Columbia L-WL-CWH Series Boilers Installation Ops and Maintenance.pdf

L • WL • CWH SERIES

BOILERS

INSTALLATION,

OPERATION and

MAINTENANCE MANUAL

COLUMBIA BOILER COMPANY

P.O. BOX 1070, POTTSTOWN, PA 19464

PHONE: 610-323-2700 • FAX: 610-323-7292

www.columbiaboiler.com

COLUMBIA

Table Of Contents

PARTS WARRANTY

INTRODUCTION

SERVICE POLICY

INSTALLATION

BOILER ROOM

VENTING

JACKET ASSEMBLY

BURNER MOUNTING

BOILER CONNECTIONS

FUEL CONNECTIONS

CLEANING AND FILLING A NEW STEAM BOILER

OPERATING THE BOILER

STARTING THE BOILER

STOPPING THE BOILER

BURNER START UP AND TEST INFORMATION

CONTROL DESCRIPTIONS

MAINTENANCE

Daily Boiler Check & Maintenance List Monthly Boiler Check & Maintenance List Semiannual Boiler Check & Maintenance List Annual Boiler Check & Maintenance List

WATER TREATMENT

APPENDICES

Recirculation; Twin Units and Tank Systems Specifications and Data - L Series; WL Series; CWH Series Replacement Parts List for L, WL & CWH Series Boilers Burks Turbine Pumps - Impeller Adjustment Instructions Piping Layout Dwgs. PL-100, PL-101, PL-099, PL-102 Corning Tubular Gage Glasses, Red Line - Use, Care and Installation Warrick Probe Series 26 Controls Warrick Probe Assembly - Replacement Parts Safety Valve Piping, Typical McDonnell & Miller Installation & Maintenance Instructions (one or more):

MM-201(B) Series 767 Low Water Cut-Offs for Steam Boilers MM-213(C) Series 750 Probe Type Low Water Cut-Offs with Remote Sensors MM-231 Series 42 Low Water Cut-Off/Pump Controller MM-316 Series 247-2 Combination Mechanical Water Feeder/Low Water Cut-Off

Pressure Control Bulletin (steam units only) Honeywell Aquastat Controllers L4006 IOM Bulletin

LWLCWH COLUMBIA BOILER COMPANY REV. 3107

IMPORTANT

1. Read and familiarize yourself with this installation, operation, and maintenance manual before installing, operating, or servicing your boiler.

2. All cover plates, enclosures, and safety devices must be installed at all times except while performing maintenance and service.

3. Only trained service technicians should do any work on your boiler.

4. All state and local codes take precedence over any recommendations given in this manual.

LWLCWH COLUMBIA BOILER COMPANY REV. 13106

LIMITED PARTS WARRANTY

The Columbia Boiler Company (hereinafter Columbia) warrants the burner compo-nents and controls installed on its boiler/burner units to be free from defects in materi-al and workmanship under normal use and service for 12 months from the date of installation or 18 months from the date of manufacture, whichever date occurs first and is subject to warranty approval by the manufacturer of the specific components. This warranty does not extend to equipment subjected to misuse, neglect, accident or improper installation. Equipment which is defective in material or workmanship and is removed within 12 months from the date of installation will be repaired or replaced as follows:

(a) Motors, fuel units, controls, and transformers should be sent for repair or replacement to an authorized service point or distributor of the manufacturer of such component when reasonably available in Customer’s locality.

(b) Where such local service is not available with respect to the above listed compo-nents, or where other components are involved, such defective equipment should be returned after receiving authorization from your dealer, freight pre-paid, to the Columbia Boiler Co., 390 Old Reading Pike, Pottstown PA 19464.

The use of the Columbia returned goods form is mandatory when returning defective material.

(c) Columbia is not responsible for any labor cost for the removal and replacement of equipment.

(d) Equipment which is repaired or replaced will carry a warranty equal to the unex-pired portion of the original equipment warranty.

(e) If inspection by Columbia does not disclose any defect covered by this warran-ty, the equipment will be repaired or replaced at the expense of the Customer, and Columbia’s regular charges will apply.

THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH

ABOVE, AND PROVIDES EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF

ALL OTHER REMEDIES. ALL IMPLIED WARRANTIES, INCLUDING BUT

NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR

FITNESS FOR A PARTICULAR PURPOSE OR USE, ARE EXCLUDED. IN NO

EVENT WILL COLUMBIA BOILER CO. BE LIABLE FOR ANY INCIDENTAL

OR CONSEQUENTIAL DAMAGES OF ANY NATURE. Columbia neither assumes nor authorizes any person to assume for Columbia any other liability or obligation in connections with the sale of this equipment. Columbia’s liability and Customer’s exclu-sive remedy being limited to repairs or replacement as set forth above.

March 10, 1997

INTRODUCTION

Series L and WL Water Tube Boilers

The Columbia Models L and WL are water tube boilers designed for hot water, and/or low pressure steam applications. These units are manufactured to the specifications set forth by Section IV of the ASME Boiler and Pressure Vessel Code. Boilers are inspected and stamped for conformity to require-ments of the National Board of Boiler and Pressure Vessel Inspectors. All boilers are designed to be fired using No. 2 fuel oil, and/or natural, manufactured, or liquid propane (LP) gas, and are powered by standard AC electrical service.

CWH Series Steam Boiler

The CWH Series is a steam boiler used for indirect hot water applications. This boiler classification consists of all L and WL Series Boilers providing heat transfer to one or two coils, depending on boil-er size. The boiler is a self contained unit allowing a steam cavity above the water line for expansion.

Columbia hot water and low pressure steam boilers are typically shipped knocked down (unassem-bled), but are also available factory packaged. All boilers are furnished with a jacket kit, burner, and boiler trim. Boiler trim consists of the operating and limit controls, pump and/or low water cut off (LWCO) controls, a safety valve, and a smokehood for all WL Series Boiler Models, and Model L-32.

Factory packaged boilers are fully assembled and test fired.

SERVICE POLICY

Anything mechanical will inevitably need servicing. Steam and hot water boilers are routinely serviced by the installer or another boiler maintenance company. Occasionally the service technician may be unable to determine the cause of the problem. In this sit-uation, the dealer or service organization should contact the selling distributor for help.

Should the problem persist, the distributor will contact the sales representative for assistance. Depending on the extent of the problem, the representative may request technical assistance from the factory.

If the problem cannot be resolved by the representative, he should contact the Technical Service/Engineering Department at the factory. The sales representative will need the following information. It is essential that this information be available to assure prompt service.

Boiler Model and Size (HP)_____________________________________________________

Boiler Serial Number __________________________________________________________

Boiler National Board Number _________________________________________________

Date Installed ________________________________________________________________

Burner Type and Model ________________________________________________________

Primary Burner Control Type ______________________________________________

Installer’s Name ______________________________ Phone (____)____________________

Address ____________________________________________________________________

Distributors Name ___________________________ Phone (____)_____________________

Address _____________________________________________________________________

Sales Representative _________________________ Phone (____)_____________________

Address ____________________________________________________________________

Specific Problem - Detailed

INSTALLATION

BEFORE BEGINNING INSTALLATION, CAREFULLY STUDY THESE

INSTRUCTIONS AND ALL CHARTS, DRAWINGS, AND DIAGRAMS

SHIPPED WITH THE BOILER.

Installation must follow all state and local code requirements, Fire and Underwriters regulations, and standard plumbing practices. The electrical installation shall be in accordance with the National Electrical Code.

Remove all boiler components from packaging and inspect prior to assembly to ensure that damage has not occurred in shipping.

BOILER ROOM

Locate the boiler in a well lit area on a noncombustible, level floor. Make available a convenient water supply and allow adequate drainage, including unobstructed floor drains, for flushing and filling the boiler. Provide sufficient make-up air for combustion at all times. Power the boiler using a properly rated electrical service. Include fused disconnects for control circuits, blower motor circuits, and feed pump circuits that require a motor contactor or motor starter relay.

Where possible, place the boiler on a 3 inch concrete pad. Allow adequate clearance between the boiler and any walls or obstructions to permit inspection and service on burner, boiler piping, controls, or combustion vent.

DO NOT install exhaust fans in or near the boiler room. Exhaust fans steal available make-up air dur-ing burner operation; and more importantly, when the boiler cycles off, exhaust fans pull hot flue gases back through the burner causing burner parts to deteriorate, and to eventually fail premature-

ly. Maintain a positive pressure in the boiler room at all times.

Do not allow your boiler room to become a storage room.

VENTING

All Columbia boiler models utilize a pressure fired burner and need only to be properly vented. For situations where unusual conditions may exist, consult the factory for proper venting.

Locate the boiler as close as possible to the chimney or other approved exhaust vent. For boiler mod-els with a rectangular flue outlet, first bolt the supplied smokehood in place. Attach all flue piping to the round flue connection and make each connection secure. The flue pipe should not be inserted beyond the inside wall of the chimney.

DO NOT REDUCE THE SIZE OF THE FLUE OUTLET OR FLUE PIPING.

Columbia Boiler recommends the use of galvanized B Type vent for stack connections suitable for temperatures to 550F. The flue pipe should be pitched upward at least 1/4” per foot of run. Avoid the use of tees, sharp bends, and long horizontal runs. Install a draft regulator if required.

COLUMBIA BOILER COMPANY OF POTTSTOWN SHALL NOT BE HELD LIABLE FOR DAMAGE

TO THE BOILER CAUSED BY INCORRECT VENT CONDITIONS AND/OR INSUFFICIENT BURN-

ER MAKEUP AIR.

JACKET ASSEMBLY

Assemble the jacket kit around the boiler as shown in Figure 1. Place each panel against its respec-tive side of the boiler.

NOTE: The side panels for boiler Models WL-120, WL-140 and WL-180 are two piece side walls. Assemble these side wall pieces together before proceeding with jacket installation.

Assemble the lower front panel to one side wall at a time. Next, attach the lower rear panel to each side wall of the boiler. When applicable, mount the upper front and rear panels in their respective locations. Attach the joiner plate behind the lower portion of the lower front panel as shown. Finally, assemble the top right and left jacket panels on top of the boiler. Attach these panels to the previ-ously assembled jacket components. If necessary, prepipe the top of the boiler before assembling the top jacket panels. The top jacket panels are designed to allow prepiping to the top center boiler fit-tings, if needed.

Figure 1

BURNER MOUNTING

If the burner is to be installed on site, first apply a gasketing material between the burner flange and the burner mounting plate to seal the burner. Use a non-asbestos fiber rope, or a wet insulating mate-rial for a gasket, as shown in Figure 2. Wet insulation is the preferred gasketing material because it compresses into a flat gasket which conforms to and fills any and all voids. Secure the burner in the boiler using the four bolts supplied with the burner. See the Burner Section of this manual for proper electrical wiring, and fuel supply piping.

Note: All factory packaged boilers use a wet insulation material as a gasket.

Figure 2

BOILER CONNECTIONS

Drains

All Columbia Boiler units have (4) washouts located around the lower corners of the boiler for drainage purposes. Install a pipe nipple and ball valve in a least one washout for use as a drain. If a washout is not needed, plug it by using the proper size nipple and a pipe cap. DO NOT use a pipe plug.

Low Water Cut-Offs

All Columbia boilers are supplied with a single low water cut-off (LWCO) as standard equipment.

Several boiler applications may require a secondary LWCO. The standard equipment is as follows:

Hot Water Boilers - McDonnell & Miller 750-MT-120 Probe Type Low Water Cut-Off with Remote Sensor - Thread the Remote Sensor into the 3/4” NPT fitting located on top of the boiler. Mount the Control Box near the top of the front jacket panel (or upper front jacket panel on some units).

Steam Boilers - McDonnell & Miller Model 767 Quick-Hook-Up Low Water Cut-Off - Install this device into the 2-1/2” NPT welded coupling found on the coil plate for L Series boilers, and on the left hand side of the heat exchanger for WL Series boilers.

Water Heaters - McDonnell & Miller Model 767 Quick-Hook-Up Low Water Cut-Off - Install this device into the 2-1/2” NPT welded coupling found on the coil plate for CWH-170 / -610 Series boilers, and on the left hand side of the heat exchanger for CWH-780 / -2460 Series boilers.

Secondary Low Water Cut-Offs

Secondary LWCO s may be required to meet local codes or CSD-1 requirements. A Warrick 26C1C1C Probe Type Low Water Cut-Off is used in steam applications to meet CSD-1 requirements. Thread the remote sensor into the 1/2" NPT fitting located on top of the boiler using a 1/2" x 3/8" bushing. See Table 1. for proper probe rod length. Mount the control box to a front or side jacket panel on the boiler.

LENGTH OF PROBE ROD IN “L” AND UP TO” CWH-610” SERIES BOILERS

BOILER L-18 L-20 L-22 L-24 L-30 L-32

MODEL CWH-170 CWH-240 CWH-300 CWH-390 CWH-475 CWH-610

ROD LENGTH 4-7/8" 6-1/4" 6-1/4" 6-1/4" 7" 9-5/8"

Table 1a

LENGTH OF PROBE ROD IN “WL” AND UP TO” CWH-780 & UP” SERIES BOILERS

BOILER WL-60 WL-90 WL-120 WL-140 WL-180

MODEL CWH-780 CWH-1200 CWH-1510 CWH-1810 CWH-2460

ROD LENGTH 14-1/2" 14-1/2" 14-1/2" 14-1/2" 14-1/2"

Table 1b

Other secondary LWCO s include combination LWCO / Water Feeders. These devices are typically connected externally using an equalizing line, and piped into the available 1" NPT fittings found in boiler top, and left side or front. Most commonly used combination units are McDonnell & Miller 42 Series Pump Controls and Low Water Cut-Off or McDonnell & Miller No. 247-2 Feeder Combination.

For piping diagram, see the List of Figures on the Table of Contents Page of this manual.

NOTE: Mount a combination unit so the low water cut-off line on the device is approximately 3 inches above the lowest permissible water level plate found on the left side jacket panel of he boiler.

Water Gauge

The water gauge is piped into the (2) 1/2" NPT fittings located in the left side of the boiler. During oper-ation, the boiler s water level should always be above the Lowest Permissible Water Level indicator label found on the left side jacket panel of the boiler. Hot water boilers do not require a Water Gauge.

Pressure Controls

Low pressure, 15 PSI controls are supplied with steam units only. These controls consist of an Operating Control and a Safety Limit. An additional operating control may also be supplied for burn-ers that function with low-high-low operation. Pipe the Pressure Control and the 30 PSI Steam Gauge using the supplied steam syphons. See Drawing PL-099 in the Appendix.

The Pressure Control must be level in order to operate accurately. A Pressure Control is level when the leveling indicator hangs freely with its pointer directly over the index mark, inside the back cover of the case.

Aquastat Controllers®

Aquastat Controllers are used to regulate boiler water temperature. Columbia supplies an Operating Control (Honeywell L4006A Aquastat®) and a Safety Limit (Honeywell L4006E Aquastat®) with all hot water boilers and water heaters. An additional Operating Aquastat® may also be supplied for burners that function with low-high-low operation or steam boilers using an optional coil. Aquastat®’s are mounted in the 3/4" NPT fittings located on the coil plate on the front of the boiler.

Safety Valve / Relief Valve

All safety or relief valves are located in the rear center fitting on top of the boiler. A 15 PSI Steam Safety Valve is supplied for steam boiler and water heater applications. A 30 PSI Water Relief Valve is used for hot water applications. All safety and relief valves should be safely piped away from the boil-er without reducing the valve s outlet port size.

Steam Supply

Pipe the steam lines to the largest fitting or flange located on top of the boiler.

Note: For CWH UNITS ONLY - Plug the main steam outlet unless an expansion tank is used.

Hot Water Supply

Use the fitting/pipe flange on the top of the boiler for the hot water supply to the system. Hot water applications also require the use of an expansion tank in the supply piping, to compensate for fluctu-ations in the water volume during heating and cooling cycles.

Feed Water Supply

Virtually any unused port on the heat exchanger can be used for the feed water supply, including any unused drain port. In situations where make up water is needed, the water supply must be treated before it enters the boiler, to prevent the formation of scale, or to protect the boiler surfaces from the corrosive effects of oxygenated water. Water treatment and a water treatment program must be prac-ticed, or the life of the boiler will be severely limited. If a Condensate Return / Feedwater Tank is used, connect the feedwater source to the float valve on the tank.

Coils

Boilers are shipped with the coil(s) assembled to the coil plate(s), and mounted in the boiler. For the smaller L-Series, L-18(CWH-170) thru L-24(CWH-390), the coil plates cover the opening for which the coils pass through. The indirect water inlet and outlet connections are made in the rear of the boiler.

All other Columbia models can be furnished with one or two coils. CWH models larger than a CWH- 390 always have two coils.

When making coil connections for twin coil units, manifold indirect water piping using copper tubing and fittings connected in parallel. Pipe the outside coil openings together for cold water inlets, and the inside coil openings for hot water outlets. If necessary, temper the hot water supply by using a mixing valve. Connect the hot water outlet source and a cold water supply line to a mixing valve, to temper the hot water supply to the proper temperature requirements for process equipment.

Whenever boilers are supplied with one or two coils, the coils must be covered by a minimum of two inches of water, during normal operation, to allow proper heat transfer through the coil. Adjust all LWCO piping to keep the coil(s) submerged in the event of a low water situation.

FUEL CONNECTIONS

OIL SUPPLY PIPING

Connect burner to oil supply. Refer to fuel unit manufacturer literature for piping, connections, lift and tank installation. If such information is unavailable use the following guidelines:

Fuel supply “level with” or “above” burner: A single stage fuel unit connected to the fuel supply with a single supply line is the most common type of installation for these conditions. Manual vent-ing of the fuel oil is usually required on initial start up. Failure to vent air could result in air lock/oil star-vation.(One Pipe)

Fuel supply below the level of the burner: Use a single stage fuel pump in lift conditions of up to 10 feet and a two stage pump when lift exceeds 10 feet. Both conditions require the use of a return line which purges the fuel pump of air, returning it to the fuel tank. The by-pass plug must be insert-ed into the fuel pump when installing a return line.(Two Pipe)

Fuel line installation: Consult the burner section of this manual for oil line type and sizing require-ments for proper operation. The size of oil lines is extremely important for proper operation.

Continuous lengths of heavy wall copper tubing are recommended and should be installed under the floor whenever possible. Fuel lines should not chaff the appliance or building structure.

All oil feed lines must be air tight. Use as few fittings as possible when assembling the oil lines.

Compression fittings allow more of a chance for air to be introduced into the oil supply. The slightest air leak, usually caused by loose fittings or bad gaskets, can cause poor starts, smoky starts, soot-ing of burner parts, inefficient operation, and a dangerous combustion condition. Always install fittings in accessible locations.

WARNING:

TEFLON® TAPE SHOULD NEVER BE USED WITH ANY OIL LINE CONNECTIONS.

THE USE OF TEFLON® TAPE ON BURNER COMPONENTS OR OIL SERVICE LINES

WILL VOID MOST BURNER WARRANTIES.

A vacuum test should be done on all installations to ensure that all fittings are tight and the oil lines are of proper size. Suction vacuums must be held to acceptable limits.

Fuel line valve and filter: (Not supplied) Install two high quality shutoff valves in accessible locations on the oil supply line. Locate one close to the tank and the other close to the burner ahead of the fil-ter. Some filters come with built-in shutoff valves. Install a generous capacity filter inside the building between the fuel tank shutoff and burner.

For additional information consult the burner section of this manual.

GAS SUPPLY PIPING

Contact your local gas company to ensure that adequate gas service is available, and to review appli-cable installation codes for your area.

The minimum gas supply pressure required by the burner is five inches water column for the GL-18, GL-20, GL-22, GL-24, CWH-170, CWH-240, CWH-300, CWH-390 and seven inches water column for the GL-30, GL-32, CWH-470, CWH-610, CWH-780, CWH-1200 CWH-1510, CWH-1810, CWH-2460 and all WL Series boilers. The maximum gas supply pressure to the burner is fourteen inches water column. Gas pressure greater than fourteen inches water column will require an additional gas pres-sure regulator to prevent damage to the primary gas regulator. Gas pressure below the minimum will cause combustion efficiency problems and should be avoided if possible. Low gas pressure may also prevent the boiler from obtaining the desired input rate, which will cause the boiler to be unable to produce the desired output. Consult the factory if your gas supply pressure is not in the recommend-ed range.

Use the following tables to determine the size of the main gas line required for the boiler that is being installed. First determine the required input volume of gas needed at the gas manifold, then deter-mine the correct pipe size for the length of run needed.

REQUIRED INPUT - CUBIC FEET OF GAS PER HOUR

L-18 L-20 L-22 L-24 L-30 L-32

CWH-170 CWH-240 CWH-300 CWH-390 CWH-475 CWH-610

NATURAL 168 252 336 420 560 700

PROPANE 67 101 134 168 224 280

WL-60 WL-90 WL-120 WL-140 WL-180

CWH-780 CWH-1200 CWH-1510 CWH-1810 CWH-2460

ROD LENGTH 840 1260 1680 1960 2520

PROPANE 336 504 672 784 1008

CAPACITY OF PIPE - CUBIC FEET OF GAS PER HOUR AT 0.2" W.C. PRESSURE DROP

Equivalent 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"

Length (ft)

10 425 725 1170 2360 4300 6250 12800

20 300 520 800 1700 3000 4500 9300

30 250 425 690 1400 2500 3750 7500

40 210 360 560 1200 2100 3200 6400

50 190 325 500 1100 1900 2850 5800

60 180 300 480 1000 1800 2300 4800

80 150 260 410 850 1550 2000 4200

100 135 230 370 750 1375 1680 3500

150 110 190 300 600 1100 1200 2750

200 75 165 260 540 950 1000 2000

Fitting Equivalent Lengths of Standard Pipe in Feet for Listed Fittings

Std. Tee 5.5 7.5 9.0 12.0 13.5 15 20

Std. Elbow 2.7 3.7 4.5 5.5 6.1 8 11

Vent lines, if required, are to be run outside the building, stopping clear of windows or fresh air intakes.

The vent should terminate in a way that will not allow the possibility of water, dirt, insects, animals, and other matter from entering and clogging the vent pipe.

GAS TYPE

GAS TYPE

Gas lines should be tested for leaks. Your gas company may wish to witness this test. Do not exceed the maximum pressures allowed by the valve train.

Additional gas piping information is included in the burner section of this manual.

COMBUSTION AIR

It is essential that provisions are made for a fresh supply of outside air into the boiler room to insure complete combustion, proper boiler efficiency, and a clean fire. Sufficient makeup air also helps pre-vent nuisance shut-downs due to excessive combustion byproduct build-up on burner parts. Outside air may be provided through ducts, fixed louvers or motorized louvers.

A rule of thumb for calculating fresh air openings to the outside is 63 sq. in. for every 100,000 BTUH gross output, or 21 sq. in. per boiler horsepower. The result of the above calculation is expressed as free area, meaning no restrictions of any kind. If louvers or screens are used over combustion air openings, calculate the percentage of free area to allow for these restrictions.

Do not have exhaust fans in the immediate proximity of the boiler room if at all possible, as they will cause a reversal of draft through the boiler when the burner is cycled off. This draft reversal draws heat from the combustion chamber back through the burner. This heat will deteriorate burner com-ponents prematurely, and eventually, burner operation will fail. The boiler room should experience a positive pressure when the burner is not firing.

In situations where a boiler room experiences a negative pressure, use a direct air intake. A direct air intake uses an adapter over the burner fan intake housing to draw in outside air through duct work, from an external source. Consult burner manufacturer for parts and availability.

Important Note: Surface discoloration of the building may occur due to improper boiler/burner adjustment and mainte-nance. Columbia Boiler Company will not accept any liability for such discoloration.

REQUIRED BOILER MAKE-UP AIR

OPENING SQUARE HOLE ROUND PIPE

BTU INPUT MIN. SQUARE SIZE - INCHES SIZE - INCHES

INCHES (APPROXIMATE) (APPROXIMATE)

L-18

196,000 84 10 X 10 1CWH-170

L-20

280,000 126 12 X 12 14CWH-240

L-22

336,000 168 14 X 14 16CWH-300

L-24

420,000 210 15 X 15 18CWH-390

L-30

560,000 273 17 X 17 20CWH-475

L-32

700,000 336 19 X 19 22CWH-610

L-60

840,000 420 21 X 21 24CWH-780

L-90

1,260,000 630 26 X 26 30CWH-1200

L-120

1,680,000 840 30 X 30 34CWH-1510

L-140

1,960,000 987 32 X 32 36CWH-1810

L-180

2,520,000 1260 36 X 36 38CWH-2460

BOILER SIZE

(HORSEPOWER)

CLEANING AND FILLING A NEW STEAM BOILER

Note: The following procedure is for steam boilers only. This procedure should also be used for indirect water boilers (CWH-Series).

In order to minimize the corrosive effects of raw water oxidation on the boiler, the water must be heated to at least 180°F immediately after entering the boiler, in order to drive off the corrosive dissolved gases. This applies to all water - whether from a well, a spring, or from the local municipal water system.

The oil and grease that accumulate in a new steam boiler can usually be washed out by boiling as follows:

1. Fill the boiler to the normal waterline.

2. Remove the safety valve.

3. Provide a boil-out compound of caustic soda and trisodium phosphate in the proportions of 2-1/2 lbs. of each chemical per 120 gallons of water.

CAUTION: USE CARE IN HANDLING THESE CHEMICALS. THE CAUSTIC SODA IS

EXTREMELY CORROSIVE TO SKIN AND CLOTHING. DO NOT PERMIT EITHER

THE DRY MATERIAL OR THE CONCENTRATED SOLUTION TO CONTACT SKIN

OR CLOTHING.

EQUAL AMOUNTS

BOILER MODEL CAUSTIC SODA AND

TRISODIUM PHOSPHATE

L-18 / CWH-1708 8 oz

L-20 / CWH-240 10 1/3 oz

L-22 / CWH-300 14 1/3 oz

L-24 / CWH-390 1 lb 2 1/3 oz

L-30 / CWH-475 1 lb 10 2/3 oz

L-32 / CWH-610 1 lb 14 oz

WL-60 / CWH-780 2 lb 12 1/3 oz

WL-90 / CWH-1200 3 lb 3 1/3 oz

WL-120 / CWH-1510 4 lb 1/3 oz

WL-140 / CWH-1810 4 lb 7 1/3 oz

WL-180 / CWH-2460 6 lb

4. Mix the chemicals with water and pour into the boiler through the safety valve opening.

5. Replace the safety valve.

6. Start the firing equipment.

7. Boil the water for at least five hours.

8. Stop the firing equipment.

9. Drain the boiler to a location where hot water can be discharged safely.

10. Wash the boiler thoroughly using a hose with sufficient pressure.

11. Fill the boiler to the normal waterline.

12. Add boiler water treatment as prescribed by a water treatment specialist.

13. Boil or bring water temperature to at least 180°F immediately.

14. The boiler is ready to put into service or on standby.

OPERATING THE BOILER

NOTE: Although each factory packaged unit has been test fired at the factory, each boiler must be “set up” for the conditions on location. Improper combustion settings may cause the burner to operate erratically, resulting in boiler shutdowns, lost time, and unnecessary service expenses.

PRE-START CHECKS AND INFORMATION

A new or relocated boiler should not be put into service until it has been inspected by an authorized inspector for the jurisdiction or the insurance company, and the required certificates have been issued.

Whenever a new boiler is placed in service, operating data should be recorded and saved for future reference. This information is extremely valuable for diagnosing problems if abnormal operation occurs. Record all operating parameters such as pressures, stack temperatures, oxygen or carbon dioxide levels, flows, draft, motor amps, damper positions, and interlock set points. A burner start up and test information sheet has been included at the end of this section for your convenience.

All cover plates, enclosures, and safety devices must be installed at all times except while perform-ing maintenance and service.

The fuel supply should not be turned on until the combustion chamber has been vented and the pilot light (if gas ignited) checked for proper operation.

All drain valves including blowdown valves for stream boilers, water column drain valves, gauge glass drain valves, and gauge cocks, should be closed.

The safety/relief valves should be inspected externally to see that they are free to operate, and that the discharge piping and drain piping are open to the atmosphere, and free to expand without impos-ing a load on the safety valve bodies. Make sure the safety valve is piped to a safe location to pre-vent injury.

The boiler feed pump(s) for steam applications should be checked to ensure that they are ready for service. Check the data on rating plates of all electrical equipment to be certain the electrical char-acteristics match those of the electric supply to which they are connected.

Before attempting start-up, carefully study the instructions included in the burner section of this manual.

It is important to have the proper test equipment in order to adjust the combustion and pilot if equipped. Those items that may be required include a manometer, micro ammeter, vacuum gauge, 0- 300 PSI pressure gauge, carbon dioxide or oxygen analyzer, carbon monoxide tester, smoke gun, and stack thermometer.

STARTING THE BOILER

WARNING: NEVER OPERATE A BOILER WITHOUT BEING SURE IT IS FILLED WITH WATER

AND THAT PROPER WATER TREATMENT CHEMICALS HAVE BEEN ADDED.

Allow the boiler to fill with water to its normal operating level.

Supply power to the boiler disconnects.

NOTE: The burner will not operate when the boiler has reached its normal water level, until the reset button on the manually reset, probe type, low water cut-off is pushed.

NOTE: Combustion efficiency must be checked at this time. See the burner manufacturers instructions for correct settings and more detailed information.

Follow the adjustment procedures outlined in the burner section of this manual to set up the burner for proper operation.

STOPPING THE BOILER

To stop the boiler turn the main disconnect to the OFF position.

BURNER START UP AND TEST INFORMATION

For a new boiler start up, or for troubleshooting an existing installation, the following information is essential for effective service assistance.

Boiler Model_________________ Serial No.________________ N.B. No.______________________ Burner Model________________ Invoice No._______________ Serial No._____________________ Installation Name__________________________________________ Start Up Date_________________ Start Up Contractor________________________________________ Phone No.____________________ Name of Technician Performing Start Up_____________________________________________________ Fuel Type: � Natural Gas � LP Gas � Fuel Oil (#2) � Other_________________________________

Gas Firing

Gas Pressure At Train Inlet Flame Signal Readings Stack Outlet Test Point Draft Burner In Off Position_______ "W.C. Pilot____________________________ High Fire__________________ "W.C.

Gas Pressure At Train Inlet CO2 Over Fire Draft High Fire__________________ "W.C. High Fire_________________________ High Fire__________________ "W.C.

Gas Pressure At Main Orifice CO Net Stack Temperature High Fire__________________ "W.C. High Fire_________________________ High Fire___________________°F

Gas Pressure At Pilot Orifice Measured Input Rate - BTU/HR __________________ W.C. High Fire__________________ "W.C.

Oil Firing

High Fire Vacuum Reading At Oil CO2 Stack Outlet Test Point Draft Pump Inlet_______________ "H.G. Low Fire________________________ Low Fire__________________ "W.C.

High Fire_________________________ High Fire__________________ "W.C.

Oil Nozzle Supply Pressure Bachrach Scale Smoke Number Net Stack Temperature Low Fire__________________PSI Low Fire_________________________ Low Fire___________________°F High Fire__________________PSI High Fire_________________________ High Fire___________________°F

Firing Rate - GPH Over Fire Draft Low Fire__________________ Low Fire___________________ "W.C.

High Fire__________________ High Fire___________________ "W.C.

Operational Check of Controls

Operating Limit__________________� Aux LWCO______________________� Flame Safeguard________________�

Safety Limit_____________________� Low Gas Pressure_______________� Ignition Failure �

Low Water Cut Off_______________� High Gas Pressure_______________� Flame Failure �

Comments

CONTROL DESCRIPTIONS

STEAM BOILERS

Pressure Controls

All Columbia steam boilers are controlled by both operating and safety limit Pressure Control. Both devices are adjustable and use pressure actuated mercury switches. These switches open when pressure reaches the main scale set point value, cycling the boiler off.

The operating Pressure Control also has an adjustable differential feature. Differential settings values are subtractive from the main scale set point value, indicating the change in pressure for when the boiler will refire. Always adjust the differential set point above the required steam pressure for the sys-tem. Make the differential value as large as possible to prevent short cycling.

The safety limit Pressure Control does not have an adjustable differential, and has a manual reset fea-ture. The safety limit Pressure Control breaks the control circuit if the operating Pressure Control becomes inoperable, and steam pressure continues to climb. The burner will not start until the exces-sive pressure situation is corrected and the reset button is pushed.

Adjust the safety limit value higher than the operating limit under normal operating conditions. This setup allows the operating control to function properly and reduces the need to reset the control cir-cuit constantly. Set the safety limit value less than the error margin of the safety relief valve, so the Pressure Control can safely control boiler pressure.

Make set point value adjustments by turning the adjusting screws found on top of the Pressure Control casing.

For additional information on either Pressure Control, see the Danfoss Publication following this book-let.

Low Water Cut-offs

Low water cut-offs safely control boiler operation in the event of a low water condition. The standard LWCO for steam applications is a McDonnell & Miller #767. If an installation needs a CSD-1 require-ment, an additional Warrick 26C1C1C probe type LWCO is supplied. Other optional equipment used in place of, or in addition to, one of the aforementioned LWCO s includes water feeders and combi-nation LWCO/ feeders.

The McDonnell & Miller #767 is a float operated control consisting of a large sediment chamber with its own spring closing blow-off valve. The float actuated low water switch opens in a low water con-dition. In the same instance, the McDonnell & Miller #767 has an extra set of contacts that close with a drop in water level. If necessary, this set of contacts could be used to activate an additional water feeder.

A Warrick 26C1C1C “Probe” type LWCO is used only as a Secondary low water cut-off device. Its primary function is to protect the boiler against low water situations where the primary LWCO fails to break the control circuit. The probe mounts in the top head of the boiler and has a rod length lower than that of the primary LWCO. This relay must be manually reset if power is interrupted to the con-trol circuit for any reason. During operation, if the water level falls below the probe rod, the energized circuit breaks, causing the relay to open, disconnecting power to the burner. Restore the water level to the normal operating level, then manually reset the control to resume operation.

The most common optional equipment includes the McDonnell & Miller 42 Series Pump Control and Low Water Cut-Off and the McDonnell & Miller No. 247-2 Feeder Combination. These controls are mounted on the left side of the boiler using the 1" tappings found in the side and on top of the boil-er, as part of an equalizing line. These devices may be used as a primary or secondary LWCO. Both controls use a float activated switch to control LWCO and pump control functionality.

For additional information on the appropriate Low Water Cut-Off, see the LWCO cut sheets following this booklet.

Safety Valve

Safety valves shall be piped so that any discharge cannot cause injury to people or damage to prop-erty. The discharge piping must be supported so that the weight of the piping is not transmitted to the safety valve body. The weight supported by the valve outlet should not exceed that of a drip pan elbow. Installations requiring long discharge piping should not be connected directly to the safety valve. Refer to Drawing PL-049 in the Appendix.

In order to achieve the topmost performance and maximum safety valve life, maintain a proper oper-ating gap between the set pressure of the safety valve and the maximum operating pressure of the boiler.

If the valve discharges on its own, contact a qualified service technician to determine the cause. This may be an indication of equipment or system malfunction.

HOT WATER BOILERS

Aquastat® Controllers

All Columbia water boilers and indirect water heaters are controlled by both operating (Honeywell L4006A-100-240F) and safety limit (Honeywell L4006E 130-290F) Aquastat® Controllers. The safety limit should always be adjusted higher than the operating limit under normal operating conditions. If for any reason the water temperature would exceed the operating limit and not trip the control, the safety limit should break the circuit to the burner.

The operating Aquastat® (Honeywell L4006A-100-240F) consists of an adjustable thermostatic con-trol and separate temperature sensing immersion well. The immersion well mounts in the boiler s coil plate. Adjust the indicating dial to set the maximum operating temperature. The differential wheel set-ting is subtractive from the operating limit indicating the refire temperature. This differential set point should be adjusted above the required water temperature for the system. The differential wheel can be adjusted for 3° to 5°F .

The safety limit (Honeywell L4006E 130-290F), like the operating Aquastat®, consists of an adjustable thermostatic control and separate temperature sensing immersion well. This controller has a manual reset switch which must be depressed in the event that the operating circuit reached and shut off on safety.

For additional information on either the L4006A or L4006E, see Honeywell Publication 60-2104-8 following this booklet.

Low Water Cut-off

Hot water boilers utilize the McDonnell & Miller 750-MT-120 Probe Type Low Water Cut-Off with Remote Sensor. The 750-MT-120 has a test feature that allows this control to meet CSD-1 require-ments. Similar to the Warrick 26C1C1C, this control breaks the control circuit in the event of a low water condition and must be manually reset once the proper water level is restored.

For additional information on the McDonnell & Miller 750-MT-120 Probe Type Low Water Cut-Off with Remote Sensor see McDonnell & Miller Bulletin MM-212(A) and Installation and Maintenance Instructions MM-213(C).

Relief Valve

Relief valves are a safety devices to relieve boiler water pressure. Like safety valves, relief valves should be piped so any discharge cannot cause injury to people or damage property. See the “Safety Valve” description in the Control Descriptions, Steam Boiler section of this booklet.

MAINTENANCE

RECORD KEEPING

All manufacturers literature, spare parts lists, operating and maintenance procedures should be main-tained in the boiler room at all times. A log book should also be provided to record maintenance work, inspections, and other performance test results.

General Clean the boiler and heating surfaces whenever required. The frequency of the cleaning required to maintain the boiler at peak efficiency will be determined only by frequent inspections. It cannot be predicted. Your operating conditions might be different from your neighbors .

When in doubt - check it out.

WARNING: DISCONNECT ALL INCOMING ELECTRICAL POWER BEFORE SERVICING THE

BOILER. USE EXTREME CAUTION AROUND BOILER PIPING THE LOW WATER

CUT OFFS, SINCE THEY MAY BE VERY HOT.

The life of your boiler will be determined by the level of care given it by those who are responsible for maintenance. A log of the following items should be maintained in the boiler room at all times.

Daily Boiler Check & Maintenance List

1. Water Level Controls and Cut Offs are operating normally.

2. Instrument and equipment settings are normal.

3. Gauge glass is clean. If leaks are detected, replace glass, gaskets, and brass washers immediately. When replacing gauge glass use only 5/8" O.D. Pyrex® red line, high pressure, high temperature, glass tubing, with fire polished ends. See gauge glass maintenance section for proper method when installing this gauge glass.

4. Boiler water at proper operating level.

5. Blow down boiler as instructed under BLOWDOWN if required by application.

Remember, the life of your boiler is drastically reduced by sludge, scale, and corrosion. By proper treatment of the boiler water and systematic blow down procedures your boiler will provide years of service.

Weekly Boiler Check & Maintenance List

1. Check flame failure detection system.

A. Gas boilers: Close fuel supply to pilot and main gas and check shut down timing.

B. Oil boilers: Remove cad cell leads and check shut down timing.

2. Check fuel valves; Open limit switch and make aural and visual check.

3. Check ignition system flame signal.

Monthly Boiler Check & Maintenance List

1. Test all fan interlocks.

2. Check main burner safety shut off valve(s) for operational closure.

3. Oil fired; check fuel pressure interlocks when provided.

4. Gas fired; check high and low fuel pressure switches.

5. Flue or stack dampers; make visual inspection for proper operation.

6. Inspect heating surfaces for cleanness.

Semiannual Boiler Check & Maintenance List

1. Inspect burner components; Refer to burner manufacturers instructions.

2. Check the flame failure system components; Refer to the burner section of this manual.

3. Check piping and wiring of all interlocks and shut off valves.

4. Internal boiler plate inspection. Remove hand-hole assemblies; use new gaskets when replacing covers.

Annual Boiler Check & Maintenance List

1. Check operating Pressure Control Controller or Aquastat Controller.

2. Check high limit Pressure Control Controller or Aquastat Controller.

3. Test safety valves.

4. Remove the Low Water Cut Off and clean inside casting.

5. Oil fired - clean/replace oil filters or strainers if equipped

6. Oil fired - replace ignition electrodes if equipped.

7. Gas pilots - conduct pilot turndown test.

8. Gas fired - replace ignition and flame rods.

9. Gas fired - check drip leg/strainer.

10. Oil fired - check for refractory hold in.

11. Check Automatic Change Over Control if equipped.

12 Gas fired - perform valve leakage test.

Gauge Glass - Not required on hot water boilers only.

The water gauge glass must be kept clean. Dirt on, or in, the glass may be mistaken for the water level. Do not allow steam or water to leak from the water glass, as this may effect the accuracy of the level indication. Leaking of the gauge glass will also reduce the wall thickness of the glass to the point where it may explode.

WARNING: DO NOT OPERATE THE BOILER WITHOUT THE GAUGE GLASS PROTECTOR

INSTALLED. NEVER ATTEMPT TO WORK ON THE GAUGE GLASS WHILE THE

BOILER IS UNDER PRESSURE. ALWAYS CLOSE GAUGE VALVES PRIOR TO

TIGHTENING GASKETS ON WATER LEVEL GAUGE GLASS. SERIOUS INJURY

COULD RESULT.

Gauge Glass Replacement Instructions:

1. Make absolutely certain that the new water level gauge glass is 5/8" O.D. and is the correct length Pyrex® red line, high pressure, high temperature glass tubing with fire polished ends.

2. Close gauge glass valves.

3. Remove gauge glass protector.

4. Remove the old glass, gaskets, brass washers, and brass nuts. Be sure threads on the gauge valves are clean.

5. Install brass nuts, brass washers, and gaskets on each end of the gauge glass.

6. Insert glass tube into top gauge valve and lower the glass tube into the bottom gauge valve which contains a seat. Then raise glass 1/16". Do not allow glass to rest directly on the valve.

7. Hand tighten the lower glass nut and then the upper nut. While tightening these nuts, be sure to keep the red line opposite the viewing side.

8. With a wrench, snug up the bottom nut and then the top nut.

9. Replace gauge glass protector.

10. Open gauge glass valves fully. Failure to completely open the gauge glass valves renders the ball check safety feature inoperative.

11. Without pressure on boiler and with gauge valves closed, snug up the bottom nut and then the top nut with a wrench, after 1 day of operation.

Blowdown

Perform blowdown procedures on boilers that require make-up water such as steam boilers. Hot water and indirect hot water heaters (CWH-Series) are closed loop systems that recirculate the same water. These boilers should require minimal make-up water.

Blowing down the boiler is done to remove excess total dissolved solids. The actual amount of blow-down should be determined through boiler water analysis, done by a water treatment specialist. Until an analysis of your boiler water is made, the following guidelines should be used.

Blow down the boiler after firing equipment has been shut down for the evening. Allow boiler water to settle for approximately 10 minutes. Then open blowdown valve at a pressure between 5 and 10 psi for 30 seconds then close. Use this same procedure with the low water cut off blowdown ball valve. Then go back to the boiler blowdown valve, open and close the valve, very fast, two more times. Repeat this procedure with the low water cut off valve. This will rid the boiler of most precip-itated sediment. DO NOT EMPTY THE BOILER OF ALL ITS WATER.

WATER TREATMENT

Proper treatment of make-up water and boiler water is necessary to prevent scale, or other deposits, and corrosion within the boiler. The absence of adequate external and internal treatments can lead to operational upsets or total boiler failure. Where a choice is available, pretreatment external to the boil-er is always preferred and more reliable than treatment within the boiler.

Obtain, and follow, Instructions for feedwater treatment, prepared by a competent feedwater chemist.

Do not experiment with homemade treatment methods or compounds.

Representative samples of feedwater and boiler water must be analyzed frequently to ensure that they are in specification. The following terms and guidelines are to be used in conjunction with the advice of a water treatment specialist.

Recommended Guidelines for Boiler Water Treatment

RECOMMENDED

ANALYSIS COMMENTS

RANGE

pH 10-11 Low pH promotes corrosion

Total Alkalinity 200-700 ppm Low; promotes corrosion

Phosphates 30-100 ppm Prevents scale formation

Total Hardness 0-50 ppm Prevents scale formation

Chlorides 60-200 ppm A measure of proper blow down

Total Dissolved Solids 2000 ppm Maximum High solids may cause surging

Sulfites 20-30 ppm A good oxygen scavenger

Specific Conductance < 700 micro ohms cm A measure of proper blowdown

Oxygen < .007 mg/liter Prevents corrosion and pitting ppm = parts per million

Use proper water treatment to prevent the buildup of scale on the boiler. After scale has built up on the walls of the boiler it is almost impossible to remove it from the boiler. The introduction of acids into the pressure vessel is thoroughly discouraged, since virtually any solution that will chemically attack the scale will also attack the boiler metal.

pH The pH value of the boiler water is a number between zero and fourteen. Values below seven are acidic, seven is neutral, and values above seven are alkaline.

The pH factor is the most important factor influencing scale formation and the corrosive tendencies of boiler water. The pH should be maintained between a minimum of 10.5, and a maximum of 11.0 to prevent acidic corrosion of boiler tubes and plates, and to provide for the precipitation of scale form-ing salts before scale is deposited.

Below a pH of 5.0 the water is acidic enough to dissolve the steel boiler plates. Under these condi-tions the steel gradually becomes thinner and thinner until its destruction. At a pH between 5 and 9.4 pitting of shell plates will occur at a rate depending on the amount of dissolved oxygen in the boiler.

Dissolved Oxygen Dissolved oxygen is caused by the solubility of atmospheric oxygen into the supply water. Aeration of the city water supply is frequently used to remove other noxious gasses.