Model 168 specification sheet for full details of the BMS flexibility. When used with a BMS, KC units should be specified and ordered with the BMS control configuration (Order Code 5) from the factory. Typical Applications KC Boilers can be used in any closed loop heating system within the design limitations of the individual modules. The following typical piping and wiring sche- matic diagrams represent only the most common types of Installation detail. They are not intended for any particular system, but are rather composites of how Aerco boilers interface with heating applications in the real world. The designer is encouraged to consider all the possibilities and benefits in applying the KC boiler to system in the manner that most uses the energy saving aspect of them. With ultimate control over the energy SUPPLY TO HEATING MAIN 4' 1500 FLANGED SUPPLY OUTLET 4' 150/ FLANGED RETURN INLET SYSTEM MAKE -UP WATER SUPPLY STRAINER -� PRESSURE REDUCING RU. VALVE UNE SIZE BYPASS BACKFLOW PREVENTER DIAPHRAGM TYPE EXPANSION TANK TYPICAL LOCATION OF MAKE -UP, AIR EUMINATION, AND EXPANSION COMPONENTS Diagram 2 Single Boiler Piping Schematic HEATING SYSTEM RETURN SYSTEM PUMP AUTOMATIC NR VENT AR SEPARATOR transfer process, and a broad range of temperatures not available before, consider first how the system best needs the energy inputted. Then, apply the boilers in the manner that best allows them to use their finite control and capability to supplement the system using a min- imum of energy. The following examples consist of piping and wiring diagrams with brief explanations of design considera- tions and sequences of operation. The examples used are: 1. Single Heating Boiler— External Reset Control Mode (I /O) 2. Four Module Heating Plant— External Reset Mode with BMS -168 3. Two Module Plant— Internal Reset Mode (Water Source Heat Pump System ) 4. Three Module Combination Heating & Domestic Water Plant— External Reset Designers are encouraged to work with their Aerco representative to fully explore and apply the ultimate exchange of energy with control in hydronic heating. 1. Single Heating Boiler— Heating Only Sequence of Operation Boiler plant should be activated by a system start device such as an outdoor air thermostat or building management system. A manual switch can be used but it puts the burden of starting and stopping on the boiler attendant. Automatic controls are more desirable. PRESSURE AND TEMPERATURE GAUGE REUEF VALVE CONNECT 5 e 1.0. HOSE TO CONDENSATE DRAIN SHELL DRAIN VALVE CONDENSATE A) DAMN 0d M. a Ir k The circulating pump for the system should be started with the KC unit and should be constant run. If intermittent pump operation is desired ( such as with multiple zones), a flow switch or other method should be used to prevent the KC unit from firing under no flow. A unit energized to fire with insufficient or no flow will trip out on high temperature limit. Once activated, the internal boiler temperature controls will modulate the input of the boiler to match the control algorithm set. Shown is a typical indoor /outdoor reset . mode. The temperature of the boiler water to the system will Increase as the outdoor temperature decreases. The rate of change can be varied by the adjustable reset ratio on the boiler control panel. If ordered with an internal setpoint control system, the temperature of the boiler water to the system will remain constant to the system at any adjustable setpoint from 50F to 220F. 2. Four Module Boiler— Heating Only KC modular boiler plants are the ultimate energy conversion for building space heating. By modulating input at extremely high combustion efficiency, there is no wasted energy from overshoot. A KC Modular plant offers inherent standby protection and ease of installation along with longevity. Boiler plants from two to eight modules can be controlled from a single Model 168 Boiler Management System. Boilers can be arranged in back -to -back or inline piping applications as space permits. Boiler plants should be laid out with appropriate space for normal maintenance and operation. Diagram 3 Single Boiler 115/1/60 Pump Fused Circuit 115/1/60 20A Boiler Fused Circuit H • At Appropriate Location as Required by Local Codes. •• Break Class Station, Flreetat, etc. *s* Independent Flow switch may be used in lieu of Reloy Contacts to activate Boller. Emergency Secondary Switch* Safety ** Service Switch at KC Heater KC Boiler Electrical Junction Box Ground * ** 0-- KC Boiler Control Interlock Terminals Box System Starter (Outdoor Air Stat, Manual switch, etc.) DPST Contactor or Relay Heating System Pump Interlock 4 Sequence of Operation In a modular boiler plant of over two modules, the use of a Model 168 BMS system is mandatory. The BMS system has an Internal Plant Start adjustment that can be set from 32F to 100F outdoor air temperature. When the boiler plant is activated, the system pump should be started simultaneously. This can be controlled from outside the BMS, but boilers that fire with no flow will trip out on internal over temperature controls. Once activated, the BMS will stage on the first module and increase the module input to increase header temperature. The first module will increase input as required until a preset adjustable percentage of input, normally 60 -70 %, is reached. At that point, the BMS will start a second module and decrease input on the first unit to equal the inputs. The two modules will continue to increase discharge temperature as required by the BMS. At the point where the two firing modules reach the transfer percentage point, the BMS will start a third module and equalize all module inputs to minimize temperature fluctuation. As the demand setpoint increases, the BMS will stage the fourth module on at the start Transfer Setpoint, and bring input on all modules up as needed. Module inputs will modulate down in response to the BMS in a reverse manner. The module will come off line at the transfer setpoint to maximize condensing. Whether the BMS is set in a Constant Temperature or Modulating Temperature mode, it will use the modulating ability to prevent header temperature fluctuation and maximize efficiency. As well, the BMS can stage auxiliary equipment such as combustion air dampers and fans. Refer to Product Spec BMS -1 for details. PIPING TYPICAL FOR ADDITIONAL BOILERS HEATING SYSTEM RETURN MAIN NOTE) LOCATE MATER INLET NIO OUTLET ETTTINOS (Lt. UNIONS. ELBOWS, ETC.) A IITRNUN Cr d' ERON RORER ETTRNOS TO PREKNT INTERPERENCE WITH REMOVAL Or ROME11 PANELS AND COVERS. ALL PIPINO SNOUID LR(ERWSE RE 0 AWAY ARON SIDE PANELS. SYSTEM MAKE —UP WATER SUPPLY STRAINER PRESSURE REDUCING FlU. VALVE UNE SIZE 'MASS RACKTIOW PREVENIER 2R TO 1011 N MAIQ -UP AND OIPNCION COMPONENTS WITTY VALVE OW.) DRAIN �� TYPICAL LOCATION OF MAKE —UP AND EXPANSION COMPONENTS OIAPISNOM TYPE OTPANSION TNOI AR VENT AIMRATOR MIS NGDOI TEMP. TO M SEPARATOR PUII /2 STRARI K HEATING SYSTEM SUPPLY MAIN EY[ROENCY DITCH 11 0/ /SO J H CMC ITS 1111RU 110/S0 42 MIN 200 /CIRCUIT MASTER CONTACTOR ♦ POLE SCt /POLL 120/ COIL EE 11 Diagram 4 Multiple Boiler Piping Schematic QII� 7lE Diagram 5 Four Module Heating Plant External Reset (I /O) Mode NORM I.PO 1. POTTER PUMPS FROM INDEPENDENT CRICURI M WORM Al NECESS4IY. 2. ALL SENSOR WINO TO SC IN SHIELDED CARL At MRMI — MP/ MI M. � OR total ammo MIN (UOmOLI t�f h a • CONTROL CIRCUIT SERVICE MEN • I ■ x/11 /M f =1 0 7 YIUOQ S 410 ENSOR . AM) PUP MOW COM CONfACTDR nrsdifirira"-- M M1RIf IMO w R. MM S7 At MM r IW a M, r �I -aradiMPLamul— I At Mal MM IM At IC MI 8 8 . -Two Module Boiler- -Water Source Heat Pump Application ' Sequence of Operation In Water Source Heat Pump systems, the function of the units Is to supplement the loop to maintain a constant temperature. This temperature range (65F to 90F) is too low for conventional fossil fuel boilers because condensation will form in the firesides causing corrosion. AERCO KC units are built to withstand Diagram 6 Two Module Water Source Heat Pump Piping condensation and excel in this type of application because the low return water temperature maximizes the condensing capability of the units. Normally the boiler plant is activated from the Main Heat Pump Control /Sequence Panel when the system requires auxiliary heat. Once activated, the boiler modules will modulate independently to maintain the loop temperature. Extremely close tolerances to temperature setpoint will be maintained. Diagram 7 Water Source Heat Pump Wiring Schematic 115/1/60 N Control Circuit H-�--�o Emergency Switch* • At Appropriate Location as Required by Local Codes, •• Break Close Station, Flreetat, etc. , 115/1/60 20A Boiler Fused Circuit 115/1/60 20A Boiler Fused Circuit f a'o Secondary Safety ** Control Circuit Fuse H - ---o N — H—'- ---o SPST Contacts in System Heat Pump Main Control Panel Double Pole / Single Throw / Main Contactor 115v Coil 20A /pole min Ho Go oN Ho Go oN Service Switch at KC Heater Ground KC Boiler Electrical Junction Box A ■ 4. Three Modules— Combination 2/1 Combination System It is best to specify and install separate heating and domestic water systems wherever possible. However a combination heating and domestic hot water plant can be specified to share the loads among common boiler modules. The domestic water must be generated in an external hot water storage generator (a storage tank with water -to -water exchanger) . This type of system is not applicable to instantaneous or semi - instantaneous systems. The heating load should be developed from ASHRAE or industry standard methods, and the do- mestic water load should be sized with conventional sizing criteria. If the design is for a replacement system, the size of the storage tank is fixed and sufficient recovery must be provided. If a new application, the tank storage should be sized large enough to prevent the boiler (s) from short cycling under low loads. Diagram 8 illustrates proper piping for an Aerco KC Combination plant. The heating only boilers should be specified with BMS control option and the boilers for domestic water should be specified with combination control option (Order Code 6). The boilers must be piped with a balanced flow piping arrangement. A two - position, two -way valve with end switch must be installed in the supply piping to isolate the domestic water modules from the heating Diagram 8 Three Module Combination Heating /Domestic Water Piping Schematic system. An AERCO Model 168 BMS system and a Model CCP Combination Control Panel must be used as an operating control regardless of plant size in a combo plant configuration. The Aerco Model CCP Combination Control Panel is an accessory partner to the Model 168 BMS for properly handling both domestic heating and space heating with KC series units. The CCP can handle from 1 to 4 boilers isolated from the heating plant to produce constant temperature water to a separate domestic exchanger. The constant setpoint of the boilers is field adjustable. The CCP also provides control of the motorized isolation valve, domestic water priority, and transfer of the boilers to the BMS when required by space heating needs. The domestic water exchanger circulating pump is also con-. trolled from the CCP Panel. A circulating pump between the domestic modules and the external hot water generator is also required. The auxiliary circulating pump should be selected for the required gpm and dynamic head losses of the isolated coil circuit. Sequence of Operation On a year round basis, the Domestic Tank Aquastat is set for the desired domestic water tank temperature. As tank temperature drops, the aquastat closes. The CCP will then activate the starting coil of the circulating pump between the domestic modules and the tank exchanger THERMOMETER SORER SUPPLY PRESSURE GAUGE HEATING ONLY MODULE /1 A SUPPLY HEADER HCATNHO ONLY mootu Hn NOM 1. PIPING SNOW IS SCHEMATIC 2. ALLOW 2' EACH SW OF SOLO MODULES FOR SaACE ACCESS J. DO NOT BLOCK RELCA1M. OF ANY JACKET PR CE MM PrIHO CONNECTIONS 4. MATINS PUMPS AND AM ELIMINATOR TO K LOCOED AS SHOP 4 ON PLAN OCTAL L4006E MASTER MANUAL RESET HIGH OMIT BMS SUPPLY HEADER SENSOR THERMOMETER SO P510 RELIEF VALVE RELIEF PIPING 12• AFF THERMO- METER CONDENSATE _ FLOOR DO NF ISOI■11ON VALVE PUMP FROM TANK CON. SUPPLY TO HEATING SYSTEM AR ELIMINATOR SUPPLY TO DOMESTIC STORAGE / GENERATOR COIL CHECK VALVE ISOLATION VALVE RETURN FROM DOMESTIC soil COIL coil :. The CCP also doses the control interlock on • domestic, water modules, allowing them to modulate up to a'constant temperature (design water temperature for domestic tank coil) . The modules fire and circulating pump will continue to operate until tank temperature is satisfied. As the heating season starts and outdoor air temperature drops, the BMS internal system start will activate central heating system pumps through internal relay contacts. The Model 168 BMS will modulate and stage the heating only modules on at the adjustable transfer setpoint in Bumpless Energy Transfer logic as setpoint demands (normally 60 -70%). The Model BMS 168 can operate in any of the normal programmable operating modes in a combination system (Constant Temp, I/0 Reset, or 4 -20ma signal). For example, when Diagram 9 Combination Heating & Domestic Water Heating Schematic External Reset Mode BMS is operating in external reset mode (110) , required header setpoint will raise as outdoor air temperature drops. The BMS will continually monitor heating header supply water temperature. When the BMS has all heating -only modules firing at 100% input, the CCP will open the two - way valve in the supply piping to allow the domestic modules to be added to the heating system. The heating boiler(s), in response to the additional energy added by the domestic boiler(s), will modulate down to maintain header temperature. If the domestic system requires heat, priority is given to the domestic load. The CCP will close the two -way valve, allowing the domestic boiler(s) to supply the exchanger coil. The two -way valve will be closed by the CCP when the boiler plant has modulated down below the auxiliary contact drop -out setpoint. 0 0M n 01y�11 I 1:41,FSC 10 001 rhP yr CUM MB MMEGS71127e ISRUIR 10 MI 1 SWIM a - MI 0 1 Kan 10001 100■13. Mar M •0121 Al DOW 10 w; M. Y .7 d=11 r 1000 a MN Id OR 0 • 0 ar a 00Y 1011 K 0, ail COMBINATION CONTROL PANEL 01 yr O 001. 0Y. 000• UMW �1 0 a o e•011 101 6+ 101 Oa O 00 Wl� WIC PUMP TO TNOI 000. 1W 10 0, Y 101 O1a01 10w�f;I1MIf�0111/. 171 2/91 3.5M HEAT EXCHANGERS • WATER HEATERS • BOILERS HEAT RECLAMATION SYSTEMS • CONTROL VALVES • STEAM GENERATORS AERCO HOT WATER SYSTEMS AERCO INTERNATIONAL, INC. • 159 PARIS AVE. • NORTHVALE, N.J. 07647 (201) 768 -2400 • TELEX 135450 • FAX 201 -768 -7789 DEC 21 '93 1723 PROCTOR SALES INC. SEATTLE CONCEPT The Taco `CA ". "CAC' and "Cr Series Expansion Tanks wens designed to fill a need in the hydronic industry. For many yearss, old style plain steel expansion tanks have been used to try and control the inherent air problems in systems while trying to maintain a minimum system operating pressure. In some cases, It was possible to make this type of system operate by keeping pressures and velocities high so that the air will remain in solution. However In many cases, the direct air to water Interface in an old style plain steel tank allowed the air to be absorbed Into solution and carried to other parts of the system thus creating waterlogged tanks, air bound terminal units, excessive corrosion, inefficient balancing, and pump cavitation. In the "CA ", "CAX" and "Cr Series Tanks, the air is held captive on the she side with all expanded SPECIFICATIONS SIZING • Shell — Fabricated Steel Designed and Con - structed per ASME Section VIII. Div, 1. • Bladder /Diaphragm Standard Optional CA' 125 PSIG (862 KPA) 150 PSIG (1034 KPa 250 PSIG (1723 KPa) CAX' 125 PSIG (862 KPa) 150 PSIG (1034 KPa) CX 125 PSIG (862 Imo) ' Bladder field replaceable • Operating Temperature - 240° F (116C) Maximurr TacoNet3 COMPUTER vs AIDED SELECTIONS IP( OF TUKWIIA PPROVED Ali 1 4 1994 4411 kA fluid being directed into the bladder (CA and CM) or diaphragm (CX) chamber. This permanent separation allows the tank to be precharged to the minimum system operating pressure (Pv) eliminating the need for many gallons of charge water to compress an atmospheric condltbn to the system requirements. The expanded fluid In the bladder or diaphragm chamber compresses the precharge to the maximum system pressure (P°) which then pushes the fluid bock into the system as it contracts. No absorption can take place during the system cycle. Properly sized, selected and located air separation and removal components can provide a stable, tight, and closed hydronic system. In most properly size "CA" systems the tank size canbe be reduced by up to 80% when compared to the old style plain steel tanks. Only five design parameters are requiredfor "CA/CAX/CX" sizing which are readily available from the system. When given the total system volume•In gallons, minimum and maximum temperatures, and min- imum and maximum pressures, a tank can be sized and selected In minutes Contact your local Taco representative for complete sizing Instructions. Examples: (Heating System) (Required) Volume 3640 gallons Min. Temp. 70°F Max. Temp. 200° F Min. Pressure 65 PSIG Max. Pressure 90 PSIG (Chilled Volume 7950 gallons (Required) l style tak — 3200ga1. Min. Temp. 40°F Max. Temp. 90°F CA Tank — 158 gal. Min. Pressure 65 PSIG Max. Pressure 90 PSIG Remo CITY OF TUKWILA JAN 3 1994 KithifT COMA P.3 Old style tank — 3000 gal. CA Tank — 528 gal. • • MODEL NUMBER TANK . VOLUME ACCEPTANCE VOLUME H HEIGHT 8 DIAMETER D DIAMETER MIFFING WEIGHT D DIM GAL UT. GAIL. UT. INCH MM NCH - MM NCH MM 185. Kg. CAX30 8 30 5 19 26% 735 12 305 14 356 90 41 CAX42 11 42 5 19 33% 859 12 306 14 356 105 48 CAX84 22 84 12 45 4514 1148 12 305 16 406 450 68 CAX130 34 130 19 72 56% 1438 12 305 16 406 200 91 CAM 70 45 170 24 91 70 1776 12 305 16 406 240 109 CAX215 57 215 31 117 6151 1570 16 38 20 508 250 113 CAX254 67 264 34 129 7114 1607 16 _406 406 20 508 280 427 CAX300 79 300 43 163 61% 1559 20 306 24 610 300 136 CAX350 92 350 43 163 6611 1740 20 508 14 610 330 150 CAX425 112 425 61 231 8111 2069 20 500 24 610 380 172_ 193 CAX500 132 500 61 231 89% 2280 20 508 24 610 425 MODEL NUMBER TANK VOWME ACCEP- TAB vOWME H HEIGHT A DIAMETER B DIAMETER i (4 D DIM APPROX. $I.{Ippy4G WEIGHT GAL UT. GAL LIT. INCH MM INCH MM INCH MM NCH INCH MM LB . KG. CX15 7.8 20.1 2.5 9.6 27% 702 1214 318 10 254 114 1314 337 45 20 CX30 8 31 5 17 23% 603 1414 368 12 305 114 i 11414 360 45 20 CX42 11 43 5 17 281/4 724 1414 368 12 305 1% 1414 360 51 23 CX84 23 85 10 36 39 909 16 419 12 305 111 2114 666 83 38 CXI30 35 131 10 38 5314 1353 1614 419 12 306 1% 27% 691 110 50 CX170 d5 171 _ 10 36 6614 1664 1614 419 12 306 114 33 838 135 61 DEC 21 '93 17:26 PROCTCR SALES INC. SEATTLE • " MARGINS VIM o"i4KCL1aI CLOSURE ( 1 14 -\ ■ )4' NPT (13MM) LIFTING - RING 4' NPT DRAIN (26MM) 00 NOT REM OA . PLUG FACTORY UM 04.Y. 01P110044. WU ffl UiiHw*AIS RM{TfM OOIAKCTION 4 ' H ' 1' RAAM (26MM) EEC M '93 17:2 7 DEAILS SINGLE INSTALLATION TACO AM VENT TACO PRESSURE REDUCING VALVE TACO PUMP TACO SUCTION DIFFUSER OPTIONAL HORIZONTAL MOUNTING TACO PRESSURE REDUCING VALVE TACO AIR VENT REMOVABLE STRAINER MULTIPLE INSTALLATION TACO PRESSURE REDUCINO VANS M t TACO MULTI- PURPOSE VALVE TACO MULTI- PURPOSE VALVE TACO SUCTION Ig g1 DIFFUSER TACO PUMP TACO MULTI- PURPOSE VALVE TACO SUCTION DIFFUSER Note: "CA/CAX" do not require Installation above boiler as air is not being directed to tank. Tanks are shipped complete with ring stand. A IM COMPARE. YOU'LL TAKE TACO. P.5 TACO, Inc., 1160 Cranston St.. Cranston, Rhode Island 02920 Telephone (401) 942 -8000 FAX: (401) 942-2360 TACO, (Canada) Ltd., 1310 Almco Blvd., Mississauga, Ontario 14W 182 Telephone (416) 625 -2160 FAX: (416) 625-8616 Form No: F400.004 Effective: 3/1/92 Printed In U.SA • DEC -16-93 THU 17 :07 SIIITMJAY CO INC 100 SERIES PREINSULATED PIPE PRODUCT DESCRIPTION FAX NO. 4356269 The preinsulated carbon steel pipe system is primarily intended for use in transporting hot water, System limitations are described below. The assemblies consists of steel carrier pipe of suitable iron pipe size and wall thickness which is encased in closed cell rigid polyurethane insulation. An outside conduit of HDPE Polyethylene pipe. CLIENT: MUSEUM OF FLIGHT PERFORMANCE REQUIREMENTS: 1) Hot Water Supply and Return Piping. a) Normal operating temperature — 180 degrees P. b) Maximum operating temperature --- 220 degrees P. MATERIALS: 1) CARRIER PPIPE• 4 "Steel pipe, Sch. 40, ERW to ASTM A 53 Grade B 2) l?XTERNAL CONDUlT: HDPE Jacket Material for, ASTM D3350, Cell Class 345434C or 22 GA Galvanized SNIP Jacket. PIPE CONDUIT CONDUIT [ CONDUIT 3 INSULATION SIZE TYPE SIZE O.D.. WALL THICKNESS 4" I IDPE 8.45 8.45 .125 1.85" 4" GSMP 9" 9' .0336 2.21" Urethane Insulation: (Polyurethane Foam) Core density range, ASTM D 1622 2.5 to 3.5 lbs\ft3 Minimum compressive strength ASTMD 1621 30 psi Minimum closed cell content ASTMD 2856 90% Maximum water absorption ASTM D 2842 0.05 lbs/ft2 Maximum water vapor permeability ASTM C 355 5.0 lbs/ft2 Dimensional stability @ -20%F (Maximum linear change) ASTMD 2126 1% P. 02 Dp -16-93 THU 17: Fabrl old ttn Dimensional stability ® +100%1 (Maximum linear change) ASTM D 2126 3% Maximum K- factor as produced ASTM C -518 or C -177 l3btu /in/bx /ft2/ System )jmeSsional Tolerances* 1) Insulation cut/back — on each end of pipe joint "6" 2) Allowable offset from center line of pipe to jacket. a) At pipe ends -- (less than) 1/4 ". b) Elsewhere along pipe length, centerline offset not greater than 3/8" for 8" nominal diameter pipe and smaller, c) Foam face at ends of pipe square to jacket and pipe, within 1/4 ". d) No pull back or shrink of foam shall be evident at shop fabrication temperature. e) Steel hot water pipe spigot ends are beveled, smooth and oriented perpendicular 1/8" to the C/L, axis, and suitable for pipe to pipe weld. Voids In Insertion: &Media Jacket pipe MIMI Treatment: SMITHNAY CO INC) , _ , _ . FAX ND. 4356269 SMITTIWAX CO., INC P.O. BOX 3219, ARLINGTON, WA 98223 1) Voids in pipe shall not exceed 0.25 inch cube, measured radially, no voids allowed at foam face, a) In order to achieve a polyurethane foam bond to jacket, the I,I). of the jacket shall be coated with an adhesive #HG -924 (or equal). Application thickness will be between 25 and 35 mils and will forth a physical lock between the foam core pipe and jacket. b) All foreign material will be removed from the HDPE jacket pipe prior to the coating operation. c) Adhesive specification: 1) Application temperature Max 187 deg F 2) FDA status All ingredients conform to 21 CFR, 175.105 3) Application. Suitable for application to HDPE, Polystyrene, polyurethane and other plastic material 4) Viscosity 4,675 cps @ 275 deg F 2,800 cps @ 300 deg F 1,800 cps OP 350 deg F 1,250 cps @ 350 deg F 5) Color Pale yellow (raw material clear as applied) 6) Adhesive limitation 120 deg F 2 P. 03 DEC -16-93 TEN _17:08 SIIITH1IAY CO INC End Coatings: Insulation Testing: Test Proceduil= E -Factor Density , 7) Minimum push out strength SMITHWAY CO., INC. P.O. BOX 3219, ARLINGTON, WA, 98223 JACKET Temperature PSI 0 +70degF,.,, 15 6 +30degF 15 0 +20degF 15 (111+65 deg F 15 FAX NO. 4356269 P.04 Waterproof coatings will be applied to exposed urethane foam faces at end of pipe with: "Nokorode Seal Kole" (15 to 63 mils). 1) Smithway will incorporate the reference project into its current Quality. Assurance program which meets or exceeds all referenced project criteria. 2) Visual inspection for systems tolerances. 3) In house testing: a) Density - twice daily (minimum) from each end of each selected pipe. (Minimum every 4 hours of production) b) K- factor - initial each production day (free rise). c) Exterior jacket foam bond, every 4000 La d) Thermal Shock every 4000 L/P, One 12 -inch length of cured insulatuion shall be removed from one uncoated foam face end of the pipe length that includes the four thousandth linear foot fabricated (or multiple thereof). Area of foam removal shall be reinsulated, The K- factor shall be measured on insulation specimens under the specified conditions as set forth in the applicable ASTM (C -177) . Density (1b/ft) shall be tested at 4 hour intervals during production of pipe and fittings. The results shall be made available to the Client upon request. All holes whore foam samples have been obtained from the pipe ends shall be cut back to the depth of the sample core and reinsulated, 3 DEC -16-93 THU 17 :09 SIIITHI#AY CO INC Urethane Foam Bond to Exterior Jacket Thermal Shock I : Metbod 91 Manufacture; SMITHWAY CO., INC. P.O. BOX 3219, ARLINGTON, WA 98223 Two 6 -inch lengths of cured insulated pipe representative of the pipe length that includes the four thousandth linear foot fabricated (or multiple thereof), will be used for this test. The test specimens shall be prepared for jacket/foam bond testing as shown on the attached drawings. Acceptance will be indicated by a minimum shear bond strength of 15 psi for exterior jacket at the product specified temperatures. One specimen shall be tested at +70 degrees F. The other specimen shall be brought to -65 degrees F, in 4 hours or less, and remain there for at least 24 hours before testing. A 12 -inch length of cured insulated pipe representative of the pipe length that includes the four thousandth linear foot fabricated (or multiple thereof), will be used for this test. The test sample shall then be subjected to a sudden decrease in temperature of at least 50 deg F, with end temperature of 0 deg F. The test section shall remain at this temperature for at least 4 hours, The section shall then be cooled to minus 65 deg F in 24 hours or less, and left at this temperature for at least 4 hours. After time above procedure, rejection will be warranted if either of the following develops; 1) Radial cracks in the insulation over 1 -inch in length. 2) Circumferential cracks in the insulation over 1/4 inch wide, The basic work commences with application of referenced adhesives to jacket pipe. Centering spiders are then applied to the core pipe. The Steel core is then inserted inside the treated HDPE/GSMP, The assembly is transported to the foam jig fixture. End blank off caps are installed at both ends of the assembly to contain the foam chemical during the foaming process. A plastic wand connected to the foam machine is inserted in the annulus area between the carrier pipe and jacket (to the back of pipe assembly). Foam dispense is initiated and the wand is retracted at a preset speed, thereby, dispensing a known preset amount of foam chemical at a known withdrawal speed which produces a fully insulated pipe, Prior to foaming, 1/8" holes are drilled in the top of jacket at predetermined points to aid in: 1) Confirmation of pipe center location in jacket prior to foam application. 2) Confrmation of pipe center location in jacket after foam application. 3) To provide means for release of gases during the foam application. 4 FAX ND, 93562 P.05 ) DEC -18-93 THU 17:09 SNITHWAY CO INC SIAIMWAY CO., INC. P.O. BOX 3219, ARLINGTON, WA 98223 Packaging: FAX M. 4358209 Aflar foam application and above Quality Assurance checks, the holes ate sealed to provide a watertight seal. Assemblies are then further subjected to Quality Assurance inspection, foam faces are coated, markings are applied, and the assembly is transported to the packaging arca for load out. 1) Marked twice along length of jacket, with 1" tall letters, pipe size, pipe series, Smithway Co., Inc. insulation thickness. 2) Each pipe shall be marked with a number which will identify production date of that particular joint of pipe. 1) Pipes will be bundled on suitable dunnage for truck/ ocean transportation (flats). 2) 4 X 4 wood dunnage bottom layer (5) 3) 1/2" plywood on top of 4 X 4's for HDPE jacketed systems. 4) 1 1/4" steel strapping each layer and each bundle (5 places, use HDPE soffits under strapping), 5) Plastic end caps installed each end of pipe. 6) Bundles to be marked with the following: a) Company name and address b) Item number c) Ship to d) Mark for NOV 10 '93 04 :33PM PSI LYNNWOOD arir a Vent Double -wall gas venting system with AL 29 -4C* alloy P.1 UL Listed File #MH16161 to UL 1738, UL 441 and portions of UL 103 for all Listed Category I, II, III or IV positive pressure, condensing or natural draft gas appliances • Made by e ibti INCOAPOAATW Manufacturer of quality venting products In the USA since 1978 NOV 10 '93 04 : 34PM PSI LY 19.a)OD r Sat T.CI Vent system, with the AL 29-4C" alloy, the ring and tab Joining mechanism and its double - wall insulating air space, is currently specified by several leading commerciallindustrial appliance manufacturers. Made in the USA by Heat -Fab Inc.® Heat -Fab, Inc, has been servicing the heating industry since 1978 and is one of the largest manufacturers of rigid stainless steel relining systems for masonry chimneys and other venting applications. k , INCOAPDRAT Manufacturer of qualify venting preducle M the USA Nina 197'8 38 Haywood Street, Greenfield, MA D1301 Toll Free 800.772 -0739 • AL 29.4C is a Registered Trademark of Allegheny Ludlum Corporation. Available from S Vents —the choice of leading manufacturers P.2 Applications Saf-T CI Yent® is suitable for venting single and multiple appliances through existing chimneys, through walls and up to the top. ' The Saf -T Cl Vent® system includes: • 5" through 12' diameters • 6" through 4' lengths • Elbows • Drain tees • Adjustable length sections • Increasing boot tees for multiple - appliance common venting • Horizontal and vertical terminations Copyright 0 1W2 Neat.Rah Incorporated • Printed in USA 1042, QM • . • NOY 10 '93 04:34PM PSI LYi NWOOD The inner flue conduit Is engineered to resist corrosion. Saf -T CI Vent® features an Inner liner wall of AL 29-4C", a patented alloy of the Allegheny Ludlum Corporation, which is the only metallic material tested to the cor- rosion resistance requirements of UL 1738. The alloy is a super ferritic stainless steel designed for extreme resistance to chloride ion pitting, crevice corrosion, chloride stress corrosion, cracking and general cor- rosion in oxidizing and moderately reducing environments. Today's high- efficiency appliances use more of the heat they produce, With in- creased efficiency comes reduced heat In the venting system. As flue gas tempera- tures drop below their dew point, conden- sation containing acids and chlorides can occur which cause corrosion and pitting, The superior corrosion resistance of the AL 29 -40" alloy makes it the material of choice. A patented ** Joining system insures the integrity of the interior. A patented"external locking ring and tab Joining system eliminates internal protruding, low -alloy fasteners that could corrode when in contact with acidic con- densate. The ring and tab mechanism, together with 100% welded seams, insures the integrity of the interior smooth -wail design, minimizing turbulence and flow • AL 2940 Is a Registered Trademark of Allegheny Ludlum Corporation. "Patent Number 4,874,191. P.3 The AL 29.4C" alloy inner flue conduit is fastened with a patented'" external ring and tad joining system. resistance. Also, there Is no corrogation on straight pieces where condensation could collect. The system is pressure tight and Listed for 1.5 Inches of we when properly installed with the factory - recommended sealant, The joining system also makes installation easy because no drilling or special tools are needed. The outer wall is engineered to provide insulation and stability. The Saf-T CI Vent® outer wall of type 430 stainless steel creates an insulating air space at approximately 1/4" and provides added stability for free- standing appli- cations, Type 316 L stainless steel is also available as an option, NOV 10 '93 4 : 35Pt1 PSI LYNNdOOD SafT CI Venteis highly engineered to safely vent high- efficiency gas appliances Saf -T CI Vents is a rigid, pressure tight, double -wail, free - standing stainless steel venting system that is ideal for high - efficiency condensing commercial and industrial gas - fired applications. Insulating air space between the two walls Patented ring and tab system joins Inner conduit sections AL 29-4C' stainless steel flue conduit Inner wall Saf -T CI Vents' is Tested and Listed by Underwriters Labora- tories to UL 1738, the venting standard for positive pressure and condensing appliances, it is also Tested and Listed to portions of UL 441 and UL 103 for natural draft gas appliances, Outer Jacket sections clamp together P.4 430 stainless steel outer layer • • 4 Foot Length Saf-T CI Vent 49.5" overall length AL 29.4C Positive Pressure Special Vent Section installed length 48" NOV 10 '93 04 :36PM PSI LYNNWOOD .. . 1 l l_' CI Vent Adj Section 1 -2 Foot 15 Degree CI Vent Elbow 30 Degree CI Vent Elbow 45 Degree CI Vent Elbow 70 Degree CI Vent Elbow 90 Degree CI Vent Elbow CI Vent Boot Tee 10X6X6 CI Vent Boot Tee 12X10X6 CI Vent Boot Tee Vertinal ( 1ffsets _ Part Nutuber 5612CI Price Each 86.00 Use as Required at Corners in Horizontal Part Number Price Each Use as Required at Corners in Horizontal Part Number Price Each Installed Length 51012CI 137.60 5614CI 51014CI 86.60 137.60 5616CI 86.60 18.5" 51016C1 137.60 23.5" Runs Runs Use at Transition from Horizontal to Vertical Part Number Price Each Installed Length Use to Connect and U ' size Vent for Third 6" A • P.6 Part Number 5606CI 5100601 51206CI Jacket Material 430S66ppS 430SS 430SS p Price Adjustable length 86.60 137.60 for insta11 lengths from 13.5 to 22.5 inches Part Number 5609CI 51009CI 51209CI Price Each 66.10 118.40 138.40 Use as Required at Corners in Horizontal Runs or Vertical Offsets Part Number 5610CI 51010CI 51210CI Price Each 66,60 118,40 138,40 Use as Required at Corners in Horizontal Runs or Vertical Offsets Part Number 5611C1, 51011CI 51211CI Price Each 66.60 118.40 138.40 Use as Required at Corners in Horizontal Runs or 51212CI 153.30 51214CI 153.30 51216CI 183,30 26.5" Part Number 51066CI Price Each 118.40 Installed Length 18.5" Use to Connect and Upsize Vent for Second 6" Appliance 512106C1 153.30 .. 18.5" liance Part Number 5690C1 5109001 51290C1 Material 304SS 304SS 304SS Price Each 125.00 , 190.00 220.00 CI Vent Horizontal Termination Horizontal Vent Outside Termination (may also be used for combustion air intake) CI Vent Roof Jack ED CI Vent Vertical Support Tee Cover with Drain OE RTV 106 I Part Number 5680CI 510800! • 51280CI Material 304SS 304SS 304SS Price Each 125.00 190.00 220.00 Vertical Vent Roof Penetration Assembly Part Number Material Price Each Price Each Part Number Price Bach 568501 304SS 66.80 Vertical Stack Support Assembly 7000RTV 24.00 51085CI 304SS 82.10 51285C1 304SS 82.10 Part Number 76170CD 710170CD 712170CD 23.00 38.80 42.00 Usc to Remove Condensate frornVent System ' High Temperature Adhesive Sealant 3 Ounce Tube approximate coverage 20 6" seams, 12 10" seams or 10 12" seams Micro -Lok Fiber Glass Pipe insulation Temperature Limit: 850 "F (454'x) Description Micro -Lok is a rigid, one -piece fiber glass pipe insulation that offers superior insulating capabilities In applications to 850 °F. It is made from long, flame - attenuated glass fibers bonded with a thermosetting resin. It is lightweight. easy to work with. and has a one-piece 'hinged" construction for easy installation. Micro•Lok is produced in 3 -ft. sections for IPS ' /a" thru 30 ", and CT sizes from n• /o" thru 12'/n depending on thickness, Jacket types and available forms AP -T 2000 (Pressure Sensitive Lap Sealing System) Jacket. The longitudinal lap of the AP -T 2000 jacket has a pressure sensitive tape tap sealing system. A strong acryllic adhesive permits installation in cold weather conditions down to 15 °F and will not soften or separate when heat and humidity are high. The adhesive is protected by a strip of easy -lift release paper with a "dry edge" 10 permit easy removal during installation. Marching pressure sensitive tape butt strips using the same adhesive and a quick release paper strip are furnished In order to totally seal the system, thug eliminating the need for staples. AP 2000 (All Purpose) Jacket, The AP 2000 Jacket is a high density, white kraft bonded to metalieed polyester, reinforced with fiber glass yarn. The kraft paper is chemically treated to enhance fire safety and minimize possible corrosion of the foil. An adhesive or staples are needed to secure the AP 2000 Jacket lap and butt strip. Plain, Micro-Lek is available unjacketed for use In applications which require field - installed jacketing. Many sizes of Micro -Lok plain are also available on a special order basis in 6 fl. lengths, which can speed Installation on long, straight runs of piping. Uses Micro - Lok pipe insulation is suitable for heating applications types up to 850 °F (see "Qualifications for use"). Jacket types AP 2000 and AP -T 2000 are designed for use on commercial, power or process lines where fire safety and the utmost in appear- ance are desired. Micro -Lok with AP 2000 or AP -T 2000 Jackets can also be used on cold and chilled water lines, brine, refriger- ant and special process knee when the joints are sealed to prevent moisture migration. A weather protective jacket is required for outdoor applications. Advantages High Insulating efficiency. For thermal conductivity values, refer to graph of "k" factors at right. Neat Finished Appearance. The AP 2000 or AP -T 2000 jackets Supplied On Micro -Lok have been specially designed to resist wrinkling, They provide the neat, clean finished appearance that is particularly desired on exposed Indoor applications, Economical to apply. Lightweight, simplicity of design and easily fabricated, one piece construction speeds on- the -job handling and application, With the AP -T 2000 Jacket, the "dry edge ", easy -lift release strip makes application easy, even with gloves on. No - staple seal. Type AP -T 2000 with its strong, super -stick adhesive assures positive seal and eliminates need for staples, providing faster installation and a neater appearance, Can be applied in cold weather conditions down to 15 °F. Seal will not separate under high heat and humidity conditions (see "Application Recommenda- lions "). Idelltlficatlnn. Each section of Micro -Lok AP 2000 or AP -T 2000 has the pipe size and wall thickness printed on the facing. The printing provides immediate identifica- tion on the job or in the warehouse. The printing also indicates the proper Zeston PVC fitting cover size for short radius 90° ell applications, 25/50 Rating. Micro•Lok AP 2000 or AP -T 2000 combined with Zestone 2000 PVC insulated fitting covers provides e complete, integrated system with all components 25/50 rated for flame /smoke. See CI.55 data sheet for information on Zeston 2000 PVC fitting covers, Qualifications for use A sufficient thickness of insulation must be used to keep the maximum surface temper- ature of Micro -Lok AP 2000 or AP -T 2000 below 150 °F, In addition, at operating temperatures above 500 °F, Micro -Lok pipe insulation must be applied in a thickness ranging from 2" minimum to 6" maximum, During initial heat -up to operating tempera- tures above 350 °F, an acrid odor and some smoke may be given off as the organic binders used in the fiber glass pipe insulation begin to decompose. When this occurs, caution Should be exercised to ventilate the area well. This loss of binder does not directly affect the thermal perfor- mance of the pipe insulation, but the compressive strength and resiliency of the product are reduced. For applications with excessive physical abuse or vibration at high temperatures, consult your local Manville sales representative for alternate material recommendations. Submittal Sheet Physical Properties Maximum service temperature 850' Moisture adsorption Less than 0.2% by volume Alkalinity Less than 0.6% expressed as Na Corrosivity Does not accelerate Capillarity (after 24 hours) Negligible Shrinkage None Resistance to fungi Does not breeder and bacteria promote Surface Burning Characteristics (Composite) Jacketing Water Vapor Permeance (ASTM E96 Procedure A) Beach Puncture (ASTM 0 781) Tensile Strength (ASTM D 828) Thermal Conductivity ( "k ") .60 .50 ,40 .30 .20 .10 FHC 25/50 per ASTM E84 NFPA 255, UL 723 .02 perm max. 50 oz. in.; in. tear min, 35 Ibe. /ln. widtn min. ASTM Specification Guidelines C 335 Thermal Conductivity C 356 Linear Shrinkage C 411 Hot Surface Performance C 547 Pipe Insulation C 585 Simplified Dimensional Standards for Nesting (Except nee' IPS, 1" IPS and to /u" CT) C 795 For Use Over Austenitic Stainless Steel C 1136 ,.,. Vapor Barrier Jacketing 0 100 200 300 400 Moan Temperature ( °F) Specification Property Compliance HH -B -1002, Type I ( Jacketing) (Replaced by ASTM C 1136) Hee1.558B Form 0, Type Ill, Class 12, Class 13 up to 850'F (Replaced by ASTM C 547) MIL- I- 22344C MIL -I. 242443 (Defiance Material Only) USCG 164.009 (except t /a" thickness) NRC Regulatory Guide 1.36 (Defiance Material Only) Canada: CGSB 51 -GP -9M 500 Application • 1. To secure lap. lift - era edge' and remove release strip from adhesive. Application Recommendations, AP -T 2000 Jacket and Butt Strips. 1. Do not apply Mtcro•Lok insulation with AP -T 2000 jacketing if air temperature is below 15''F or above 130tF due to the effect of temperature on tape performance. We recommend AP 2000 Jacket when app: • cation falls outside this temperature range. Limited Warranty Manville Mechanical Insulations ( "Manville warrants that its products are manufactured ir. accordance with its applicable material specifications artd are free from defects in materials and workmanship using Manville s specifications as a standard. Only products which are installed and used in accordance with applicable Manville instructions and specifications are in any way warranted by Manville. This warranty is applicable only to 1 made to writing and received by t, . •,tile within 30 days atter the detect was discovered and within one year after me da:c of shipment of the prcouct by Mvtanville. Ali other claims are waived. If a claim Is made. you must allow reasonable investigation of the product you claim Is defective and you must supply S3moles that adequately demonstrate the problem you claim for testing by Manville MANVILLE DISCLAIMS ALL IMPLIED WARRANTIES INCLUDING THE WARRANTY OF MERCHANTABILITY AND THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. THIS LIMITED WARRANTY PROVIDES YOUR EXCLUSIVE REMEDY AS A PURCHASER OF MANVILLE PRODUCTS. THIS LIMITED WARRANTY MAY BE MODIFIED OR AMENDED ONLY BY A WRITTEN INSTRUMENT SIGNED BY A DULY AUTHORIZED REPRESENTATIVE OF MANVILLE. WITHOUT AN EXPRESS. WRITTEN AUTHORIZATION FROM MANVILLE. NQ RETAILER OR DISTRIBUTOR OF MANVILLE PRODUCTS HAS THE AUTHORITY TO MODIFY OR AMEND THIS LIMITED WARRANTY Manville -hanical Insulations A Division of Schuller International, Inc. P.O. Box 5108 Denver. CO 80217.5108 lit i 2. Firmly press lap down using squeegee. 3. Remove quick-release paper from butt strip. 2. If stored below 15'F or above 130'F, insulation cartons shouto stand within tree recommended temperature range for 24 hours prior to application. 3. Once release paper is removed, both adhesive ano lap must be kept free of dirt and water. arid the lap seated immediately Limitation of Liability This limited warranty is your sole and exclusive remedy. It is expressly understood and agreed that the limit of Manville's liability will be. at Manville's option, repair or resupply of a like quantity of non-defective product. AI: labor and service charges which may be incurred with respect lo either the original or replacement product are excluded. Manville shall have no liability except where the claim results solely from breach of Manville's limited warranty. MANVILLE SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, FURTHERMORE, MANVILLE SHALL NOT BE LIABLE FOR DAMAGE TO THE PROPERTY TO WHICH THE PRODUCT IS APPLIED OR ITS CONTENTS, LOSS OF TIME, PROFITS, OR ANY INCONVENIENCE ARISING OUT OF ANY BREACH OF THIS LIMITED WARRANTY OR OBLIGATIONS UNDER THIS LIMITED WARRANTY. MANVILLE SHALL NOT BE LIABLE FOR ANY DAMAGES WHICH ARE BASED UPON NEGLIGENCE, BREACH OF WARRANTY. STRICT LIABILITY, OR ANY OTHER THEORY EXCEPT THE LIMITED WARRANTY SET FORTH ABOVE. INCIDENTAL AND CONSEQUENTIAL DAMAGES SHALL NOT BE RECOVERABLE EVEN IF THE REPLACEMENT REMEDY FAILS OF ITS PURPOSE OR FOR ANY OTHER REASON. Government Certification When ordering material to comply with any government specification. a statement of that fact must appear on the eurchare order. Government regulations prohibit the certift• cation of compliance after shipment has been made. For information on other Manville thermal insulations and systems, write Manville Mechanical Insulations, Product Information Center, P.O. Box 5108, Denver, CO 80217.5108, or call nnn erA n• nn I •'' 4. Apply butt strip around pipe insulation at butt joint and press firmly into place using squeegee 4 When adhered, the lap and butt strips must be pressurized by rubbing firmly with a plastic squeegee or the back of a knife blade to assure positive Closure. 5. Trio maximum surface temperature of Micro•Lok AP.T 2000 should be kept below 150' F. Manville Mechanical Insulations Zone Sales Offices Zone I P.0 Box 156 Defiance, OH 43512 (419) 784.70Q0 (800)334.2399 ($00) 835.2341 (From Ontario S Eastern Canada) Fax: (419) 784.7866 Zone II P.O. Box 5108, Mail Stop 10.02 Denver, CO 80217 (303) 978.2284 (800) 368 -4431 (800) 635.4346 (From Manitoba 8 Western Canada) Fax: (303) 978.2338 Manville Canada, Inc, 295 The West Mall Etobicoke, Ontario M9C.4Z7 (416) 626.5200 Fax: (416) 626.8235 For worldwide export Manville Mechanical Insulations Export Department P.O. Box 5108 Denver, CO 80217.5108 (303) 978.3842 Fax' (303) 978.2808 • Telex: 216115 MANV UR The physical and chemical properties of Micro•Lok' fiber glass pipe insulation represent typical, average values obtained in accordance with accepted test methods ano, are subject to normal manufacturing variations They are supplied as a technical service and are subject to change without notice. Numerical flame spread and Smoke developed ratings are not intended to reflect hazards presented by this or arty other materials under actual fire conditions. Check the Manville Mechanical Insulations Zone Zeston'`` PVC y' Insulated Fitting Covers and Jacketing Temperature Limits: PVC; 0'F to 150`F ( -18'C to +66'C) Insert: 0 ^F to 450 ( -18 "C to + 232''C) Flame Spread: 25 or less Smoke Developed; 50 or less (up to 20 mil) Grade: Weathcrable Color: White Finish: Gloss Description Zeston 2000 PVC fitting covers come in many shapes and sizes with a HI -Lo Tempe fiber glass insulation insert, all of which fit snugly over a variety of fittings. The insulation and the cover provide insulation, plus a vapor retarder, In a eimpie quickly applied system. Manville Zeston 2000 PVC Jacketing is a high- impact, UV- resistant polyvinyl chloride covering designed for insulated pipe or bare metal. Easy to install and maintain, it is white in color to match Zeston 2000 PVC insulated fitting covers. The rugged, pliable PVC jacketing provides an inherent vapor retarder and will withstand water and most chemical and low - solvency washdowns, Available shapes and sizes Fitting covers. Shapes available for 45' and 90' short and long radius elbows. tees and valves plus a wide variety of other fittings; flanges, reducers, end caps, soil pipe hubs, traps and mechanical line fittings. IPS sizes from W through 24 "; CT sizes from 1/2" through 61 ". Rolls. Zeston 2000 PVC Jacketing is available in standard thicknesses of 10, 15. 20, and 30 mil, and In standard widths as shown below. Nonstandard sizes are available on special request. Cut & Curled, • Zeston 2000 PVC Cut & Curled Jacketing in thicknesses of 20 mil or 30 mil is available in factory -cut sizes to fit se" to 24" iron pipe with 1/2" to 3" thick Insulation, and 'ii" to 61/2' copper tubing with' ' to 3" thick insulation. All sections of Zeston 2000 PVC Cut & Curled jacketing are 48" in length and are factory curled to fit snugly, Applications For Insulating chilled water, hot water, steam arid Other piping systems in commercial, institutional, industrial construction on indoor or outdoor piping systems. Outdoor covers need not be coated or painted. For use with Micro -Loks fiber glass pipe insulation and a variety of other pipe insulations. The fitting covers, combined with Zeston 2000 PVC jacketing and Perma- Welds) Adhesive form a completely sealed system for USDA and FDA applications in food, beverage, and pharmaceutical facilities. Zeston 2000 PVC jacketing meets the requirements of USDA and FDA for use in the food processing, beverage and pharmaceutical industries, Standard stock dimensions of Zeston 2000 PVC jacketing in rolls Thickness Width Length Area (mIl.) (In. (ft.) (sq. ft.) 10 351/2 203 600 15 35 135 400 20 351/2 102 300 20 48 100 400 30 35'/i 671'2 200 30 48 67 270 Advantages Code compliance. Meets code requirements of flame spread rating of 26 or less and a smoke developed rating of 50 or less according to ASTM E 84. Fire safety, Lower smoke developed rating than traditional PVC fining covers and PVC jacketing. Weatherability. When used outdoors, jacketing and fitting covers need not he painted or coated. Ease of maintenance. The jacketing and fitting covers are easily washed down with 8001) and water and most commercial cleaners, The ability lobe easily cleaned. combined with the non - toxic, odorless and tasteless properties of the material and its attractive appearance, make It especially suitable for food, beverage, and pharmaceutical applications. Simple, fast installation. Requires no special tools. Just wrap the fiber glass insert around the fitting and tuck It in as necessary; pop on the fitting cover and smooth it into position; secure with tacks. or tape as required. Over insulation. jacketing is secured with tacks. tape or adhesive. Where the jacketing is applied over bare pipe, it Is quickly banded, taped, or solvent welded, Neat appearance, paintable. Attractive, white Zeston 2000 PVC provides excellent appearance, The smooth finish may be painted if desired. Use pastel-colored, high quality acrylic latex paints outdoors. Exceptional durability, The tough, durable Zeston 2000 PVC resists damage from impact and will withstand humidity, salt water, adverse weather conditions, and most industrial fumes. In addition, the jacketing will not support combustion. Corrosion resistance. Unlike aluminum or most stainless steel jacketing materials, Zeston 2000 PVC Is immune to galvanic or electrolytic corrosion. Specification Property Compliance USDA New York City MEA ,;:7.87 ICBQ SSCCI BOCA ASTM 0 1784, Class 14253 -C L P -535E; Composition A. Type II, Grade GU L•P- 1o35A, Composition A, Type II, Grade GU Canada: CGSB 51- GP -53M 'Impact rslnngth delvm11160 by ou0noi•SYI toll meino0 . r>ttnir than Tice, aInce GMpacris more ypprppna:o for OUf! • M....w�� �. ar.... •,n Physical properties of Zeston 2000 PVC Property Specific Gravity, g /cc Tensile Strength at Yield, psi Elongation at Yield (MD), % Tensile Modulus, psi Flexural Strength, psi Temperature limits Vapor and moisture resistant Sanitary Vibration resistant Fire safety Thermal Mean conductivity temperature 'F 75 150 300 Value 1.48 5500 3.0 475,000 9,800 General properties of Hi -Lo Temp fiber glass Insulation Insert OF to 450 "F ASTM Test Method D 702 D 638 D 638 D 638 D 790 (min. .135" thick specimen) Flexural Modulus, psi Flame Spread 25 or less E 84 Smoke Developed 50 or less E 8a (up to 20 mil) Electrical Non -Con• D 257 Conductance dueler Gardner —SPI 10mil1,76 03679 Impact, in lb /mil 15 mil 1.84 (4 lb. weight; by Ductile 20 mil 1.96 8 lb for FAilure 30 mil 2,20 30 mil) Note: Data on chemical resistance is available on request. 460,000 0 790 "k" BTU'in/ (heft .28 .34 .45 Resistance to moisture facilitates rapid drying out. Odorless. Will not absorb odors. Provides no food for insects, rodents, or mildew. Will not settle or separate. Meets most requirements of federal, state and local codes. Accepted for comet mercial, Institutional, Indus- trial, and residential projects in all parts of U.S. The fiber glass inserts have UL 25/50 rating and are non -com- bustible per ASTM E 136. Sizing Tables for Cut & Curled Jacketing The following tables are designed to aid in quickly determining the correct Zeston 2000 PVC Cut & Curled jacketing size for iron pipe or copper tubing Insulated with Micro -Lok" 'fiber glass oroe insulehon or other pipe insulations manufactured in accordance with P' "'• C 585. Zeston 2000 PVC feting cover correspond to Zeston 2000 PVC Cut & Curled jacketing sizes. For example, number 2-5 jacket.r'q fits applications requiring number 2 3. 4, or 5 fitting covers Iron Pipe Size InvV1411On Thickness (In.) (In,) 'h 1 1'11 2 2'/2 3 '•b 2.5 6.8 9.10 - - e 2-5 6.8 9.10 11.12 15-16 '7 1 h 2.5 6.8 9.10 11-12 15-16 17 I 2 -S 9.10 11.12 13.14 15.16 17 1'4 6.8 9.10 11-12 13.14 15.16 17 11 6.8 9.10 11.12 15.16 17 ie 2 9.10 11.12 13.14 15-16 17 18 2't 9. 11.12 15.16 17 18 19 11.12 1304 15.18 17 18 I9 3.. 1 15.16 17 18 I9 20 4 13-1.1 15.16 17 i8 19 20 5 15.14 17 16 19 20 21 6 17 18 19 20 21 22 r' 19 20 21 22 23 34 10 21 22 23 24 25 26 12 23 24 25 26 27 28 14 24 25 26 27 28 29 1e 26 •" 27 28 29 30 31 19 26 29 30 31 32 33 20 30 31 32 33 34 35 27 . 32 3e 24 35 36 37 34 35 36 37 38 39 Copper Tubing Size (0.13,1 (In.) '/ 1 11/2 2 21/2 3 Insulation Thickness (in.) 1/2 2.5 2.5 9.10 11-12 13-14 15.16 se 2-5 6.8 9-10 11.12 13.14 15.16 S. 2.8 6-8 9.10 11•12 15-16 17 11/2 2.5 6.8 9-10 11•12 15-16 17 111 2.5 9.10 11.12 13.14 15.16 17 6.8 9.10 11.12 13.14 15.16 17 21'. 6.8 9.10 11.12 15 -16 17 18 214 9.10 11-12 13.14 15.16 17 18 31/2 9-10 11-12 15.10 17 18 19 34i 11.12 13.14 15.16 17 18 19 41/2 11.12 15.16 17 18 19 20 5is 13-14 17 18 19 20 21 61/2 15.16 16 111 20 21 22 Hot systems The contractor shall furnish and install Zeston 2000 PVC Insulated feting covers on all pipe finings. flanges. valves and pipe terminations. The temperature of the PVC tilting cover must be kept below 150 "F (66°C) by,tlea use of proper thickness of insulation and by keeping the PVC cover away from contact with, or exposure to. sources of direct or radiant heat. Fittings shall be insulated by applying the r '"•r factory preeut Hi•Lo'' Temp insulation to the pipe f;wng, The ends of the Hi•Lo Temp insulation insert shall be tucked snugly into the throat of the fitting and the edges adjacent to the pipe insulation tufted and tucked in. fully insulating me pipe fitting, The ZeslOn 2000 PVC fitting cover is then applied and shall be secured by tack fastening, banding or taping the ends to the adjacent pipe insulation. On fittings where the operating temperature exceeds 250'F (121`C) or where the pipe insulation thickness is greater than 11/2", two or more layers of the Hi -Lo Temp insulation inserts shall oe applied prior to the installation of the PVC fining cover. The first layer shall be applied with a few wrappings of fiber glass yarn to eliminate voids or hot spots. One additional Hi -Lo Temp insert shall be used for each additional 1' of pipe insulation above 11' -' Cold systefns The contractor shall furnish and install Zeston 2000 PVC insulated fitting covers on all pipe fittings, flanges, valves and pipe terminations. Fittings shall be insulated by applying the proper factory precut Hi -Lo Temp insulation insert to the pipe fining. The ends of the Hi -Lo Temp insulation insert shall be tucked snugly into the throat of the fining and the edges adjacent to the pipe insulation tunec and tucked In, fully insulating the pipe fitting. An approved vapor retarder mastic compatible with the PVC shall be applied around the edges of the adjoining pipe insulation and on the fitting cover throat overlap seam. The Zeston 2000 PVC fitting cover is then applied and Shall be secured with pressure sensitive PVC Z- Tape'' along the circumferential edges. The tape shall extend over the adjacent pipe insulation and have an overlap on itself at least 2' on the downward side. On fittings where the operating temperature is below 45 "F (7 ° C) or where the pipe insulation thickness is greater than 1'W, two or more layers of the Hi -Lo Temp insulation inserts shall be applied with the first layer being secured with a few wrappings of fiber glass yarn to eliminate voids. One additional insert shall be used for each additional 1" of pipe insulation above 1,'a'. Refrigerant systems and cold systems in severe ambient conditions The contractor shall furnish and install Zeston 2000 PVC Insulated fitting covers on all pipe fittings. flanges, valves and pipe terminations, Fittings shall be insulated to a full thickness the same as the adjacent pipe insulation with factory precut Hi•Lo Temp insulation inserts tucked snugly into the throat of the fitting and the edges adjacent to the pipe insulation tufted and lucked in. fully insulating the pipe fitting, When 2 or more insulation inserts are used to provide full thickness, the first layer shall be secured with a few wrappings of fiber glass yarn to eliminate voids. Mitered pipe insulation segments, fabricated, or pre. melded insulation shapes conforming to the Zeston 2000 PVC fitting cover may be used in lieu of Hi -Lo Temp inserts, An intermediate vapor retarder compatible with the PVC shall then be applied. completely sealing the insulation prior to installing the Zeston 2000 PVC tilting cover, An approved vapor retarder mastic compatible with the PVC shall then be applied around the edges of the adjoining pipe insulation and on the 'fitting cover overlap seam. The Zeston 2000 PVC fitting cover is then applied and shall be secured with pressure sensitive PVC Z -Tape along the throat seam and the circumferential edges overlapping itself 2' on the downward side. Totally sealed systems (USDA approval) The contractor shalt furnish and install Zeston 2000 PVC insulated fitting covers on all pipe fittings. flanges. valves and pipe terminations. The contractor shall also furnish and install Zeston 2000 PVC jacketing in 20 or 30 mil thickness as the insulation jacket on all straight piping runs. Zeston Perma -Weld' solvent welding adhesive shall be used to permanently seal all the PVC lap joints in the system. Fittings shall be insulated by applying the proper factory precut Hi -Lo Temp insulation Insert to the pipe tilting. The ends of the Hi -Lo Temp insulation insert shall be tucked snugly into the throat of the filling and the edges adjacent to the pipe insulation tutted and tucked in, fully insulating the pipe fitting. Mitered pipe insulation segments, labricateo. or pre•rnlolded insulation shapes conforminc to the Zeston 2000 PVC fitting cover may be used in lieu of Hi -Lo Temp insane. The Zeston 2000 PVC filling cc ver is then applied en0 Shall be sealed In the throat overlap with Perma -Weld sot, ent welding adhesive, Elastic cord or taps shall be used to hold the cover in place Ice st least 10 minutes while the adhesive lakes an initial set. Exposed adhesive in the lap area shall be feathered along the lap seam, The Zeston 2000 PVC jacketing is trier. applied over the pipe insulation and shall overlap the fitting cover by approximately 1 ". Perma -Weld adhesive shall be applied in the circumferential lap between me jacket and the fitting cover as well as along the VA" to 2" longitudinal overlap of the jacket. Elastic cord or tape shall again be used to hold the jacket in place for at least 10 minutes. Subsequent sections of jacketing shall be applied as above with the appropriate amounts of circumferential and longitudinal overlap. Upon completion, all seams shall be visually checked for sealing and touched up with adhesive where necessary. Complete curing of the Perma -Weld adhesive takes approximately 8 to 10 Hours. For high temperature installations, slip - joints shall be applied periodically between fixed supports and on continuous long runs of straight piping. Slip - joints shall be formed by increasing the amount of Circumferential overlap to 81010 inches and by applying a white flexible caulking in the overlap area to maintain a sealed system. For refrigerant systems or cold systems in severe ambient conditions an intermediate vapor retarder shall be applied prior to the installation of the PVC fitting covers and jacketing • SiCIH�U�L�L�E�R Manville Mechanical Insulations A Division of Schuller Internationai, Inc. P.O. Box 5108 Denver, Colorado 80217 -5108 Physical Properties USA Metric SI ASTM Test Absorption of moisture Nb by volume} 0.2% C 240 Only moisture retained is that adhering to surface cells after Immersion. Walar•vapor permeability 0,00 eerm•in 0.00 perm.cm E 96 Acid resistance Impervious to common acids end their fumes except hydrofluoric acid, Caplilarily None None None Combustibility Noncombustible, will not burn. E 136 Composition Pure glass, totally iuergmtic. container no binder. Contpressivc strength Averaga for standard material 100 psi 7.0 kglcm' 689 kPa C 165, Strength when surfaces seeped with hot asphalt, C 240, different tannings will give different values. C 562 Density, average 8 Ibift' 128 kglmt 128 kgim' C 303 Dimensional atehilily Excellent —does not shrink, swell or warp. Flexural strength, black average 80 psi 5,6 kglem' C 203, 552 kPa C 240 Hygroscopicity No increase in weight at 90% relative humidity, Linear coefficient of thermal expansion 4.8 x 10 °F 8.6 x 10' 1 °C 8,6 x 10 °K E 228 Maximum service temperature +900 °F +482 °C 755 °K Modulus of elesticitY, approx. 1,3 x 10‘ psi 9,200 kgicm' 906 MP' C 623 Sheol sueuytl' 50 psi 3.5 kglem' _ 345 kFa Specific haat .18 81ulib• °F .l8kcallkg•°C 0.78 k.ifkgK Thermal conductivity Btu•inlhr•ft kcalIm•h••C 0.31 @ 50 °F 0,038 0 0 °C 0,33 (I0.75 °F 0.039 rJ 10 ° C W1mK C 177, 0.044 0 0 °C C 518 0.045 (fD 10 °C Thermal diffusivity .019 ft'Ihr .0049 cmxlsec 4.9 x 10 "'IYm ,...- Cellular Glass Insulation Insulation Systems for Industrial Piping and Equipment • Roofs, Walls, Floors, Ceilings, Plazas and Parking Decks • FOAMGLAS' insulation is a lightweight, rigid material composed of millions of completely sealed glass cells, Each cell is an insulating entity. FOAMGLAS` -' insulation's all- glass, closed -cell structure provides the following benefits: • Constant Insulating Efficiency o Zero Water Vapor Permeability • Moisture Resistance • Fire Protection • Corrosion Resistance • Long -Term Dimensional Stability • Vermin Resistance These benefits result in FOAMGLAStx - Insulation Systems that are long - lasting, require little maintenance and are ideal for: • Tapered and flat roofs. • Exterior and interior walls, • Ceilings and floors, * Plazas and parking decks. • Freezer and cooler buildings. • Cryogenic and low temperature pipe, equipment, tanks and vessels. • Medium and high temperature pipes and equipment. • Hot oil and hot asphalt storage tanks. • Heat transfer fluid systems. j• Hydrocarbon processing systems. • Chemical processing systems. • Above ground and underground steam and chilled water piping. • Commercial piping and ductwork. FOAMGLAS' insulation is manufactured by Pittsburgh Corning Corporation in a basic block form, Flat and tapered blocks are employed in Pittsburgh Corning roof, wall, floor,, ceiling, plaza and parking deck insulation systems. 13loeks are also fabricated into a wide range of Shapes, thicknesses and sizes to satisfy industrial insulation requirements. Physical and Thermal Properties of FOAMGLAS Insulation Tre Only Impermeable Insulation on the Market Long -Term Performance. Bgcause It consists of closed glass cells, FOAMGLAS r insu- lation resists moisture in bath ligt d vapor form, When tes accordance with ASTM E96, It has a permeabil- ity rating of 0.00 perm•in, Nonoombustible. FOAMGLASr insulation is 100% glass and contains no binders or fillers — it cannot burn. FOAMGLAS r insulation will not absorb flammable liq- uids or vapors. If a fire does occur, FOAMGLAV' insulation will help contain it. Corrosion- Resistant. All -glass FOAMGLASx insulation is unaf- fected by common chemicals and by most corrosive plant atmospheres. It does not pro- mote metal corrosion and its moisture resistance will help keep water from reaching equip- ment and piping. Dimensionally Stable. FOAMGLAS ` insulation is unaf- fected by temperature differen- tials and humidity. It will not swell, warp, shrink or otherwise distort. The insulation system's Intearity remains Intact. Jompressive Strength. FOAivIGLAS`. ins.. ation can withstand loads witch crush most other insulating materials. Ina properly designed piping system, FOAMGLAS" insulation eliminates the need for special treatment at pipe cradles. It also provides a firm base for root membranes, jacketing. or vapor retarders, prolonging their life. in addition, FOAMGLAS/ insulation weighs only 8 lb /fts. This makes it easy to handle and permits the installation of long vertical pipe runs. 'a &uaLA4•, StnataFab• and PITYWRAP• Ora tp•rally ra9,lISrad lladamal lU awned by i"IUbw0R COIN an Corpoquon O 1460. Mt Passings Corium; Corporation FOAMGLASx' Insulation Systems for Industrial Applications Pittsburgh Corning has devel- oped insulation systems for a wide range of piping and equip- ment applications --- above ground or underground, in- doors or outdoors — at oper- ating temperatures from – 450'F to 1000 "F (– 268 ° C to 538 ° C). FOAMGLASA" insulation is fabri- cated by a network of distributor fabricators into coverings for virtu- ally all standard pipes. valves, fittings, and curved segments, as wail as beveled head and lag segments, Contact your Pittsburgh Corning representative for the nearest source of these fabricated shapes. FOAMGLAS' insulation can be easily cut, shaped or modi• tied on -site with ordinary hand tools to insulate valve covers, lees. flanges. etc. With the patented StrataFab-' System, blocks of FOAMGLASII insulation are laminated into billets using a special high temperature adhesive. These billets are labrlcated into the desired shapes and sizes for pipe, tank, vessels, flanges and valves— practically any Industrial Insulation application. ins 'Alm m.11an n.le,, is 00 t 41.111 8-0 r11.0. to Inn a.11 of ow knnW.d4n. 16.1, Ns 'AYI' Ihusswgn Corn; hat no tont/010001 .r'os iinon not kmtnenis. Act of 00IY mal*/Ws Cr C0ndl1oni 01 000 ,IC 000 n. NO REPREEENTATIQ/l OR WARRA4TY. fRPREsfi QRIMPLIEQ. EITHERAB TOMERCH ANTABILITY on FITNESS FOR A PARTICIriAP Peer 03E, 15 MACE.Iu Ina porlCrmannor W an'nt1as00on I0"M•+11 Ins p•OOOCII wn"C n s.1OMl O0YO "d Ins 0Y10"Onon On Ins IOSO NIgt Ana ANY ANQ ALL LIAOILITY FOR NEOLIOEN:t. STRICT LIABILITY OR ANY OTHER THEORY OF TORT LIABILITY IS C *Pr:QOIYQ . ' uI.,. Io allo .m :oih0 mot OSnI.I,on/ ,Ma.10n n0,18 11 0 awM 1. 8KI.11.801018110 , m1410080 W t$ptLternent 01 POI806198 C000nl'l o01Nr•.tY•+ + +TIKOnl9InvQ D•Od,C'I Or 0011*1M40 r 0 e P11t,C1/10+ "v. vl tn'OOtng O O•nt In no a enl frail Pdtsbaton to totoolvolo o1 1.1010 for am al WOO*. LptCW, C088 04non11AI 01 • 1RW.•AOOt An,C0 l" 11Ve0, t Nom 0OOICI Iatvl,.'r ,CIH0 of Int O.ory Ol 100.1111090n an i'a I"l,.iw.C,1.-nop FOAMGLASx Insulation for Building Applications Tapered FOAMGLAS:= Insula- tion Systems provide positive drainage on flat concrete. metal or wood roofs, plazas, and parking decks. Tapered FOAMGLAS'' block insu• lation is available in 18" x 24" blocks with tapers of 1 141; / "and ". Tapered FOAMGLAS t -Board insulation is available In 2' .'<• 4' boards with tapers of ;i "per fool and !4" per foot. Flat FOAMGLAS= blocks are used for insulating fiat roofs, walls, floors, ceilings. plazas, parking decks, or large diameter curved structures, Available In 12" x 18" and 18" x 24" blocks up to 6" thick. 14 1ati� `wl.�F1.- PITTSBURGH CORNING Pittsburgh Corning Corporation 800 Presque Isle Drive Pittsburgh, Pennsylvania 15239, U.S.A. Tel; (412) 327 -6100 Telefax: 412-327-5890 International Manufacturing and Distribution FOAMGLASr insulation is manufactured in the United States and Europe. It is avail- able through an international network of distributors and fab- ricators. For more information, contact Pittsburgh Corning at any of the following locations: Sales Offices Chicago, Illinois Tel: (312) 242.4348 Telefax: (708) 990.1549 Houston, Texas Tel: (713) 961 -3855 Telefax: (713) 960.8843 New York, New York Tel: (212) 986.1350 Telefax: (212) 983.3519 In Canada Toronto, Ontario Tat: (418) 222.8084 International Pittsburgh Corning Europe S.A. Brussels, Belgium Tel: 32.2. 7359036 Telefax: 32-2-7332170 Pittsburgh Corning (UK) Ltd, London, England Tel: 44.734.500555 Telefax: 44-7344509019 Deutsche Pittsburgh Corning GmbH Mannheim, Germany(West) Tel: 49-621-440030 Telefax: 49.621 -4400348 Pittsburgh Corning Nederland B.V. Nieuwegein. The Netherlands Tel: 31. 3402.35241 Telefax: 31-3402-34562 Nippon Pittsburgh Corning K,K. Tokyo, Japan Tel: 81.3.36692581 Telefax: 81.3.35693053 Pittsburgh Corning France Paris, France Tel: 33. 14.3378824 Telefax: 33.1.45871570 Pittsburgh Corning Gea.mbH Linz, Austria Tel: 43- 732. 230963 Telete x: 43-732-237409 Pittsburgh Corning (Switzerland) AG Sienne, Switzerland Tel: 41.32. 235555 Telefax: 41-32-231081 Pittsburgh Corning Scandinavia Stockholm, Sweden Tel: 45.8.661015 Telefax: 46.8.616274 4. EL 9.00 dres NUER44001 r-r COMILISOCN al Ir -7 1/t t— COaOS TONER s-r IMO OCO EE DAt ICON COE a WOK* PO OoaNa TONER VIOL MOP CNN OPAL a 0001 CO CAMP Is MUM T Oa axe Wow 103 p110 PRONPATUI ONO OAP PPE 014101 PPE: c 111UL 301-40 a►a n °w 22 OR OLt Ma virr "r ` aa w/NM/Iw MJ. • % . PDIC MNL N EOM= OM t m 1 00YO"O erJ I I i " iwoaAl o lur d Pw raw a SUMMED S 141t nMrt 00174.11 AOw t WO 1.10110 O Id-V of woe En OWED EWER SK OP its rut, t, 11MT OCU.1012 A am m MP nca PR Kiina IIOIItD >aPPON11 20 A rr MUM CI rin as su MM. 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SUPOISMut _p0�f11DN1n s _���10 a1ICNCr LENIN 11 W OO ni a OIL MVO ME MOOT MON tote We a AOOn —i • GOO Its DO M (010 • 700 11s NEM OMNI 0 on �M eh 3 I understand that the Plan Check approvals !o 9 llhlect to errors and omissions and WWW aof of ns don not `uo or ordinance. Reel. d G orr tractor's e oofapproved planeack1Nw11M11 BY Date Permit No. ,I EL 9.00 SS S S 11.11 t incs ,,c9), sts • NaDNr - - -. - -- - - - - -- a S al 1• MSS El 4.00 A JAN 3199~ sarlin MUSEUM OF FLIGHT BOILER ROOM ADDITION • R IRS IN Plalla MECHANICAL SOUTH BASEMENT PLAN NOVEL BOILER 11-1 WILL BE INSTALLED AT A LATER DATE IN CONJUNCTION WITH AODRION OF HUMIDIFICATION SYSTEM. HWR BOILERS, CONTROLS, AND RETURN PIPING 3. -a BOILER SPECIFICATIONS MANUFACTURER: MODEL NUMBER: RATED INPUT: NET OUTPUT AT FULL INPUT: ASME RATED OPERTING PRESSURE: MINIMUM GAS OPERATING PRESSURE: MAXIMUM GAS OPERATING PRESSURE: GAS CONNECTION: FLUE SIZE: HEATING LOOP CONNECTIONS: MINIMUM WATER FLOW: MAXIMUM WATER FLOW: WATER PRESSURE DROP: WATER VOLUME: OPERATING TEMPERATURE RANGE: INSTALLED WEIGHT: LISTINGS AND APPROVALS: TURNDOWN RATIO: LOW WATER CUTOFF TYPE: HIGH TEMPERATURE LIMIT: AFUE I =B =R (NET) POWER REQUIREMENTS SYSTEM SPECIFICATIONS NUMBER OF BOILERS TO BE INSTALLED: BOILER PLANT MAXIMIM BTU /H INPUT: BOILER PLANT RATED OUTPUT: DESIGN FLOW RATE MAIN LOOP: DESIGN FLOW RATE BOILER LOOP: MINIMUM OPERATING PRESSURE: MAXIMUM OPERATING PRESSURE: MAXIMUM OPERATING TEMPERATURE: 3 128/ FLANGED IRON GLOBE VALVE } AERCO KC -1000 1000000 860000 150 8.5 14 1 -1/4 6 4 25 150 0.23 23 50 — 220 1200 U/L FM ASME 14: 1 INTERNAL DUAL 95 842000 120V/20A/10 3 3000000 Btu /h 2580000 Btu /h 190 gpm 180 gpm 12 psig 50 psig 200 Deg.F. 2r x 63' X 3 t/2' HOUSEKEEPING PADS Btu /h Btu /h psig in.H20 in.H2O NPT in. in. Flanged gpm gpm ft. of head Gallons Deg. F. Lbs. X Btu /h 150 lb. ANSI at 100 gpm ` -2 AERCO KC -1000 CONDENSING FIRE TUBE BOILER AERCO B1IS -1 BOILER MANAGEMENT SYSTEM 4at624 AP BOX In 0 1 4- 00 D � U.L. LISTED NATURAL GAS LEAK DETECTOR HWS HWS III =III =III 3' 1251 CAST IRON GATE VALVE FLANGED ENDS 200 WOO EXISTING REINFORCED CONCRETE WALL EXISTING CONCRETE PAVERS (REINSTALL UPON COMPLETION) AUTOMATIC NR BLEED &t PITPE , •.•II■ AIR ERAT AIR SEPERATOR AUTO NR BLEED i rl 24 OA COMBUSTION AIR DUCT cat SAND BEDDING EARTH FILL 6 MIL POLYETHYLENE FILM 5 /s' MINUS GRAVEL FILL COMPACTION BY HAND ONLY. EXISTING EARTH FILL SMRMWAY 100 SERIES PRE - INSULATED DIRECT BURIEL PIPE 22 GUAGE GALVANIZED JACKET 5/V MINUS CRUSHED GRAVEL BEDDING COMPACTED BEFORE PIPE INSTALLATION. DETAIL A SCALE - -1 r EXISTING �T� TANK ROOM REINFORCED CONCRETE WALL MANVILLE AP 2000 OR AP -T 2000 JACKET 1.5* MANVILLE MICRO -LOK FIBERGLASS PIPE INSULATION 4" SCHEDULE 40 STEEL PIPE 8 -UNE 03161 -4 PIPE COVERING PROTECTION SADDLE 111 8 -UNE 83126 -4to6 ROLLER SUPPORT - RATED DESIGN LOAD CAPACITY a 600 LBS DESIGN LOAD IN 160 LBS BYSTEMS 83064 -3 A DJUSTABLE STRUT BRACKET SIGN LOAD CAPACITY 600 LBS OAD - 360 LBS 1/2" x 5' MOLLY PARABOLT CONCRETE ANCHOR TENSILE LOAD RATING IN 4000 PSI CONCRETE a 12000 WS DETAIL B SCALE - 1 • - 1' SUPPLY PIPING AND COMBUSTION AIR DUCT 4' SCH-40 IC x ITC WEATHERPROOF I LA � FOR COMBUSTION AIR CO RISER 26 GUAGE GALVANIZED COMBUSTION NR DUCT C'I HEAT -FAB sAF-T CI VENT PIPE, HORIZONTAL TERMINATION, AND sO DECREE FRRNDS UL 1738 LISTED a NOTES ALL EXPOSED PIPING SKILL BE PROTECTED FROM FREEZING BY THERMOSTATICALLY CONTROLLED HEAT TAPE. INSIAATION SHALL BE 2 FUEROLASS PROTECTED BY «m um METAL WRAP. BEAM! IN METAL WRAP SHILL BE LAPPED NC SULECA in III III III III III II III III III II 6' -0 x r -G• i f SLOPE BACK TO BOILER AT 1/4' PER FOOT EXHAUST VENT PIPING BOILER ROOM PIPING SECTION SUPERSTRUT E -1200 METAL FARING CHANNELS INSTALL AT 2 -o* O.C. TO PROVIDE FOR SUPPORT OF PIPING RUN ADJACENT TO WALL _ _ EXISTZM �: II I. tr „II � fro I �i S! 15'11 • . ....._„.._ „} iJ LII■]4II�IuIiIII I r ra INST AL1ATION O THE mat S COMPLY WRM nix gammons OF MALL APPENDIX BOILER ROOM PIPING PLAN WALL t REFERENCE NORTH CONTINUE BOTH LINES TO COSTING COOLING TOWER FLOOR DRAIN 0 O I I I ft I I I I I I I I I I II I I II II firCil ga=r Sr' 1' TYPE M COPPER MANIFOLD SLOPE - 1/4' PER FOOT LOCATION OF PROJECT 9404 EAST MARGINAL WAY SOUTH I 1 REGULATOR, UNION, SHUTOFF, AND GAS UNE ,CON NATURAL GAS PIPING I Il■1■( Ju1■I■Ii i Ns( 'IArI L ■ CONDENSATE AND DRAIN PIPING DRAWING NUMBER CAS AVER AND CONNECTING PIPING BY WAG. C GAS AMMFOLD TURN UP TO MANIFOLD TURN DOWN TO DIRT TRAP 1 1/4' OAS SHUTOFF 1 ESS GAS REGULATOR lPR RE RELIEF VALVE JACKET DRAIN OUT 2' TYPE OW COPPER MANIFOLD SLOPE ■ 1/4” PER FOOT RELIEF LINE 1 1 TYPE M COPPER SLOPE 1/4' PER FOOT CONDENSATE DRAIN UNE 5/e TYPE M COPPER AsME APPROVED PRESSURE RELIEF VALVE. 50 PSG SETPOINT TU GOWN TO TEE MUSEUM OF FLIGHT so- wa. BOILER ROOM ADDITION SCALE = 1 /e PER FT UNLESS OTHERWISE NOTED MECHANICAL DETAILS DRAWN BY FENTON KRAFT REVISED 12/29/1993