5.4.11 Columbia Boiler Manual.pdf

CT SERIES BOILERS

CT-10 CT-15 CT-20

CT-25 CT-35 CT-50

INSTALLATION, OPERATION and

MAINTENANCE MANUAL

COLUMBIA BOILER COMPANY

POTTSTOWN, PENNSYLVANIA

RECOMMENDED ANALYSIS COMMENTS RANGE

pH 10-11 Low pH promotes corrosion Total Alkalinity 200-700 ppm Low promotes corrosion Phosphates 30-100 ppm Prevent 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

Recommended Guidelines for Boiler Water Treatment

WARNING

Have your water tested by a local waer treatment specialist!

Proper Water Chemistry is essential to prevent scale, or other deposits, and corrosion with-in the boiler. The absence of adequate external and internal treatments can lead to oper-ational upsets or total boiler failure that is not covered under warranty.

Table Of Contents

PARTS WARRANTY

SERVICE POLICY

INSTALLATION

CLEANING AND FILLING A NEW STEAM BOILER

OPERATING THE BOILER

STARTING THE BOILER

STOPPING THE BOILER

BURNER START UP AND TEST INFORMATION

BOILER ROOM

DESCRIPTION OF BOILER COMPONENTS

MAINTENANCE

MAINTENANCE LOGS

TESTING OF BOILER COMPONENTS

WATER TREATMENT

RETURN SYSTEMS

BLOWDOWN SEPARATOR

TROUBLESHOOTING

APPENDICES

Replacement Parts for CT Series Boilers Panel Box - Inside View - Replacements Parts Probe Assembly - Replacement Parts Replacement Parts List for CT Series Boilers Gas Train Piping Diagrams Gas Train Components Boiler Wiring Diagram Safety Valve Piping, typical Typical CT Boiler Piping Layout - Drawing PL-098

Technical manuals for all controls are provided in the data package including level, pump, gage glass and pressure controls.

COLUMBIA BOILER COMPANY, REV 2-17

- 1 -

IMPORTANT SAFETY IFORMATION

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 recommendtions given in this manual.

5. Normal burner cycling is required. Undersizing the boiler, causing continuous firing without cycling will eventually damage the boiler, voiding the warranty.

6. Wrapping the CT Boiler with insulation will cause the boiler to overheat, voiding the warranty.

7. A draft regulator or barometric damper is required in the breaching to maintain a –.02 to –.04 draft when the burner has cycled off, and a –.06 to –.10 draft when firing. (Draft measured in inches of water column)

Read this manual before installing and using this product. Failure to do so can result in serious injury or death.

You have just purchased a quality steam boiler designed to the ASME Boiler Code and registered with the National Board of Boiler Inspectors. Treat this industrial equipment with care and respect. It is safe when installed, maintained, and used properly. Read the instruction carefully and contact the factory if you have any questions.

This manual contains safety messages. Each of the safety messages are preceded by one of the following signal word panels:

Safety messages preceded by this label contain information, that if not followed will result in death or serious injury.

Safety messages preceded by this label contain information, that if not followed could result in death or serious injury.

Safety messages preceded by this label contain information, that if not followed could result in minor or moderate injury.

Messages preceded by this label contain important information, but are not hazard-related.

Ensure that this manual is available to the boiler operator at any time.

Read carefully all safety labels attached to the boiler. If any safety label was damaged during shipment, contact the factory immediately:

DANGER

WARNING

NOTICE

CAUTION

- 2 -

LIMITED PARTS WARRANTY

The Columbia Boiler company (hereinafter Columbia) warrants the burner components and con-trols installed on its boiler/burner units to be free from defects in material 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, neg-lect, 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 fol-lows:

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 reason-ably available in Customer’s locality.

b. Where such local service is not available with respect to the above listed components, or where other components are involved, such defective equipment should be returned after receiving authorization from your dealer, freight prepaid, to the Columbia Boiler Co., 390 Old Reading Pike, Pottstown, PA 19464. The use of 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 equip-ment.

d. Equipment which is repaired or replaced will carry a warranty equal to the unexpired por-tion of the original equipment warranty.

e. If inspection by Columbia does not disclose any defect covered by this warranty, the equip-ment 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 EXCLU- SIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER REMEDIES. ALL IMPLIED WARRANTIES, INCLUD-

ING 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 con-nection with the sale of this equipment. Columbia’s liability and Customer’s exclusive remedy being limited to repairs or replacement as set forth above.

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SERVICE POLICY

Anything mechanical will inevitably need servicing. Steam and hot water boilers are rou-tinely 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 situation, the dealer or service organization should contact the selling distributor for help.

Should the problem persist, the distributor will contact the sales representative for assis-tance. 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 fol-lowing information. We must insist that this information be available to assure prompt serv-ice.

Boiler Model and Size (HP) ______________________________________________________ Boiler Serial Number ___________________________________________________________ Boiler National Board Number __________________________________________________ Date Installed _________________________________________________________________ Burner Type and Model ________________________________________________________ Installer’s Name ____________________________________ Phone (_____) ______________ Address ______________________________________________________________________ Distributor’s Name __________________________________Phone (_____) ______________ Address ______________________________________________________________________ Sales Representative ________________________________ Phone (_____) ______________ Address ______________________________________________________________________ Specific Problem - Detailed

- 4 -

INSTALLATION

The Columbia Model CT Steam Boiler is furnished completely piped, wired, and assem-bled. It has been factory tested and is ready for operation. This steam boiler is designed to operate using No. 2 fuel oil and/or natural, manufactured, or liquid propane (LP) gas, and to be powered by standard AC electrical service.

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. The electrical installation must be in accordance with the National Electrical Code.

CLEARANCES

The boiler is to be placed on noncombustible flooring, in an approved boiler room, with the following clearances to combustible materials.

Underwriters Laboratories (UL) approved clearances:

Side: 18 inches Top: 18 inches Front: 48 inches Chimney connector: 18 inches

Reduced clearance installation must follow the recommendations as outlined in NFPA-31.

Reduced clearance installations should be avoided if possible, as this will make it much harder for qualified technicians to perform routine maintenance in and around your boiler.

Clearances to noncombustible materials shall be in accordance with state and local codes.

In the absence of local codes, it is recommended that the above stated clearances be fol-lowed.

FLUE PIPING

The CT Series Boilers are power fired, steam boilers and are considered a Category I - Fan-Assisted Gas Appliance – An appliance that operates with negative static pressure in the vent, a temperature that is high enough to avoid condensation in vent, and an integral fan to draw a controlled amount of combustion supply air through the combustion cham-ber; and must be vented accordingly. Consult the factory for proper venting of the boiler for any unusual conditions that may exist at the job-site.

CONVENTIONAL VENTING

For boilers vented into a chimney, be certain the chimney is clean, and clear of obstruc-tions. The stack and chimney material shall comply with all local codes. The flue pipe

- 5 -should be pitched upward at least 1/4" per foot of run. Use only elbows and straight sec-tions. Tees may be used in straight sections with a barometric draft regulator. Tees, howev-er, should not be used for a ninety-degree turn. Each joint should be securely fastened with sheet metal screws. The flue pipe must not be inserted beyond the inside wall of the chim-ney.

It is recommended that a mechanical draft regulator or barometric damper be installed in the flue and set to maintain a -0.02” to -0.04” water column pressure at the breach when the burner is off and a -0.06” to -0.10” water column pressure while the burner is in oper-ation.

Refer to the following list for proper size of the flue pipe. DO NOT REDUCE THE FLUE OR CHIMNEY SIZE TO LESS THAN THE OUTLET SIZE ON THE BOILER. Consult the factory if the boiler must be vented into a chimney that is smaller than the boiler outlet size.

SIDEWALL VENTING

This section provides instructions for the installation of boiler assemblies for which sidewall venting may be utilized. This includes No. 2 fuel oil, natural gas, or combination No. 2 fuel oil and natural gas sizes 9.5 to 50 H.P. The following criteria is required for installa-tions using sidewall venting:

1. Flue vent piping shall be pitched upward at 1/4" per foot of length.

2. A U.L. Approved draft fan must be installed to provide sufficient draft, minimum (-.02 to -.04”) WC pressure) to safely vent the products of combustion.

3. The draft fan should be located as close to the flue outlet from the building as possible.

4. Draft regulation sufficient to lower the draft to between -.02” and -.04” WC pressure may be required. The draft regulator(s) must be between the boiler and draft fan.

5. The draft fan shall have an air flow proving switch wired in series with the boiler air safety switch.

6. The sidewall vent total length from boiler exhaust to termination shall not exceed 40 feet with 4 elbows maximum.

While the instructions and suggestions set forth in this manual are safe and proper, it is the responsibility of the installer and the owner to assure adherence to all local codes.

BOILER

CT-10 6"

CT-15 8"

CT-20 8"

CT-25 10"

CT-35 12"

CT-50 12"

PROPER FLUE

PIPE SIZE

- 6 -

GAS SUPPLY PIPING

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

The minimum gas supply pressure required by the burner is seven inches water column, measured at the first gas valve, for all CT model 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 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 recommended 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 determine the correct pipe size for the length of run needed.

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

COLUMBIA BOILER COMPANY, REV 2-17

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REQUIRED INPUT - CUBIC FEET OF GAS PER HOUR

GAS TYPE CT-10 CT-15 CT-20 CT-25 CT-35 CT-50

NATURAL 399 630 840 1050 1470 2100

PROPANE 160 252 336 420 735 840

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 lines should be tested for leaks using a soap solution. 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.

- 8 -

OIL SUPPLY PIPING

Consult the burner section of this manual for oil line type and sizing requirements for prop-er operation. The size of oil lines is extremely important for proper operation. Suction vac-uums must be held to acceptable limits.

All oil feed lines must be air tight. Use as few fittings as possible when assembling the oil lines. The slightest air leak, usually caused by loose fittings or bad gaskets, can cause poor starts, smoky starts, sooting of burner parts, inefficient operation, and a dangerous com-bustion condition.

A vacuum test should be done on all installation to ensure that all fittings are tight and the oil lines are of proper size. Always use flare fittings instead of compression fittings on oil service lines. Compression fittings allow more of a chance for air to be introduced into the oil supply.

WARNING: TEFLON® TAPE SHOULD NEVER BE USED WITH ANY OIL LINE CONNEC-

TIONS. THE USE OF TEFLON® TAPE ON BURNER COMPONENTS OR OIL

SERVICE LINES WILL VOID MOST BURNER WARRANTIES.

For additional information consult the burner section of this manual.

ELECTRICAL SUPPLY

Connect the electric supply to the boiler and condensate return system as shown in the wiring diagrams. Separate electrical services and disconnects must be provided for both the boiler and the return system. If both 110 volts AC and 220 volts AC are needed, sep-arate disconnects should be provided. The wiring must be installed in accordance with the National Electrical Code and any other state and local codes.

All disconnects should provide overload protection to prevent injury to personnel or dam-age to equipment.

Be sure that the incoming voltages match that of the appliances before applying power.

Make a special point of checking the internal wiring of the blower motor as most motors can be wired for either 110 or 220 volts.

FEEDWATER

Connect the feedwater supply from the condensate return tank to the boiler inlet feedwater connection. See Figure 2 and Piping Layout PL-098 in Appendix. Columbia Boiler Company provides one spring type check valve in the feedwater piping. An additional swing type check valve should be installed in the feed line as close to the pump as possible.

These valves should be piped in the horizontal position.

Do not use the pump as a piping support. It is very important that the piping be independ-ently supported at the pump.

WAWAW RNING: WARNING

- 9 -

FEEDWATER PIPING

Figure 2

Do not fill the boiler until the installation is complete and you are ready to fire the burner.

Firing the burner will then boil the water which will drive off the dissolved oxygen in the water and help maintain the proper boiler water chemical balance.

See the WATER TREATMENT section for important information regarding the proper chem-ical water treatment required to insure satisfactory service life of the boiler.

On long horizontal runs of piping, it is best to maintain the piping as level as possible.

Avoid high spots that will collect air and lead to erratic pumping. Install a check valve to prevent the boiler water from back feeding into the service water supply.

STEAM PIPING

Figure 3

EQUIPMENT

REQUIRING

STEAM

- 10 -

STEAM OUTLET

Connect the field steam piping to the outlet on top of boiler. See Figure 3. If a main steam manifold is used, it should be pitched 1/4" per foot of horizontal run so that condensate will run into a steam trap, rather than back into the boiler. All steam supplies should be taken off the top of the manifold to prevent condensate from entering the process machines.

SAFETY VALVE

Safety valves should be piped so that they cannot discharge on people or damage prop-erty. The discharge piping must be supported so that the weight of the piping is not trans-mitted to the safety valve body. Refer to drawing PL-049 in the Appendix for an example of typical safety valve piping. the weight supported by the valve outlet should not exceed the weight of a drip pan elbow. Use only Schedule 40 pipe for discharge piping. DO NOT USE Schedule 80, extra strong, or double extra strong discharge pipe or connections.

Installations requiring long discharge piping should not be connected directly to the safety valve.

During installation, be sure that pipe compound or tape is used only on external threads and that the inlet of the valve is free of any foreign material.

DO NOT USE A PIPE WRENCH when working on the safety valve. use only the proper type and size wrench.

WARNING: NEVER REDUCE THE INLET OR OUTLET SIZE OF THE SAFETY VALVE;

NEVER HANG PIPING ON THE SAFETY VALVE;

NEVER INSTALL VALVES(S) IN THE SAFETY VALVE PIPING;

NEVER PLUG THE BONNET VENT. SERIOUS DAMAGE OR INJURY

COULD RESULT FROM THE FAILURE OF THE SAFETY VALVE.

BLOWDOWN PIPING

Connect the boiler, the Warrick Low Water cut Off, and sight glass blowdown lines in accordance with local code requirements. See Figure 4. the blowdown must be piped to a safe place of discharge to prevent injury to personnel or property damage.

It is recommended that a blowdown tank be used to safely discharge the blowdown into the sewers. Check state and local codes concerning the maximum allowable temperature for blowdown entering public sewer systems.

Do not reduce blowdown piping from boiler outlet. All valves, piping, and forged fittings used n the blow-down lines shall be of suitable rating, and in accordance with ASME Code B31-Power Piping. All pipe nipples used shall be Schedule 80 pipe.

WARNING: NEVER REDUCE THE VENT SIZE OF THE BLOWDOWN TANK.

To properly and safely blow down the boiler, the vent must be piped full size for the entire length, and must terminate at a safe place of discharge per local codes.

- 11 -

Figure 4 BLOWDOWN PIPING

- 12 -

CLEANING AND FILLING A NEW STEAM BOILER

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

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 CONCENTRATE-

ED SOLUTION TO CONTACT SKIN OR CLOTHING.

3. Mix the chemicals with water and pour into the boiler through any convenient opening in the boiler.

4. Start the firing equipment.

5. Boil the water for at least five hours.

6. Stop the firing equipment.

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

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

9. Fill the boiler to the normal waterline.

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

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

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

EQUAL AMOUNTS

CAUSTIC SODA AND

TRISODIUM PHOSPHATE

CT-10 8 oz.

CT-15 12 oz.

CT-20 1 lb.

CT-25 1 lb. 4 oz.

CT-35 1 lb. 14 oz.

CT-50 4 lbs. 9 oz.

BOILER

MODEL

CAUTION

- 13 -

OPERATING THE BOILER

NOTICE: Although your new Columbia Boiler has been test fired at the factory, it must be “set up” for the conditions at your 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 certifi-cates 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 tem-peratures, 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.

The Gauge Glass Protector must be properly installed prior to operating the boiler, and all cover plates, enclosures, and safety devices must be installed at all times except while per-forming 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 blowdown valves, including water column drain valves, gauge glass drain valves, and gauge cocks should be closed.

The safety 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 imposing a load on the safety valve bodies. Make sure the safety valve is piped to a safe location to prevent injury.

The boiler feed pump(s) 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 characteris-tics match those of the electric supply to which they are connected.

All Columbia boiler company CT Series boilers are test fired at the factory, however, 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, microammeter, vacu-

- 14 -um gauge, 0-300 PSI pressure gauge, combustion analyzer and DC volt meter.

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.

Turn the boiler disconnect switch to the ON position.

Open the feedwater valve and turn on the main disconnect for the condensate pump. The pump should come on and fill the boiler to its normal operating level.

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

Push the RESET button on the Control panel Cover. The burner should start.

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

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

New CT boilers will normally expel a vapor from joints and openings in the jacket. This is a temporary condition, caused by moisture evaporating out of the refractory insulation behind the jacket, and will eventually disappear.

STOPPING THE BOILER

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

INLET GAS PRESSURE

Inlet gas pressure to the main gas valve should be between seven and fourteen inches water column.

If the inlet gas pressure exceeds fourteen inches water column, the pilot regulator and main gas regulator will “lock up” and become inoperative, and damage may occur. Inlet gas pressure above fourteen inches water column will require an additional pressure reducing valve.

If the inlet gas pressure is below seven inches water column the burner may not be capable of the rated boiler output. If the gas pressure is below seven inches water column contact your local gas company. If the local gas company is unable to help, contact the factory for assistance.

NOTICE

- 15 -

BURNER START UP AND TEST INFORMATION: REQUIRED

For a new boiler start up, or for troubleshooting an existing installation, the following infor-mation 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: q Natural Gas q LP Gas q Fuel Oil (#2) q Other_____________________

Gas Firing

Gas Pressure At Train Inlet Burner in Off Position________"W.C.

Gas Pressure At Train Inlet High Fire__________________"W.C.

Gas Pressure At Main Orifice High Fire__________________"W.C.

Gas Pressure At Pilot Orifice __________________________"W.C.

Oil Firing

High Fire Vacuum Reading At Oil Pump Inlet__________________"H.G.

Oil Nozzle Supply Pressure Low Fire______________________PSI High Fire_____________________PSI

Firing Rate - GPH Low Fire________________________ High Fire_______________________

Operational Check of Controls

Operating Limit_________________q

Safety Limit____________________q

Low Water Cut Off______________q

Flame Signal Readings Pilot____________________________

CO2

High Fire________________________

CO

High Fire________________________

Measured INput Rate - BTU/HR High Fire __________________"W.C.

CO2

Low Fire ________________________ High Fire________________________

Bachrach Scale Smoke Number Low Fire ________________________ High Fire________________________

Over Fire Draft Low Fire___________________"W.C.

High Fire __________________"W.C.

Aux LWCO ____________________q

Low Gas Pressure ______________q

High Gas Pressure ______________q

Stack Outlet Test Point Draft High Fire __________________"W.C.

Over Fire Draft High Fire __________________"W.C.

Net Stack Temperature High Fire______________________°F

Gas Pressure At Pilot Orifice __________________________"W.C.

Stack Outlet Test Point Draft Low Fire___________________"W.C.

High Fire__________________"W.C.

New Stack Temperature Low Fire______________________°F High Fire_____________________°F

Flame Safeguard _______________q

Ignition Failure q

Flame Failure q

Comments

- 16 -

BOILER ROOM

Lighting The boiler room should be well lighted and should have a source of emergency lighting. If a flashlight is used for this purpose, it should be maintained in usable condition, and it should not be removed from the boiler room.

Care should be taken to prevent bright, direct sunlight from shining on the burner, as the flame sensing controls may receive a false flame signal.

Water Supply and Drain Connections

Convenient water supply connections for flushing the boiler and cleaning the boiler room floor should be installed.

Unobstructed floor drains, properly located in the boiler room floor, will aid in the proper cleaning of the boiler room.

Make-up Air

The burner must have adequate air supply, which must be kept clear at all times. Do not run exhaust fans in the immediate proximity of the boiler room, as they will cause a reversal of draft at the burner. Ensure that sufficient make-up air is available, even if that requires a window to the outside to be left open. This air is necessary to insure complete combus-tion, a clean fire, and to prevent nuisance shutdowns due to excessively dirty burner parts.

Air from the outside may be provided through ducts, fixed louvers, or motorized louvers.

WARNING: WITHOUT SUFFICIENT MAKE-UP AIR, THE BOILER WILL NOT OPERATE

PROPERLY, AND BURNER COMPONENT DAMAGE COULD OCCUR.

To calculate the required fresh air opening to the outside, allow 21 square inches for every boiler horsepower. For example a 10-horsepower boiler would require two hundred and ten square inches of free opening. This is equal to a 15" x 15" square hole, or a 18" diam-eter round hole of free, unrestricted area. If louvers or screens are used, contact the man-ufacturer for percentages (typically around 40%) that must be added to allow for restric-tion.

The following table can be used to size the amount of free area needed for the various sizes of CT boilers. A point to remember for round openings - two 10" round openings DO NOT equal one 20" round opening. Four 10" round openings are needed to obtain the same amount of free area.

Columbia Boiler Company will not be held liable for damage to the boiler or burner components caused by insufficient burner make up air.

- 17 -

REQUIRED BOILER MAKE-UP AIR

OPENING SQUARE HOLE ROUND PIPE

MIN. SQUARE SIZE - INCHES SIZE - INCHES

INCHES (APPROXIMATE) (APPROXIMATE)

9.5 399,000 210 15 X 15 18

15 630,000 315 18 X 18 20

20 840,000 420 21 X 21 24

25 1,050,000 525 23 X 23 26

35 1,470,000 735 28 X 28 32

50 2,100,000 1050 33 X 33 38

Housekeeping

Provide adequate space around the boiler for inspection and service. Do not allow the boiler room to become a storage room.

Fire protection apparatus, and fire prevention procedures for boiler room areas shall conform to the recommendations of NFPA and all local codes.

WARNING: DO NOT STORE OR USE GASOLINE OR ANY OTHER FLAMMABLE LIQUIDS

AND VAPORS IN THE VICINITY OF THE BOILER OR BOILER ROOM.

BOILER SIZE BTU

(HORSEPOWER) INPUT

- 18 -

DESCRIPTION OF BOILER COMPONENTS

Refer to the drawings in this manual for the location of the following listed components.

See Table of Contents for location of applicable drawing and/or specification sheet.

The standard control circuit for the CT Series Boilers consists of probe type, primary and secondary low water cut off and pump controls enclosed in a panel box; and typical oper-ating and safety limit pressure controls. The standard water column consists of three probes used for the primary low water cut off and pump control, the Operating Pressure control, Safety Limit Pressure Control, and a 0-300 psi pressure gauge.

DESCRIPTION OF PANEL BOX COMPONENTS

Water Level Control

The boiler water level control consists of a combination low water cut-off and pump control.

The control handles two separate level functions, one differential, and one single level, using probes and contactors. The differential function uses a low probe (L) and high probe (H) to operate the pump. When the water level in the boiler drops below the level of the low probe, the normally closed contact is energized, which in turn supplies power to the pump motor contactor/starter, causing the pump to feed water to the boiler. The “PUMP ON” light will also come on. As the pump raises the level in the boiler and the water makes contact with the high probe, the contactor is de-energized, breaking the circuit, stopping the pump and turning off the “PUMP ON” light.

If the pump or water supply should fail, and the water level in the boiler continues to fall below the Low Level Cut Off (LLCO) probe, the second contactor de-energizes the normally closed contact, shutting off power to the burner, and energizes the normally open contact, turning on the “LOW WATER” light and/or an optional low water alarm bell.

Contact the factory with your boiler serial number to determine correct probe lengths for your boiler.

The water level control will reset automatically after a Low Water Cut Off. If preferred, a normally closed, Manual Reset push button is available as an option.

Motor contactor or Starter

A Motor contactor or Starter is provided to take the high amperage electrical load off the pump motor switches of the water level control. A Motor Starter also provides electrical overload protection for the feedwater pump motor.

A Motor Contactor is provided as standard equipment on the CT-9.5 thru CT-25 Boilers, and a Motor Starter is provided as standard equipment on the CT-35 and CT-50 Boilers.

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Low Water Cut-Off

The manual reset “probe” is used as a supplementary safety device for protecting the boiler against damage from low water. It is designed to operate if the water level control low water cut-off should fail to operate for any reason. This unit is set to operate at a water level in the boiler lower than that of the water level control. See drawing CT-415 in the appendix for installation of probe rod.

This unit consists of a circuit board design with one normally open (N.O.) non-powered contact. When reset, it completes a circuit between the probe rod and the boiler drum, through the water in the boiler. If the water level falls below the probe rod, the circuit is broken causing the contact to open, breaking the circuit to the burner and energizing an alarm circuit (if equipped).

NOTICE: This relay must be reset after a low water condition has been corrected or after any interruption in the electrical supply.

DESCRIPTION OF OPERATING CONTROLS AND SAFETY DEVICES

Operating Pressure Control

This switch opens on pressure rise. It should be set at the maximum operating pressure desired. Do not set the operating pressure higher than 135 PSI. The differential deter-mines when the burner will restart. The differential should be set at a value as large as pos-sible to keep the unit from short cycling.

The pressure control must be level in order to operate accurately. It is level when the level-ing indicator hangs freely with its pointer directly over the index mark inside the back cover of the case.

The upper operating or cut-off pressure is determined by the main scale set point, while the lower operating or cut-in pressure is determined by the main scale operating point minus the differential.

Adjust the main scale set point for the desired operating pressure by turning the main scale adjusting screw on top of the case until the main scale setting indicator is at the desired pressure. Adjust the differential set point for the desired cut in pressure by turning the adjusting screw on top of the case until the differential setting indicator is at the desired setting.

Safety Limit Pressure Control The Safety Limit operates essentially the same as the pressure control described previously except this limit is equipped with a reset button and does not have a differential. The pur-pose of the Safety Limit is to shut down the burner if the operating pressure control becomes inoperable and steam pressure continues to climb. The burner will not start until the situa-tion is corrected and the reset button is pushed. The high limit of the Safety limit must be set above the operating pressure control setting.

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Adjust the main scale set point about 20 PSI higher than the operating pressure control by turning the main scale adjusting screw on top of the case until the main scale setting indi-cator is at the desired pressure.

There are a number of pressure controls that may be used interchangeably. Please see additional information in the manual appendices.

Safety Valve

Safety valves shall be piped so that any discharge cannot cause injury to people or dam-age to property. 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 operating gap between the set pressure of the safety valve and the maximum oper-ating pressure of the boiler.

The minimum recommended operating gap for this valve is 10%, but at no time less than 7 PSI. Under no circumstances should this gap be less than 7 PSI or seat leakage can occur. Failure to maintain this operating gap can result in an accumulation of deposits on the seating surface that may impede proper operation of the safety valve.

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.

Gauge Glass Protector

The gauge glass protector is provided to guard against personnel injury and component damage in the event of a breakage of the sight glass. The gauge glass protector must be properly installed prior to operation of the boiler.

DESCRIPTION OF OPTIONAL EQUIPMENT

Manual Dual Pressure (Optional) A toggle switch is provided in conjunction with an additional Pressuretrol to manually change from a high operating pressure to a low operating pressure. See wiring diagrams enclosed.

Manual Reset Pushbutton (After Low Water Cut off) (Optional) A normally closed, Manual Reset Pushbutton and Control Board is available. This pushbut-ton, when installed, must be pressed and held for 10 seconds to start burner operation after a low water condition has been corrected.

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Time Control (optional) A seven-day time clock, when furnished, provides Automatic Dual Pressure or Automatic Off/On Operation, whichever is desired. An adjustable time switch makes one circuit and breaks another simultaneously at as many intervals every 24 hours as required. See wiring diagrams enclosed.

When used for On/Off operation, one side of the circuit is connected in series with the pressure control. The other side is not used. On dual pressure operation an additional pres-sure control is connected in series, on one side of the time switch.

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MAINTENANCE

RECORD KEEPING

All manufacturers’ literature, spare parts lists, operating and maintenance procedures should be maintained 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.

DISCONNECT ALL INCOMING ELECTRICAL POWER BEFORE SERVICING THE

BOILER. USE EXTREME CAUTION AROUND BOILER PIPING AND THE WAR-

RICK SERIES DF LOW WATER CUT OFF 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 boil-er 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 and protector is installed. If leaks are detected, replace glass, gaskets, and brass washers immediately. When replacing gauge glass use only 5/8" O.D. x 10-1/4" long 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.

6. Blow down probe type low water cutoff.

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.

WARNING

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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.

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.

2. Check high limit Pressure Control.

3. Test safety valves.

4. Remove the Warrick Series DF 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.

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Boiler Lay-Up When a boiler is taken out of service,the unit should be cooled until the water is below the atmospheric boiling point or to a temperature suitable for site specific requirements. The boiler may then be drained and flushed out and an inspection should be made to deter-mine what repair work, if any, is necessary and what cleaning should be done. A decision should then be made to employ dry or wet storage.

Whenever a package boiler is taken out of service for any purpose, it should be internally cleaned when put back into service or placed in wet or dry storage. Loose material in the form of dirt, trash, mill scale, or deposits should be removed by washing or other mechan-ical methods.

Dry Storage

Dry storage is a procedure preferable for boilers out of service for extended periods of time or in locations where freezing temperatures may be expected during storage.

The cleaned boiler should be thoroughly dried, since any moisture left on the metal surface would cause corrosion to occur on long standing. Precautions should be taken to preclude entry of moisture in any form, into the water side of the unit.

To prevent moisture attack during dry storage, moisture absorbing material such as quick-lime at the rate of 2 pounds or silica gel at the rate of 10 pounds for 1000 gallon capacity, may be placed on trays inside the boiler to absorb moisture from the air. The hand holes should be closed and all connections on the boiler be tightly blanked. The effectiveness of the materials for such purposes and need for their renewal may be determined through regular internal boiler inspections.

Wet Storage

Wet Storage is preferable when boilers are to be paced in storage condition for short peri-ods of time, typically less than a year. The procedure should not be employed for boilers in locations where freezing temperatures may be expected during standby.

The cleaned boiler should be filled to the top using condensate or feed water, either of which should be conditioned chemically to minimize corrosion during standby and closed.

Prescribed concentrations of caustic soda and of scavenger such as sodium sulfite may be employed. Concentrations of approximately 450 parts per million (ppm) of caustic soda and 200 ppm of sodium sulfite may be used for this purpose. You should consult your boil-er water treatment company for the specific requirements at your site. Water pressure greater than that of the atmosphere should be maintained within the boiler during the stor-age period.

The percentage of soda and sulfite noted above is greater than recommended for operation of the unit. It will be necessary to completely drain the unit prior to placing it on-line and to treat the water during operation according to the recommendation of the boiler water treatment company employed.

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Gauge Glass 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.

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. x 10- 1/4" long 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. Open gauge glass valves fully. Failure to completely open the gauge glass valves renders the ball check safety feature inoperative.

10. Without pressure on boiler and with gauge valves closed, tighten gaskets again after 1 day of operation.

Blowdown

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

Blow down should be done in the evening after firing equipment has been shut down for approximately 20 minutes and at a pressure between 20 and 40 psi. Some pressure must be left on the boiler for proper blow down. Important: Boiler water must be settled for proper blowdown.

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Blowdown Instructions To blow down the boiler, open the slow opening (“Y” type) blowdown valve first. Open boiler blowdown ball valve 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 precipitated sediment. DO NOT EMPTY THE

BOILER OF ALL ITS WATER.

The Warrick Series DF Low Water cut Off & Pump Control should be blown down at least once each day when the boiler is in operation. This is essential to flush accumulation of sediment from the float chamber. Failure to do so will result in the failure of the control to shut off the burner on low water. During the blowdown operation, check to see that all of the control probes are operating properly. To check operation of the probes, open the blowdown valve while the burner is in operation. When the water level drops, the alarm circuit should close and sound the alarm (if alarm is installed) and the burner should stop firing.

Hand Hole Gasket Replacement

Part number 480210 (fits all models)

Remove the old gasket and thoroughly clean the mating surfaces inside the boiler and on the hand hole surfaces. A thin wire or a piece of string tied to the hand hole casting will help prevent “losing” the casting in the boiler when removing or installing gaskets.

Place the new gasket on the hand hole making sure that it fits evenly all the way around.

The use of adhesive on the plate gasket is recommended in order to hold the gasket in place while installing the assembly in the boiler.

PROPER PRESSURE ON GASKET OF HANDHOLE PLATE

Figure 7

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Install the plate assembly in the boiler, evenly spaced as possible.