1003.2.1 Automatic Boilers

Automatic boilers shall be equipped with controls and limit devices in accordance with ASME CSD-1 or Table 1003.2.1.

     The Authority Having Jurisdiction shall have the authority to approve solid-fuel-fired boilers that comply with the safety requirements for automatic gas fired boilers or oil fired boilers.

TABLE 1003.2.1
CONTROLS AND LIMIT DEVICES FOR AUTOMATIC BOILERS

BOILER GROUP	FUEL	FUEL INPUT RANGE1 (INCLUSIVE), BTU/H	TYPE OF PILOT2	SAFETY CONTROL TIMING (NOMINAL MAXIMUM TIME IN SECONDS)				ASSURED FUEL SUPPLY CONTROL4	ASSURED AIR SUPPLY CONTROL5	LOW FIRE START UP CONTROL6	PRE-PURGING CONTROL7	HOT WATER TEMPERATURE AND LOW WATER LIMIT CONTROLS8	STEAM PRESSURE AND LOW WATER LIMIT CONTROLS9	APPROVED FUEL SHUT OFF10	CONTROL AND LIMIT DEVICE SYSTEM DESIGN11
				TRIAL FOR PILOT	TRIAL FOR MAIN BURNER FRAME		MAIN BURNER FLAME FAILURE3
					DIRECT ELECTRIC IGNITION	FLAME PILOT
A	Gas	0 - 400000	Any type	90	Not Required	90	90	Not Required	Required	Not Required	Not Required	Required	Required	Not Required	Required
B	Gas	400001 - 2500000	Interrupted or Intermittent	15	15	15	2-4	Not Required	Required	Not Required	Not Required	Required	Required	Not Required	Required
C	Gas	2500001 - 5000000	Interrupted or Intermittent	15	15	15	2-4	Required	Required	Required	Required	Required	Required	Required	Required
D	Gas	Over 5000000	Interrupted	15	15	15	2-4	Required	Required	Required	Required	Required	Required	Required	Required
E	Oil	0 - 400000	Any type	Not Required	90	90	90	Not Required	Required	Not Required	Not Required	Required	Required	Not Required	Required
F	Oil	400001 - 1000000	Interrupted	Not Required	30	30	2-4	Required	Required	Not Required	Not Required	Required	Required	Not Required	Required
G	Oil	1000001 - 3000000	Interrupted	Not Required	15	15	2-4	Required	Required	Not ' Required	Not Required	Required	Required	Not Required	Required
H	Oil	Over 3000000	Interrupted	15	15	60	2-4	Required	Required	Required	Required	Required	Required	Required	Required
K	Electric	All	Not required	Not required	Not required	Not required	Not required	Not required	Not required	Not required	Not required	Required	Required	Not Required	Required
L	Gas, Oil and/or Coal	12500000 or more	Any	10 sec Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per ASME Power Boiler Code, Section 1 and NFPA 85	Per ASME Power Boiler Code, Section 1 and NFPA 85	Per NFPA 85	Per NFPA 85
M	Heat Recovery Steam Generator	Any	None	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per NFPA 85	Per ASME Boiler & Pressure Code & NFPA 85	Per ASME Boiler & Pressure Code & NFPA 85	Per NFPA 85	Per NFPA 85

For SI units: 1000 British thermal units per hour = 0.293 kW

1. ¹ Fuel input shall be determined by one of the following:
   
   The burner input shall not exceed the input shown on the burner nameplate or as otherwise identified by the manufacturer.
   The nominal boiler rating, as determined by the building official, plus 25 percent.
2. ² Automatic boilers shall have one flame failure device on each burner, which shall prove the presence of an ignition source at the point where it will ignite the main burner, except that boiler groups A, B, E, F, and G, which are equipped with direct electric ignition, shall monitor the main burner, and boiler groups using interrupted pilots shall monitor the main burner after the prescribed limited trial and ignition periods. Boiler group A, equipped with continuous pilot, shall accomplish 100 percent shutoff within 90 seconds upon pilot flame failure. The use of intermittent pilots in boiler group C is limited to approved burner units.
3. ³ In boiler groups B, C, and D a 90 second main burner flame failure limit shall be permitted to be applied where continuous pilots are provided on manufacturer assembled boiler-burner units that have been approved by an approved testing agency in accordance with nationally recognized standards approved by the building official. Boiler groups F and G equipped to re-energize their ignition systems within 0.8 second after main burner flame failure will be permitted 30 seconds for group For 15 seconds for group G to re-establish their main burner flames.
4. ⁴ Boiler groups C and D shall have controls interlocked to accomplish a non-recycling fuel shutoff upon high or low gas pressure, and boiler groups F, G, and H using steam or air for fuel atomization shall have controls interlocked to accomplish a nonrecycling fuel shutoff upon low atomizing steam or air pressure. Boiler groups F, G, and H equipped with a preheated oil system shall have controls interlocked to provide fuel shutoff upon low oil temperature.
5. ⁵ Automatic boilers shall have controls interlocked to shut off the fuel supply in the event of draft failure where forced or induced draft fans are used or, in the event of low combustion airflow, where a gas power burner is used. Where a single motor directly driving both the fan and the oil pump is used, a separate control is not required.
6. ⁶ Boiler groups C, D, and H, where firing in excess of 400000 Btu/h (117 kW) per combustion chamber, shall be provided with low fire start of its main burner system to permit smooth light-off. This will normally be a rate of one-third of its maximum firing rate.
7. ⁷ Boiler groups C, D, and H shall not permit pilot or main burner trial for ignition operation before a purging operation of sufficient duration to permit not less than four complete air changes through the furnace, including a combustion chamber and the boiler passes. Where this is not readily determinable, five complete air changes of the furnace, including combustion chamber up to the first pass, will be considered equivalent. An atmospheric gas burner with no mechanical means of creating air movement or an oil burner that obtains two-thirds or more of the air required for combustion without mechanical means of creating air movement shall not require purge by means of four air changes, so long as its secondary air openings are not provided with means of closing. Where such burners have means of closing secondary air openings, a time delay shall be provided that puts these closures in a normally open position for four minutes before an attempt for ignition. An installation with a trapped combustion chamber shall, in every case, be provided with a mechanical means of creating air movement for purging.
8. ⁸ An automatic hot-water-heating boiler, low-pressure hot-water-heating boiler, and power hot water boiler shall be equipped with two high-temperature limit controls with a manual reset on the control, with the higher setting interlocked to shut off the main fuel supply, except that manual reset on the high-temperature limit control shall not be required on an automatic package boiler not exceeding 400 000 Btu/h (117 kW) input and that has been approved by an approved testing agency. An automatic hot-water heating, power boiler, and package hot-water supply boiler shall be equipped with one low-water level limit control with a manual reset interlocked to shut off the fuel supply, so installed as to prevent damage to the boiler and to permit testing of the control without draining the heating system, except on boilers used in Group R Occupancies of less than six units and in Group U Occupancies and further, except that the low-water level limit control is not required on package hot-water supply boilers approved by a nationally recognized testing agency. However, a low-water flow limit control installed in the circulating water line shall be permitted to be used instead of the low-water level limit control for the same purpose on coil-type boilers.
9. ⁹ An automatic low-pressure steam-heating boiler, small power boiler, and power steam boiler shall be equipped with two high-steam pressure limit controls interlocked to shut off the fuel supply to the main burner with manual reset on the control, with the higher setting and two low-water-level limit controls, one of which shall be provided with a manual reset device and independent of the feed water controller. Coil-type flash steam boilers shall be permitted to use two high-temperature limit controls, one of which shall be manually reset in the hot water coil section of the boiler instead of the low-water level limit control.
10. ¹⁰ Boiler groups C, D, and H shall use an approved automatic reset safety shutoff valve for the main burner fuel shutoff, which shall be interlocked to the programming control devices required. On oil burners where the safety shutoff valve will be subjected to pressures in excess of 10 psi (69 kPa) where the burner is not firing, a second safety shutoff valve shall be provided in series with the first. Boiler groups C and D using gas in excess of 1 psi (7 kPa) pressure or having a trapped combustion chamber or employing horizontal fire tubes shall be equipped with two approved safety shutoff valves, one of which shall be an automatic reset type, one of which shall be permitted to be used as an operating control, and both of which shall be interlocked to the limit-control devices required. Boiler groups C and D using gas in excess of 1 psi (7 kPa) pressure shall be provided with a permanent and ready means for making periodic tightness checks of the main fuel safety shutoff valves.
11. ¹¹ Control and limit device systems shall be grounded with operating voltage not to exceed 150 volts, except that, upon approval by the building official, existing control equipment to be reused in an altered boiler control system shall be permitted to use 220 volts single phase with one side grounded, provided such voltage is used for all controls. Control and limit devices shall interrupt the ungrounded side of the circuit. A readily accessible means of manually disconnecting the control circuit shall be provided with controls so arranged that where they are de-energized, the burner shall be inoperative.