Installation, Operating and Maintenance of Air Break Vertical Controls for Industrial Steam Boilers

1 2 3 12 4 13 14 6 5 15 9 10 11

8
Introduction

1. Top Cover 2. Switch Box 3. Lower Cover 4. Top Flange 5. Float Chamber 6. Steam Side Flange 7. Water Side Flange 8. Reducer 9. S. S. Pipe 10. Magnet Of Float Rod 11. Air Break Switch 12. Spacer Pipe 13. Stopper Nut 14. Float Rod 15. S. S. Float

Magnetically - operated controls of the vertical type in float chambers for external mounting on steam boilers and pressure vessels, are designed to meet all requirements for automatic on/off control of boiler feed pump, burner cut-out or lock-out high and / or low level alarm or a combination of these.

Operation
A primary permanent magnet attached to the float rod slides vertically inside a non-magnetic stainless steel centre tube and transmits the movement of the float to a secondary magnet in each switch unit, which are operated with a snap action. SWITCH UNITS Electrical Characteristics
Single-pole double-throw operation capable of carrying the following currents : AC (25 to 60 c.p.s.) Power Factor 1 to 0.4 4 A at 110 V 2 A at 250 V 1 A at 440 V DC Inductive Loads Time Constant L/R = 40 milisec. max. 0.25 A at 250 V 0.17 A at 110 V 0.17 A at 250 V

Switches must not be used for the direct starting of motors. Contacts should be wired in series with the operating coils of relays, contactor starters or solenoid valves, and fused separately.
A four-way terminal block labelled A-A and B-B is provided for each switch unit. The A-A circuit makes on a rise of water level and the B-B circuit makes on a fall of water level.

Important : Blow- Down the Air Break Vertical Control Twice daily.

NOTE The temperature of the switch head may at times approach the temperature of the boiler and suitable heat resisting cables should therefore be used.
Switch mechanisms are interchangeable and may be fitted with any float chamber provided the control range does not exceed the maximum for which the float chamber is designed. Each switch unit has a nominal differential of 25 mm (1") If a differential greater than 25 mm is required for pump control, two switch units must be used and a holding circuit arranged for the starter control circuit. Wider differential may obtained by increasing the separation between the switches. Switches must be positioned with centres not less than 8 mm (5/16") apart to avoid simultaneous operation.

Adjustments
Any required adjustment to the operating level(s) of controls is made entirely within the switch head. The switch units allow variable adjustment between the circlip stops on the support rods and are secured in position by clamp screws. To avoid two switches operating together, their centres must be at least 8 mm (5/16") apart. Control Range Switch should always remain between circlips. Control range is 6" (150 mm). Switches can be moved up & down and water level controlled in the boiler as desired.Adjustments Any required adjustment to the operating level(s) of controls is made entirely within the switch head.

INSTALLATION 1. A horizontal raised band is provided externally on the float chambers of all Air Break Vertical Controls. This raised band indicates the lowest level at which the control can operate and the range of the control is measured upwards from this band. IT IS IMPORTANT THAT AIR BREAK VERTICAL CONTROLS OPERATE WITHIN THE VISUAL LIMITS OF THE GAUGE GLASS AT ALL TIMES. 2. The steam and water connections between the boiler and the float chamber of the control must be independent of any other boiler mounting, relatively short and free from sharp bends or packets. If Boiler connecting Pads and valves have any obstruction , then the differential pressure is created which can effect the up and down movements of float assembly, hence the working of Mobray. It is Important that the controls should be mounted vertically, close to the Boiler guage glasses and with the water leg as short as possible. This will minimise any differences in water level between the guage glass and the control float chamber. 3. Steam and water stop valves must be provided so that the chamber can be isolated from the boiler for inspection purposes. All mounting arrangements should include a blow-down valve provided at the lowest point in the water connection. Important : Blow- Down the Air Break Vertical Control Twice daily.

Float and Float Rod Assembly

S N 10

10. Magnet of Float Rod

14

12. Spacer Pipe 13. Stopper Nut

L (See the table 1) 4 MM

14. Float Rod 15. S. S. Float

12

13
152mm 63mm 70.5mm

15

Type Of Mobray 1. CC 216 mm side & side 2. CC 295 mm side & side 2. CC 300 mm side & side 3. CC 370 mm side & bottom 3. CC 400 mm side & side 4. CC 450 mm side & side 5. CC 500 mm side & side

Standard Length of Float rod (L) 310 mm 395 mm 400 mm 365 mm 500 mm 550 mm 600 mm Table 1

Note : Length of the Float Rod as well as weight of the Float and Rod assembly is set as such , when the pump on/off Switch is fixed in the centre of the Control Box then Pump should starts from 1/2 ( 12.5 mm ) below the centre of guage glass and stops 1/2 above the centre of guage glass. If in case , the Pump On is desired from 60-65 % of Guage Glass , then the length of the Float Rod should be shortened , accordingly. Float Size : (i) (ii) (iii) (iv) Outer Dia Outer Dia of Welding Part Length Cap Internal Threading - 63 mm - 70.5 mm - 152 mm -6 mm

Important : Blow- Down the Air Break Vertical Control Twice daily.

High Level Alarm Pump Off Pump On Low Level Alarm

N W L

SIDE AND SIDE ENTRY CHAMBER ON STEAM DRUM

1. Pump should start from 1/2 ( 12.5 mm ) below the centre of guage glass and stops 1/2 above the centre of guage glass Each switch unit has a nominal differential of 25 mm (1") If a differential greater than 25 mm is required for pump control, two switch units must be used and a holding circuit arranged for the starter control circuit. Wider differential may obtained by increasing the separation between the switches. To avoid two switches operating together , their centres must be at least 8 mm (5/16) apart. 2 . Low Level Alarm switch should be set 1.1/2 ( 28 mm ) below the Pump on/off switch. 3. High Level Alarm switch ( If provided ) should be set 1.1/2 ( 28 mm ) above the Pump on/off switch.

To test pump control switch

Under normal operating conditions : (a) Allow the water level to rise until the 'Pump Cut-out" level is reached. At this point the pump should stop. (b) Allow the water level to fall until the 'Pump Cut-in'level is reached. At this point the pump should start.

To test low water alarm and cut-out switch.

Shut off the feed water to the boiler, either by closing down the feed pump or in certain cases closing the feed valve. WITH A COMPETENT ATTENDANS STANDING BY, allow the water level to fall by evaporation until the low alarm level is reached. At this point the machine should operate the low alarm and the firing apparatus should cease to operate. With the feed pump under hand control, restore the feed water to the boiler. Upon a short rise in water level the low alarm should re-set and the firing apparatus should commence to operate. Restore normal feed water control to the boiler. Any change in operating level from the set position may be indicative either of blocked connections to the float chamber, a waterlogged float or a loose switch unit and should be investigated immediately. Warning : Any unauthorised interference or modification to the mechanisms of these machines can be detrimental to their correct operation.

Important : Blow- Down the Air Break Vertical Control Twice daily.

ELECLRICAL CONNECTIONS AND APPLICATIONS

SINGLE-SWITCH CONTROL
High Level Alarm Switch A A B B A A B B A A B B Alarm ON Pump Control Switch

TWO-SWITCH CONTROL
Combined Pump Control and Low Level Alarm A A B B

TWO-SWITCH CONTROL
High and Low Level Alarm A A B B Alarm ON

High Level Alarm Switch Pump ON

Pump Control Switch

Pump ON Firing OFF Alarm ON Low Level Alarm Switch

Low Level Alarm Switch

A A B B

Firing OFF Alarm ON

Low Level Alarm Switch

A A B B

Firing OFF Alarm ON

THREE-SWITCH CONTROL
High Level Alarm Switch A A B B A A B B A A B B Alarm ON

THREE-SWITCH CONTROL
Pump Control Switch A A B B A A B B A A B B

FOUR-SWITCH CONTROL
High Level Alarm Switch A A B B A A B B A A B B A A B B Alarm ON

Pump Trip

Pump Control Switch

Pump ON

Pump Control Switch

Pump On

Pump Control Switch

Pump Trip

Firing OFF Alarm ON Low Level Alarm Switch

Firing OFF Alarm ON Pump Control Switch

Low Level Alarm Switch

Pump On Firing OFF Alarm On

Low Level Alarm Switch

Type Available : Flanges machined to BS 10, IBR.

Type Centre to Centre distance of side flanges 400 mm 400 mm 216 mm 295 mm 300 mm _ _ Max. Working Pressure 250 psig (17.5 kg/cm2 ) 350 psig (24.6 kg/cm2 ) 250 psig (17.5 kg/cm2 ) 250 psig (17.5 kg/cm2 ) 250 psig (17.5 kg/cm2 ) 250 psig (17.5 kg/cm2 ) 250 psig (17.5 kg/cm2 ) Chamber Connection Steam Side (Holes) Side (Holes) Side (Holes) Side (Holes) Side (Holes) Side (Holes) _ Water Side (Holes) Side (Holes) Side (Holes) Side (Holes) Side (Holes) Bottom (Holes) _ Blow Down Connection 1/2BSP 1/2BSP 1/2BSP 1/2BSP 1/2BSP _ _ No. of Switches TWO TWO TWO TWO TWO TWO TWO Type No.

Side & Side Side & Side Side & Side Side & Side Side & Side Side & Bottom Top Mounted

400-6253-7376 5783-6253-7376 216-6253-7376 295-6253-7376 300-6253-7376 5742-6253-7374 TOP-6253-7376

Types also availables against order with flanges machined to BS 10 R,B 16.5 #150,#300,#600,ND-40,DIN etc.

Electrical Wiring diagram

N/V Coil N R B Y
2 A Fuse

Auxiliary Contacts On Starter

A A B B A B A B

Pump Motor Starter

OFF

ON

Pump Start/Stop Switch

Auto Pump On/Off ( 1 Differential )

Pump Motor

Diagram Shows Starter Fitted With 250 V Coil

N/V Coil N R B Y
2 A Fuse

Auxiliary Contacts On Starter

A A B B A B A B

Pump Motor Starter

OFF

ON

Auto Pump On/Off ( 1-4 Differential )

A A B B A B A B

Pump Motor

Two Switch Pump Control Circuit Using Auxillary Contacts On Starter

A A B

Relay R1

Pump Stop Switch

B A B A B

A A B

Pump Start Switch

B A B A B

2 A Fuse

To Pump Motor Starter

Live Supply From Pump Starter

Two Switch Pump Control Circut Using Holding Relay For Starters Without Auxiliary Contacts

Important : Blow- Down the Air Break Vertical Control Twice daily.

Applications
One Switch Operation
N/V Coil N R B Y
2 A Fuse

Auxiliary Contacts On Starter

A A B B A B A B

Pump Motor Starter

OFF

ON

Pump Start/Stop Switch

Auto Pump On/Off ( 1 Differential )

Pump Motor

Two Switch Operation

N/V Coil N R B Y
2 A Fuse

Auxiliary Contacts On Starter

A A B B A B A B

Pump Motor Starter

OFF

ON

Pump Start/Stop Switch

Auto Pump On/Off ( 1 Differential )

Pump Motor

Upper Switch

A A B B A B A B

2A Fuse

Solenoid Valve
X

P N P

Low Level Trip

In Oil Fired Boilers

2A Fuse

Hooter

Low Level Alarm

Lower Switch

Important : Blow- Down the Air Break Vertical Control Twice daily.

Applications
Three Switch Operation- I

A A B B A B A B

Hooter
2A Fuse

P N

High Level Alarm

Upper Switch

N/V Coil

Y
2 A Fuse

Auxiliary Contacts On Starter

A A B B A B A B

Pump Motor Starter

OFF

ON

Pump Start/Stop Switch

Auto Pump On/Off ( 1 Differential )

Pump Motor

Middle Switch

A A B B A B A B

2A Fuse

Solenoid Valve
X

P N P

Low Level Trip

In Oil Fired Boilers

2A Fuse

Hooter

Low Level Alarm

Lower Switch

Important : Blow- Down the Air Break Vertical Control Twice daily.

Applications
Three Switch Operation - II

N/V Coil

Y
2 A Fuse

Auxiliary Contacts On Starter

A A B B A B A B

Pump Motor Starter

OFF

ON

A A B B A B A B

Auto Pump On / Off (1"-4" Differential)

Pump Motor

Middle Switch

A A B B A B A B

2A Fuse

Solenoid Valve
X

P N P

Low Level Trip

In Oil Fired Boilers

2A Fuse

Hooter

Low Level Alarm

Lower Switch

Important : Blow- Down the Air Break Vertical Control Twice daily.

Applications
Four Switch Operation

A A B B A B A B

Hooter
2A Fuse

P High
Level

N Alarm

Upper Switch

N/V Coil

Y
2 A Fuse

Auxiliary Contacts On Starter

A A B B A B A B

Pump Motor Starter

OFF

ON

Auto Pump On / Off (1"-4" Differential)

A A B B A B A B

Pump Motor

Middle Switches
Solenoid Valve
X

A A B B A B A B

2A Fuse

P N P

Low Level Trip Low Level Alarm

In Oil Fired Boilers

2A Fuse

Hooter

Lower Switch

Important : Blow- Down the Air Break Vertical Control Twice daily.

Trouble Shooting
1. Mobray not maintaing level. Move the switch up and down to achieve the required level. 2. Pump is running and filling water in the boiler , but not stopping. A. Check the SS Float i If puncture, replace the same with a new one. ii Strucking in the float chamber Isolate the Mobray open the top flange, clean the chamber and fit it again. B. Check the Float Rod If bend either make it straight or replace the same C. Check the Top flange SS Pipe , it should be perpendicular with the flange. If tilting on one side, either get it set on lathe machine or send it to our works. D. Check the Spacer Pipe. If missing Put it in the float rod above the brass Stopper Nut. E. Check the water side valve , If closed , open it. 3. Pump is not filling water in the boiler. A. Check electrical connections of mobray and pump motor B. Check the Air Break Switch. If faulty replace the same with a new one. C. Check the pump Motor. D. Check the water and steam connecting valves. If closed , open it. E. Check the water in the Tank. 4. Mobray maintaing level out side the visible range of gauge glass. A. Check the Padding of Mobray , it should coincide with the Padding of gauge Glass. If maintaing level outside the upper limit of Gauge Glass Shorten the length of float rod, accordingly. ii. If maintaing level outside the lower limit of Gauge Glass Increase the length of float rod, accordingly. B. Check the obstruction in the water and steam side mounting of the boiler connecting mobray. 5. Float rod is climbing upward , but not coming down. A. Check the Steam connecting valve If closed, open it. 6. Low Level Alarm not working. A. Check the alarm unit ( Hooter ) and its electrical wiring. B. Check the Lower Air Break Switch BB point and its continuity by Multimeter. If the continuity shows its open , replace the same with a new switch. i.

Important : Blow- Down the Air Break Vertical Control Twice daily.

Possible Various Faults In The Mobray And Their Corresponding Effects Two Switch Operation
Lower Switch BB Circuit Open Lower Switch AA Circuit Open Upper Switch BB Circuit Open Upper Switch AA Circuit Open Low Level Alarm / Indication would not work ID Fan would not work (husk, coal fired Boilers) Solenoid Valve would not work ( oil fired Boiler ) Pump would not start No Action because not connected

Three Switch Operation - I

Lower Switch BB Circuit Open Lower Switch AA Circuit Open Middle Switch BB Circuit Open Middle Switch AA Circuit Open Upper Switch BB Circuit Open Upper Switch AA Circuit Open Low Level Alarm / Indication would not work ID Fan would not work (husk, coal fired Boilers) Solenoid Valve would not work ( oil fired Boiler ) Pump would not start No Action because not connected Pump would not start ( in holding circuit for differential 1- 4 ) No Action because not connected

Three Switch Operation - II

Lower Switch BB Circuit Open Lower Switch AA Circuit Open Middle Switch BB Circuit Open Middle Switch AA Circuit Open Upper Switch BB Circuit Open Upper Switch AA Circuit Open Low Level Alarm / Indication would not work ID Fan would not work (husk, coal fired Boilers) Solenoid Valve would not work (oil fired Boiler) Pump would not start No Action because not connected No Action because not connected High Level Alarm / Indication would not work

Four Switch Operation

Lower Switch BB Circuit Open Lower Switch AA Circuit Open Middle Switch BB Circuit Open Middle Switch AA Circuit Open Middle Switch BB Circuit Open Middle Switch AA Circuit Open Upper Switch BB Circuit Open Upper Switch AA Circuit Open Low Level Alarm / Indication would not work ID Fan would not work (husk, coal fired Boilers) Solenoid Valve would not work ( oil fired Boiler ) Pump would not start No Action because not connected Pump would not start No Action because not connected No Action because not connected High Level Alarm / Indication would not work

Important : Blow- Down the Air Break Vertical Control Twice daily.

SS Float Puncture -i Pump is running & filling water in the boiler, but not stopping. ii Low Level Alarm would sound Float Rod having Bend - Float with Rod assembly cannot move up and down. Mobray is not fitted Vertical - Float with Rod assembly cannot move up and down. Top SS Tube has a Bend - Float with Rod assembly cannot move up and down Steam side connecting Padding/Valve has an obstruction - Pump will not start even after water level in the Guage glass goes down because of partial vaccum in the float chamber. Water side connecting Padding/Valve has an obstruction - Pump is running but not stopping even after water level in the Guage glass goes up because float chamber does not have sufficient water Float Rod Magnet Polarity is Reverse - all operation related to switches get reversed. Float Rod Magnet Strength goes down - Air Break Switch will not actuate on passing of primary Magnet.of Float Rod. Mobray fitted with shorter length of Float rod than standard length-----Mobray will maintain the water level and low level alarm out side the upper range of guage glass. Mobray fitted with larger length of Float rod than standard length-------Mobray will maintain the water level and low level alarm out side the lower range of guage glass.

Blow Downing The ControlWhile blow downing the control first comes the hot water and then steam this way the whole float assembly will go down tripping the firing and sounding the alarm and as soon as closing S alarm the blow-down valve the float assembly will move up resuming the firing and stopping the this way the low level alarm/trip switch got tested ,automatically

SPARES

TOP CONTROL BOX

AIR BREAK SWITCH

S. S. FLOAT

ROD ASSEMBLY

Important : Blow- Down the Air Break Vertical Control Twice daily.

TYPICAL MOUNTING ARRANGEMENTS OF AIR BREAK VERTICAL CONTROLS ON VARIOUS TYPES OF BOILER

N W L

N W L

SIDE AND BOTTOM ENTRY CHAMBER WITH SEQUENCING BLOW - DOWN VALVE

SIDE AND SIDE ENTRY CONTINENTAL CHAMBER

N W L

SIDE AND BOTTOM ENTRY CHAMBER WITH SEQUENCING BLOW - DOWN VALVE ON VERTICAL BOILER

SIDE AND SIDE ENTRY CHAMBER ON STEAM DRUM OF WATER TUBE BOILER

Malhotra Bros & Co.

Registered Office : EA-198, Tagore Garden, New Delhi - 110027 Ph. : Office : 42133632, Works : 25461405 Tel. / Fax : 5417828 Mobile : 098100 52558 E-mail : mobray@vsnl.com, mobrays@gmail.com Important : Blow- Down the Air Break Vertical Control Twice daily.