CT SERIES BOILERS CT-6 CT-10 CT-15 CT-20 CT-25 CT-35 CT-50 INSTALLATION, OPERATION and MAINTENANCE MANUAL COLUMBIA BOILER COMPANY POTTSTOWN, PENNSYLVANIA CT BOILER WITH PARTIAL SECTION Figure 1 Table Of Contents PARTS WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CLEANING AND FILLING A NEW STEAM BOILER . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STOPPING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BURNER START UP AND TEST INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDEWALL VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOILER ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION OF BOILER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 13 13 15 16 19 21 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE LOGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING OF BOILER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 31 33 39 RETURN SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 BLOWDOWN SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Replacement Parts for CT Series Boilers Panel Box - Inside View - Replacements Parts Warrick 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 Warrick Dual Function Controls Warrick Series 3K Electrode Fittings Warrick Probe Series 26 Controls Tubular Gage Glasses - Use and Care Danfoss Pressure Controls Typical CT Boiler Piping Layout - Drawing PL-098 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 your boiler. 4. All state and local codes take precedence over any recommendations given in this manual. 5. NOTE: The CT Boiler is not designed for continuous, nonstop operation. Normal burner cycling is required. Continuous operation will eventually damage the boiler, voiding the warranty. 6. Wrapping the CT Boiler with insulation will cause the boiler to overheat, voiding the warranty. service technicians should FM-148 COLUMBIA BOILER COMPANY, REV 6-06 -1- do any work on LIMITED PARTS WARRANTY The Columbia Boiler company (hereinafter Columbia) warrants the burner components and controls 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, 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 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 equipment. d. Equipment which is repaired or replaced will carry a warranty equal to the unexpired portion of the original equipment warranty. e. If inspection by Columbia does not disclose any defect covered by this warranty, 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 connection with the sale of this equipment. Columbia’s liability and Customer’s exclusive remedy being limited to repairs or replacement as set forth above. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 -2- 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 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 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. We must insist 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 ________________________________________________________ Installer’s Name ____________________________________ Phone (_____) ______________ Address ______________________________________________________________________ Distributor’s Name __________________________________Phone (_____) ______________ Address ______________________________________________________________________ Sales Representative ________________________________ Phone (_____) ______________ Address ______________________________________________________________________ Specific Problem - Detailed FM-148 COLUMBIA BOILER COMPANY, REV 6-06 -3- INSTALLATION The Columbia Model CT Steam Boiler is furnished completely piped, wired, and assembled. 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: Top: Front: Chimney connector: 18 18 48 18 inches inches inches 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 followed. FLUE The CT series boilers are pressure fired steam boilers, and need only to be properly vented. Consult the factory for proper venting of the boiler for any unusual conditions that may exist at the job-site. For boilers vented into a chimney, be certain the chimney is clean, and clear of obstructions. Connect the boiler flue outlet to the chimney using galvanized flue pipe. 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. The flue pipe should be pitched upward at least 1/4" per foot of run. Use only elbows and straight sections. Tees FM-148 COLUMBIA BOILER COMPANY, REV 6-06 -4- may be used in straight sections with a barometric draft regulator. Tees, however, 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 chimney. Columbia Boiler approves the use of galvanized “B” type vent that is suitable for 550°F stack temperature as proper and safe for this application, but any and all codes take precedence. BOILER PROPER FLUE PIPE SIZE CT-6 CT-10 CT-15 CT-20 CT-25 CT-35 CT-50 6" 6" 8" 8" 10" 12" 12" 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 five inches water column for the CT-6 and CT-10, and seven inches water column for the CT-15, CT-20, CT-25, CT-35 and CT-50. 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 -5- REQUIRED INPUT - CUBIC FEET OF GAS PER HOUR GAS TYPE CT-6 CT-10 CT-15 CT-20 CT-25 CT-35 CT-50 NATURAL 252 399 630 840 1050 1470 2100 PROPANE 101 160 252 336 420 735 840 CAPACITY OF PIPE - CUBIC FEET OF GAS PER HOUR AT 0.2" W.C. PRESSURE DROP Equivalent Length (ft) 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" 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 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 -6- OIL SUPPLY PIPING Consult the burner section of this manual for oil line type and sizing requirements for proper operation. The size of oil lines is extremely important for proper operation. Suction vacuums 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 combustion 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 CONNECTIONS. 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, separate 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 damage 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 independently supported at the pump. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 -7- 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 chemical 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 FM-148 COLUMBIA BOILER COMPANY, REV 6-06 -8- 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 property. The discharge piping must be supported so that the weight of the piping is not transmitted 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. 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 -9- Figure 4 BLOWDOWN PIPING FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 10 - 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 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 CONCENTRATEED 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. BOILER MODEL CT-6 EQUAL AMOUNTS CAUSTIC SODA AND TRISODIUM PHOSPHATE 5 1/3 oz. 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 11 - OPERATING THE BOILER NOTE: 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 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. 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 performing 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 characteristics 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, vacuFM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 12 - um 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. 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. Turn the boiler disconnect switch to the ON position. NOTE: 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. 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 outlines in the burner section of this manual to set up the burner for proper operation. NOTE: 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 13 - GAS BURNERS BURNER NATURAL GAS ORIFICE SIZE AND ORIFICE PRESSURE (INCHES WATER OCLUMN) LIQUID PROPANE GAS ORIFICE SIZE AND ORIFICE PRESSURE (INCHES WATER COLUMN) CT-6 POWER FLAME JR15A-10 5/16 (.313) / 3.5" “D”(.242) / 3.5" CT-10 POWER FLAME JR15A-10 3/8 (.375) / 3.5" 19/64 (.297) / 3.5" CT-15 POWER FLAME JR15A-10 15/32 (.469) / 3.5" “T”(.358) / 3.5" CT-20 POWER FLAME JR30A-12 9/16 (.563) / 3.5" 15/32 (.469) / 3.5" CT-25 POWER FLAME JR30A-12 23/32 (.719) / 3.5" 1/2 (.500) / 3.5" CT-35 POWER FLAME JR50A-15 11/16 (.688) / 3.5" 19/32 (.594) / 3.5" CT-50 POWER FLAME JR50A-15 BOILER MODEL None x 3.5" 25/32 x 3.5" 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 14 - 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: 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. Flame Signal Readings Pilot____________________________ Stack Outlet Test Point Draft High Fire __________________"W.C. Gas Pressure At Train Inlet High Fire__________________"W.C. CO2 High Fire________________________ Over Fire Draft High Fire __________________"W.C. Gas Pressure At Main Orifice High Fire__________________"W.C. CO High Fire________________________ Net Stack Temperature High Fire______________________°F Gas Pressure At Pilot Orifice __________________________"W.C. Measured INput Rate - BTU/HR High Fire __________________"W.C. Gas Pressure At Pilot Orifice __________________________"W.C. High Fire Vacuum Reading At Oil Pump Inlet__________________"H.G. CO2 Low Fire ________________________ High Fire________________________ Stack Outlet Test Point Draft Low Fire___________________"W.C. High Fire__________________"W.C. Oil Nozzle Supply Pressure Low Fire______________________PSI High Fire_____________________PSI Bachrach Scale Smoke Number Low Fire ________________________ High Fire________________________ New Stack Temperature Low Fire______________________°F High Fire_____________________°F Firing Rate - GPH Low Fire________________________ High Fire_______________________ Over Fire Draft Low Fire___________________"W.C. High Fire __________________"W.C. Oil Firing Operational Check of Controls Operating Limit_________________q Aux LWCO ____________________q Flame Safeguard _______________q Safety Limit____________________q Low Gas Pressure ______________q Ignition Failure q Low Water Cut Off______________q High Gas Pressure ______________q Flame Failure q Comments ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 15 - OPTIONAL SIDEWALL VENTING (and Combustion Air intake) Installation Instructions General This section provides instructions for the installation of UL listed Gas-Fired Boiler Assemblies with Side Wall Venting and Combustion Air intake Assemblies, MEA number 15-95-E. 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. Equipment (Available with Power Flame Burners Only) Note: All Columbia boilers ordered for Sidewall Venting will be provided with a Combustion Air Intake Adapter. CT-6 Boiler with Power Flame JR15A-10 Burner CT-10 Boiler with Power Flame JR15A-10 Burner CT-15 Boiler with Power Flame JR15A-10 Burner CT-20 Boiler with Power Flame JR30A-10 Burner CT-25 Boiler with Power Flame JR30A-12 Burner CT-35 Boiler with Power Flame JR50A-15 Burner BOILER MODEL VENT SIZE DIAMETER (INCHES) INTAKE SIZE DIAMETER (INCHES) CT-6 6 6 CT-10 6 6 CT-15 8 6 CT-20 8 6 CT-25 10 6 CT-35 12 8 CT-50 NOT UL OR MEA APPROVED FOR THIS OPTION Vent Caps Use only UL listed vent caps for the combustion vent termination and the combustion air intake. The following vent cap model is shipped with your boiler when the direct vent option kit is ordered. Heat-Fab Incorporated 38 Haywood Street Greenfield, MA 01301 (800) 772-2356 “Saf-T CI Vent Rain Cap” FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 16 - Installation The Columbia Model CT Direct Vent Series Steam Boiler is furnished completely piped, wired, and assembled. It has been test fired at the factory and is ready for installation. This steam boiler is designed to operate with natural gas, and is suitable for standard AC electrical service. The CT Series requires the following minimum clearances to combustible material: top, sides, and rear - 18", front - 36", flue vent duct - 18". Location The CT boiler must be mounted on a level non-combustible floor, or the floor must be protected in accordance with the requirements of accepted building code practices. In the absence of local codes, it is suggested that NFPA-31 section 4-4.1.5 be followed. Flue Vent Duct For direct venting, galvanized smoke pipe is acceptable, but local codes take precedence. The maximum length of flue vent duct allowed is 40 feet, and at no time can the diameter of the flue vent duct be less than the diameter of the smoke outlet of the boiler, see Table on the previous page for size. The flue pipe should be sloped upward 1/4" per horizontal foot of run. All sections of flue pipe should be joined and fastened securely with sheet metal screws. The maximum number of 90° elbows in the flue vent duct is four. A barometric swing type draft regulator may be installed in the flue vent duct if desired, but is not necessary. The vent must end with the UL listed vent cap that was shipped with your boiler. the vent cap can be installed either horizontally (Figure 5-A below) or vertically with a tee (Figure 5-B below). It is suggested that a screen or vent pipe plug be inserted into the bottom of the tee to prevent animals and other matter from entering. Figure 5 FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 17 - All through the wall connections must adhere to safety standards set forth by standard building practices and local codes. In the absence of local codes, UL listed wall thimbles and through the wall connectors should be used. The combustion vent cap must extend a minimum of four feet from the building, and must be located as far from the combustion air intake as possible. The combustion vent must terminate a minimum of seven feet above the ground where pedestrian traffic can be expected. It shall also terminate at least three feet above any forced air inlet within ten feet, and shall terminate at least four feet below or four feet horizontally from, or one foot above and two feet horizontally from, any door, window, or gravity air inlet into any building as provided in the National Fuel Gas Code NFPA 54. See Figure 6. Both the Combustion Flue Vent and the combustion Air Intake must be in the same wall. COMBUSTION VENT LOCATIONS Figure 6 Combustion Air Intake The air for combustion must be ducted directly to the burner intake and must terminate outside with the applicable Intake Air cap listed in the Table on page 15. The vent cap can be installed either horizontally or vertically in conjunction with a tee. It is suggested that a screen or vent pipe plug be inserted into the bottom of the tee to prevent animals and other matter from entering. The maximum length of combustion air intake duct shall be 40 feet. The combustion air intake shall be full size for the complete run and shall not have more than four 90° elbows. The combustion air intake cap must be at least one foot off the ground in an area that is always free from obstructions. The Combustion Air Intake must be in the same wall as the Combustion Vent. Important Note: Surface discoloration of the building may occur due to improper boiler/burner adjustment and maintenance. Columbia Boiler Company will not accept any liability for such discoloration. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 18 - 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 combustion, 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" diameter round hole of free, unrestricted area. If louvers or screens are used, contact the manufacturer for percentages (typically around 40%) that must be added to allow for restriction. 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 19 - REQUIRED BOILER MAKE-UP AIR (HORSEPOWER) BTU INPUT OPENING MIN. SQUARE INCHES SQUARE HOLE SIZE - INCHES ROUND PIPE SIZE - INCHES (APPROXIMATE) (APPROXIMATE) 6 252,000 126 12 X 12 14 9.5 399,000 210 15 X 15 18 15 630,000 315 18 X 18 20 20 840,000 420 2 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 BOILER SIZE 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 20 - 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. PANEL BOX WITH WARRICK SERIES 3K ELECTRODE FITTING 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 operating and safety limit pressure controls. The standard water column consists of the Warrick Series 3K Electrode fitting which houses the three probes used for the primary low water cut off and pump control, the Honeywell L404A Operating Pressure control, the Honeywell L404C Safety Limit Pressure Control, and a 0-300 psi pressure gauge. DESCRIPTION OF PANEL BOX COMPONENTS Warrick Series DF (Dual Function) The boiler water level control consists of the Warrick Series DF (Dual Function) combination low water cut-off and pump control. The Series DF 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. The three probe lengths in the Series 3K are: A - High Probe 6.0" B - Low probe 7.5" C - LWCO Probe 9.0" Boilers built before September 2006 will have 2" longer probes. The Warrick Series DF Control will reset automatically after a Low Water Cut Off. If preferred, a normally closed, Manual Reset push button is available as an option. Electrical contact ratings for the Warrick Series DF Control are 10 amps at 120 volts. Motor contactor or Starter A Motor contactor or Starter is provided to take the high amperage electrical load off the FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 21 - pump motor switches of the Warrick Series DF Low Water cut Off and Pump 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-6 thru CT-25 Boilers, and a Motor Starter is provided as standard equipment on the CT-35 and CT-50 Boilers. Warrick Series 26 Probe Type 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 Series DF low water cutoff 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 Warrick Series DF. 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). NOTE: 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 The operating pressure consists of a pressure actuated switch with an adjustable differential. 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 determines when the burner will restart. The differential should be set at a value as large as possible to keep the unit from short cycling. The pressure control must be level in order to operate accurately. It is level when the leveling 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 22 - 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 purpose 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 situation is corrected and the reset button is pushed. The high limit of the Safety limit must be set above the operating pressure control setting. 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 indicator 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 damage 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 operating 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 23 - 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 pushbutton, when installed, must be pressed and held for 10 seconds to start burner operation after a low water condition has been corrected. 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 pressure control is connected in series, on one side of the time switch. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 24 - 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. WARNING: DISCONNECT ALL INCOMING ELECTRICAL POWER BEFORE SERVICING THE BOILER. USE EXTREME CAUTION AROUND BOILER PIPING AND THE WARRICK 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 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 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 25 - Monthly Boiler Check & Maintenance List 1. 2. 3. 4. 5. Test all fan interlocks. Check main burner safety shut off valve(s) for operational closure. Oil fired; check fuel pressure interlocks when provided. Gas fired; check high and low fuel pressure switches. 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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Check operating Pressuretrol. Check high limit Pressuretrol. Test safety valves. Remove the Warrick Series DF Low Water Cut Off and clean inside casting. Oil fired - clean/replace oil filters or strainers if equipped. Oil fired - replace ignition electrodes if equipped. Gas pilots - conduct pilot turndown test. Gas fired - replace ignition and flame rods. Gas fired - check drip leg/strainer. Oil fired - check for refractory hold in. Check Automatic Change Over Control if equipped. Gas fired - perform valve leakage test. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 26 - 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. 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. 2. 3. 4. 5. 6. 7. 8. 9. 10. Make absolutely certain that the new water level gauge glass is 5/8" o.d. x 101/4" long Pyrex red line, high pressure, high temperature glass tubing with fire polished ends. Close gauge glass valves. Remove gauge glass protector. Remove the old glass, gaskets, brass washers, and brass nuts. Be sure threads on the gauge valves are clean. Install brass nuts, brass washers, and gaskets on each end of the gauge glass. Insert glass tub 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 n the valve. 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. With a wrench, snug up the bottom nut and then the top nut. Replace gauge glass protector. Open gauge glass valves fully. Failure to completely open the gauge glass valves renders the ball check safety feature inoperative. 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 treatment 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 27 - 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 basket 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 FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 28 - Install the plate assembly in the boiler, evenly spaced as possible. Set the yoke over the bolt, install the nut and make it hand tight to keep the plate from moving. Using the correct size socket wrench, tighten the nut one quarter turn. See Figure 7. If the gasket leaks while the pressure is being brought up on the boiler, tighten the nut only enough to stop leaking. See Figure 8. Check the gaskets for leakage for the next three days after installation and if leakage is detected tighten only enough to stop it. WARNING: EXCESSIVE TIGHTENING WILL FLATTEN OUT THE GASKETS TO A POINT WHERE THEY WILL NO LONGER BE ABLE TO SEAL. DO NOT TIGHTEN MORE THAN IS REQUIRED TO SEAL IMPROPER PRESSURE ON GASKET OF HANDHOLE PLATE Figure 8 Cleaning the Flue Passages Under normal operating conditions the flue passages do not need to be cleaned. If poor combustion has been experienced and soot has built up on the flue passages they can be cleaned following this procedure. Before cleaning have your boiler technician check the stack temperature and combustion efficiency to make sure that cleaning is necessary. Do not disassemble the jacket top ring without first obtaining a millboard top gasket. This gasket can become brittle over time and will be impossible to reinstall after removing. This can cause combustion gasses to leak and can cause a dangerous situation. If your boiler was built after February 1991 you will also need an upper hand hole gasket, part number 480210. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 29 - Millboard top gasket part numbers: CT-6 332200 CT-25 332230 CT-10 332210 CT-35 332232 CT-15 332220 CT-50 332233 CT-20 332225 Disassembly, Cleaning and Assembly Instructions 1. Obtain a top refractory millboard ring from your local supplier before attempting to look inside the flue passages. 2. Take off the top jacket by removing the three screws that connect it to itself and the four screws that connect it to the top cover small mounting angles. Set the top jacket and the fiberglass insulation strip found behind it to the side. 3. Scribe or mark a line on the outer jacket and top cover to aid in aligning the top cover during reassembly. This is important to assure that the screw holes will line up later. 4. Remove the sheet metal screws around the outside of the top cover and save for reassembly. 5. Remove the upper hand hole assembly if your boiler was manufactured after February 1991. 6. Lift the top and place as far up and out of the way as possible. The piping and electrical connections do not have to be disconnected but the top ring will not come all the way off. 7. Remove the millboard refractory ring. 8. The flue passages should now be visible and can be cleaned as desired. It is suggested that the soot be brushed down to the bottom and vacuumed out by pushing a long hose or pipe down between the baffles. 9. Clean the baffle area as desired. 10. Place the new millboard refractory ring in place of the old one and seal between the sections and any other small openings with a small amount of furnace cement or high temperature caulk. 11. Place the top jacket back over the millboard making sure to line up the marks made in Step #3 above. 12. Reinstall the sheet metal screws in the top cover, starting at one side and working around the boiler. The use of a pry bar is suggested to pull the outer edge down far enough to line up the holes. 13. Replace the gasket on the hand-hole plate (see previous pages of part number and instructions), and reinstall the top hand hole assembly. 14. Reinstall the top jacket fiberglass insulation strip. Replace this insulation strip with a new one if necessary. 15. Reinstall the top jacket and secure it to the top cover and to itself with the seven (7) screws that were removed. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 30 - MAINTENANCE LOG FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 31 - MAINTENANCE LOG FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 32 - TESTING OF BOILER COMPONENTS Refer to Boiler Check & Maintenance Lists earlier in this section for frequency of testing. Warrick Series DF Low Water Cut-Off and Pump Control Testing while operating. (Red LED ON indicates normal operating condition.) 1. Fill the boiler to a level higher than the normal operating water level. 2. With the burner running, lower the water level in the boiler by using the bottom blow down valve. At about the normal boiler water level the pump should come on and start pumping water into the boiler. 3. When the water level drops approximately 1-1/2 inches below the level at which the pump turned on, the burner should turn off and the alarm circuit will close, and activate the optional alarm bell (if so equipped). Testing while not in operation. 1. Fill the boiler to a level high than the normal operating water level. 2. Open the Panel Box and locate the terminal blocks; TB1 is the upper block, TB2 is the lower block. 3. Using an AC Continuity Tester, Check for continuity between terminal “PH” and Ground, indicating the high Water probe circuit is functioning properly. 4. Check for continuity between terminals TB1-A2 and TB2-3, indicating the burner circuit is making, and the burner would be operating. 5. Terminals TB2-M and TB2-M2 should be open, indicating the pump circuit is not energized. 6. Open the bottom blow down valve and allow the water level to drop below the normal operating water level. 7. Check for continuity between terminals TB1-A2 and TB2-3, indicating the burner circuit is making, and the burner would be operating. 8. continuity across Terminals TB2-M1 and TB2-M2 signifies the boiler feed pump circuit is energized, causing the pump to operate. 9. Open the bottom blow down valve and allow the water level to drop below the Low probe level. Check for continuity between terminals TB1-A2 and TB2-3. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 33 - The burner circuit should be open, signifying the burner circuit is broken. 10. Continuity across Terminals TH2-MI and TH2-M2 signifies the boiler feed pump circuit is energized, signifying the pump is attempting to fill the boiler. Warrick Series 26 Probe Type Low Water Cut-Off Testing While Operating. (Red LED ON indicates normal operating condition.) 1. While the boiler is operating normally, open the lower blow down valve and allow the water level to drop below the level of this probe. 2. The probe relay should open and lockout. 3. Fill the boiler to a level higher than the probe. The relay should not reset automatically. 4. After the water level has risen to the normal operating level, depress the Probe Reset switch on the front of the panel box. The burner should start operating normally. Testing While Not in Operation. 1. Energize the control circuit and fill the boiler to the normal operating water level. 2. Depress the Probe Reset switch on the front of the panel box. Open the panel box and locate the terminal blocks; TB1 is the upper block, TB2 is the lower block. 3. Using an AC Continuity Tester, Check for continuity between terminal “P2” and Ground, indicating that the Secondary Low Water probe circuit is functioning properly. 4. Open the lower blow down valve and allow the water level to drain below the level of the probe. The relay should open and continuity between terminals “P2” and Ground should be broken. 5. Close the lower blowdown valve and fill the boiler to the normal operating water level. The relay should not reset automatically and continuity between terminals “P2” and Ground should remain broken. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 34 - Danfoss Operating Pressure Control Testing While in Operation. 1. Start the burner and allow the boiler pressure to rise to the main set point. The burner should shut off. 2. Open the steam valve and relieve pressure until the pressure is below the lower set point. the burner should now start. The lower set point is determined by taking the differential from the main set point. Testing while not in operation. 1. To test operation of pressuretrols while unit is not in operation requires the use of an external source of pressure such as an air compressor. 2. Close all valves and connect the pressure source to the boiler. 3. Increase the pressure in the boiler until the pressure is higher than the setting on the controller. The mercury switch should rock over such that continuity is now broken. 4. Decrease the pressure in the boiler until the differential is satisfied. The mercury switch should rock back to a position that causes continuity to be made across the switch. Danfoss Safety Limit Pressure Control Testing while in operation. 1. Adjust the safety limit set point below the main set point. 2. Start the burner and allow the boiler pressure to rise to the safety limit pressure level. 3. The burner should shut off and not restart until the manual reset lever is depressed. Testing while not in operation. 1. To test operation of pressuretrols while unit is not in operation requires the use of an external source of pressure such as an air compressor. 2. Close all valves and connect the pressure source to the boiler. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 35 - 3. Increase the pressure in the boiler until the pressure is higher than the setting on the controller. The mercury switch should rock over such that continuity is now broken and the manual reset switch should open. 4. Decrease the pressure in the boiler. The mercury switch should rock back to a position that causes continuity to be made across the switch but should not close until the manual reset lever is depressed. Safety Valve WARNING: USE CAUTION PRIOR TO PERFORMING A “TRY LEVER TEST” SINCE LOUD, VERY HOT AND HIGH VELOCITY STEAM WILL DISCHARGE FREELY FROM THE DISCHARGE PORT AND THROUGH THE DRAIN HOLE PROVIDED IN THE SIDE OF THE VALVE BODY. 1. Bring the boiler pressure up to maximum operating pressure, but not less than 75% of maximum pressure (112 PSI), otherwise distortion could occur. If necessary adjust operating and high limit controls to a higher setting. 2. Test the valve at or near maximum operating pressure by holding the test lever fully open for approximately five seconds to flush the valve seat free of any debris or sediment and then permit the valve check to snap shut. 3. If lift lever does not activate and there is no evidence of valve discharge, shut down equipment immediately and replace the valve. 4. Adjust operating and high limit controls to their normal settings. Honeywell S8600 Series Intermittent Pilot Modules - Gas Fired Units The following is a list of tests that may be required. For more information see Honeywell publication form number 68-0085-2 (Rev 12-89), located in the appendix of this manual. Pilot turndown test Flame failure test Power failure test The S8600 Series control is used to prove a pilot flame. This test insures that the main burner flame can be lit by the smallest pilot flame that will prevent loss of pilot shut down. 1. Shut off the main fuel supply to the burner by closing the manual main burner shut off cock. Do not shut off fuel supply to the pilot valve. 2. Connect a Honeywell W136A tet meter, or equivalent microammeter, in series with the flame rod. Connect a standard electrical meter, set for 24 volt range, to terminals MV-MV on the control. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 36 - 3. Start the burner. After the prepurge is complete, the pilot will light and indicate between 1-1/2 and 4 microamps. The main gas valve should try to open and indicate power between terminals MV-MV. 4. Reduce the size of the pilot flame to the turndown position by slowly closing the manual valve on the pilot gas line. At the turndown condition, the pilot will be small enough so it just barely causes the main gas valve to open (about 1 to 11/2 microamps.). a. slowly turn down the pilot until the main gas valve will not open and the burner shuts down on flame failure. NOTE: The burner motor will continue to run. b. Allow the burner to complete prepurge. If the control locked out, reset the control by depressing the reset switch for sixty seconds and restart the burner. c. As the control attempts to restart the pilot, turn the pilot back up slowly until the gas valve tries to open. d. Again turn the pilot down slightly but not enough so the flame drops out. If the relay drops out simply repeat step c above. If the control locks out allow the safety switch to cool, reset the switch, and repeat step c. 5. Check that the pilot is lit and the gas valve is trying to open. 6. Open the manual main burner gas cock. Main flame should light within one second. If the burner does not light within one second, close the shutoff cock and shut off power to the relay. Proceed to step 8. 7. If the burner lights, repeat step 6 a number of times to verify the light off. Proceed to step 10. 8. If the light off is unsatisfactory, readjust the flame detector to require a larger pilot flame to cause the main gas valve to open. a. Adjusting the flame rod detector so that a larger minimum pilot flame is required by moving the flame rod farther from the grounding rods. 9. repeat the entire turndown test until the flame is established promptly in step number 6. 10. Turn the pilot up to full flame at the completion of the test. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 37 - Flame Failure Test 1. Let burner operate normally for five minutes, then manually shut off the fuel supply to simulate flame failure. 2. The system should drop out and fuel valves should close. NOTE: The burner motor will continue to run. 3. Let the safety switch cool, reopen manual fuel valve, and reset safety switch. 4. Burner should start. Power Failure Test 1. Let the burner operate normally for five minutes. Simulate power failure by opening a line switch. All relays should drop out and the fuel valves should close. 2. After a minimum of five seconds, close the line switch. 3. The control should go through a normal operating cycle. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 38 - 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 boiler is always preferred and more reliable than treatment within the boiler. Instructions for feed water treatment as prepared by a competent feedwater chemist should be followed. Do not experiment with homemade treatment methods or compounds. Representative samples of feed water 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 ANALYSIS pH Total Alkalinity Phosphates Total Hardness Chlorides Total Dissolved Solids Sulfites Specific Conductance Oxygen RECOMMENDED RANGE 10-11 200-700 ppm 30-100 ppm 0-50 ppm 60-200 ppm 2000 ppm Maximum 20-30 ppm < 700 micro ohms cm < .007 mg/liter COMMENTS Low pH promotes corrosion Low: promotes corrosion Prevent scale formation Prevents scale formation A measure of proper blow down High solids may cause surging A good oxygen scavenger A measure of proper blowdown 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 attach 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 ar 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 FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 39 - for the precipitation of scale forming salts before scale is deposited. Below a pH of 5.0 the water is acidic enough to dissolve the steel boiler plates. Under these conditions 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. Efficient aeration results in saturation of the water with oxygen. The majority of corrosion problems are directly related to the quantity of dissolved oxygen in the boiler water. Elimination of the corrosive effect of dissolved oxygen can be accomplished both directly or chemically. Direct or mechanical removal of dissolved oxygen is done through the use of a deaerator or by heating the water to a temperature above 180°F. Heating the water can be done with a preheater or a sparge tube installed in the return system. Chemical deaerator is done through the introduction of specific chemicals in the boiler to react with the oxygen. The dissolved oxygen content should be maintained at a minimum but at no time should it exceed 0.007 mg/l. Sulfites Sodium sulfite is generally used for the chemical removal of dissolved oxygen within the boiler water. To assure the rapid and complete removal of the oxygen entering the boiler feedwater system the concentration of sulfite in the boiler must be maintained at a minimum of 20 PPM. (parts per million) Solids Solids can be broken up into two categories: suspended solids, and dissolved solids. Suspended solids are those which can be removed by filtration, while dissolved solids are in solution with the water. The best test for the determination of solids content of the boiler water is through a conductance test. The conductance value of boiler water varies by the various ionized salts present. The conductance can be used to measure the total dissolved solids in the boiler water and to serve as an accurate means for the control of solids through the use of blowdown. Another test which is sometimes used as a gauge of solids is to measure the chloride present in the boiler water. The ratio of chlorides in the boiler water to that of the feed water can be used as a means to determine the amount of blowdown required. The chloride test is unsuitable for feedwater with low incoming concentrations and the concentrations in the feedwater must be averaged over time for accuracy. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 40 - High boiler solids will lead to foaming, priming, surging and carry over. These problems can be overcome by proper, daily blowdown of the boiler. Alkalinity The alkalinity of boiler water should be sufficiently high enough to protect shell and plates against acidic corrosion, but not high enough to produce carryover. A minimum value for alkalinity for adequate protection is 200 PPM. High boiler alkalinity, which is in excess of 700 PPM. should be avoided. Values higher than this can lead to embrittlement of the steel. Phosphates Phosphates are used to react with calcium hardness in the boiler water. In order for this reaction to take place it is important to maintain a pH at a minimum value of 9.50. It is desirable to keep the concentration of phosphates in the water to 30-50 PPM in order for complete reaction of the phosphates with the calcium hardness entering the boiler through the feedwater. Hardness The hardness of water is caused by calcium and magnesium ions which will vary greatly throughout the country depending on the source of the water. In boilers the hardness of the water can cause the formation of scale and sludge or mud. The hardness must be removed in the makeup water to the return system. Total hardness should not exceed 50 PPM. Oils Every effort should be made to prevent oils from getting into the boiler water. Oil causes foaming, or combines with suspended solids to form a sludge which can cause the overheating of boiler plates. If oil does get into the boiler, the boiler should be taken out of service immediately, and thoroughly cleaned. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 41 - RETURN SYSTEMS (Optional) Pump Operation The boiler feedwater pump is controlled by probes sensing the water level in the combination water column, level control, and low water cut off. Operation of the specific control is described in the component section of this manual. Whenever a pump is used to feed water to a boiler, it is recommended that a motor starter be used with the pump. The motor starter will take the electrical load off the mercury switch in the level control. Detailed instructions for the maintenance of the boiler feedwater pump are provided with the Return System. Make-up Water Control The field water supply enters the boiler feedwater tank through the make-up valve assembly, The water level in this tank is maintained at a level near the center of the tank by a float operated valve. This make-up valve is built into the boiler feedwater return tank. The maximum allowable pressure to the make-up valve is 50 PSI. Pressures in excess of this value must be reduced. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 42 - BLOWDOWN SEPARATOR (Optional) The blowdown separator design incorporates an internal water seal at the outlet, which permits the operator to introduce cold water from the bottom to mix with the hot water from the boiler blowdown. This reduces the outlet water temperature for safe discharge. If the separator is less than half full of water after the boiler is blown down, cold tap water must be added to bring the water level to the half-way mark before the next blowdown. The vent must be piped, full size, to a safe location so that steam flashing off the blowdown will not injure individuals or damage equipment. Do not reduce the outlet pipe or vent pipe size coming off of the tank. BLOWDOWN SEPARATOR Figure 9 FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 43 - TROUBLE SHOOTING The first step in trouble shooting is to have a qualified service technician, with the required instruments and expertise, diagnose your system and attempt to fix the problem. Please adhere to the Service Policy at the beginning of this manual. Surging or bouncing water level Surging or bouncing water levels are caused by boiler water which has a high concentration of solids or oils. It is recommended that the frequency of blowdown be increased until the surging condition is corrected. Extreme cases may require the boiler to be boiled out following the previously outlined procedures. A water treatment specialist should be consulted immediately. Pump runs but does not put water in the boiler. Check that the feedwater piping is not clogged between pump and boiler. Insure that all of the steam traps in the system and the check valves between the pump and boiler are working properly. Many times, steam in the impeller area of a pump will cause cavitation and damage. Refer to pump manufacturer for instructions. Boiler flooded in the morning. When the boiler is shut off and the steam in the system condenses, a vacuum is created. On tight or new systems there may be no way for air to enter the system to eliminate the vacuum. When this happens, water is drawn through the return system into the boiler, This will also cause flooding of the return tank. The replacement of a swing type check valve and manual valve on the boiler with the direction of flow into the boiler, will eliminate this problem. It is recommended that the manual valve be closed during normal operation so that a failure of the check valve will not result in steam being released into the boiler room. Fan motor runs but burner does not light. The air switch has not proved an air flow. Check for continuity across the terminals of the air switch and replace the air switch if it is defective. If a S8600 Series control is used, try resetting the control. If the S8600 Series control loses the pilot signal, the control will “lock out” until it reset, and the fan will continue to run. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 44 - APPENDICES PART OF CT-35 & CT-50 W/OIL BURNER ONLY. REPLACEMENT PARTS FOR CT BOILERS WITH PANEL-BOX & WARRICK DF LWCO, WITH PRESSURETROLS IN/ON PANEL BOX PANEL BOX - INSIDE VIEW DWG CT-546-A FOR USE WITH REPLACEMENT PARTS LIST WARRICK PROBE ASSEMBLY - CT SERIES DWG. CT-415 NOTES __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ REPLACEMENT PARTS FOR CT SERIES BOILERS 150 PSI w/ Panel Box with Pressure Controls & Warrick LWCO/Pump Control REF. No.† DESCRIPTION BOILER MODEL ITEM NUMBER 1 BURNER – CONSULT FACTORY ALL 2 BOILER BLOWDOWN 1” Y-VALVE ALL X/C CT-50 579005 BOILER BLOWDOWN 1-1/4” Y-VALVE CT-50 579006 BOILER BLOWDOWN 1” BALL VALVE ALL X/C CT-50 570118 BOILER BLOWDOWN 1-1/4” BALL VALVE CT-50 570132 CONTROL PANEL-BOX (SEE DWG. CT-546) CT-6 THRU CT-25 558850 CONTROL PANEL-BOX (SEE DWG. CT-546) CT-35, CT-50 558854 4A SWITCH, “POWER” ON-OFF ALL 558858 4B SWITCH “PUSHBUTTON, “PROBE RESET” ALL 558904 4C LAMP ASSEMBLY “PROBE ON” (RED) ALL 558860 4D LAMP ASSEMBLY “LOW WATER” (RED) ALL 558860 4E LAMP ASSEMBLY “PUMP ON” (AMBER) ALL 558862 4F TERMINALS (SUPPLIED IN 3-TERMINAL UNITS) ALL 558864 4G TERMINAL BLOCK MOUNTING END ALL 558866 4H WARRICK DUAL FUNCTION CONTROL MODULE ALL 558800 4J WARRICK PROBE LWCO MODULE, 26C1C0-C ALL 558885 4K MOTOR CONTACTOR ALL 558885 4M MOTOR STARTER, 3-PHASE CT-35, CT-50 901716 WARRICK LWCO & PUMP CONTROL ALL 558840 5A HIGH PROBE, “PUMP OFF”, 8” ALL 5B LOW PROBE, “PUMP ON”, 9-1/2” ALL 5C PRIMARY LOW WATER CUT-OFF PROBE, 11” ALL WATER GAUGE SET ALL 571020 6A 5/8” X 10-1/4” GAUGE GLASS ALL 571090 6B TRI-COCKS (3) – (OPTIONAL) ALL 571080 6C GAUGE GLASS PROTECTOR, LEXAN ALL 966044 7 LWCO BLOWDOWN VALVE, 1” BALL VALVE ALL 570118 8 PRESSURE CONTROLS 3 4 5 6 SEE PARTS LIST 8A SAFETY LIMIT W/ MANUAL RESET ALL 553615 8B OPERATING LIMIT, KP36 ALL 553610 8C HIGH FIRE, KP36 CT-35 & CT-50 oil only 553610 STEAM PRESSURE GAUGE, 0-300 PSI ALL 559305 SECONDARY LOW WATER CUT-OFF PROBE ASSY. w/MANUAL RESET, WARRICK ALL (ALSO SEE “4J”) SECONDARY LWCO PROBE PLUG ALL 558920 9 10 10A REPLACEMENT PARTS FOR CT SERIES BOILER 150 PSI w/ Panel Box with Pressure Controls & Warrick LWCO/Pump Control REF. No.† DESCRIPTION BOILER MODEL ITEM NUMBER 10B SECONDARY LWCO PROBE ROD, 16” ALL 558908 10C SEC. LWCO RUBBER BOOT – PROBE PLUG ALL 558930 11A SAFETY VALVE, 150 PSI, 3/4” X 3/4” CT-6 THRU –25 11B SAFETY VALVE, 150 PSI 1” X 1-1/4” CT-35, CT-50 570420 12A MAIN STEAM BALL VALVE, 3/4” CT-6, CT-10 570110 12B MAIN STEAM BALL VALVE, 1” CT-15, CT-20 570118 12C MAIN STEAM BALL VALVE, 1-1/4” CT-25, CT-35 570132 12D MAIN STEAM BALL VALVE, 2” CT-50 570140 13A FEEDWATER BALL VALVE, 1/2” CT-6 THRU –15 570100 13B FEEDWATER BALL VALVE, 3/4” CT-20 THRU –35 570110 13C FEEDWATER BALL VALVE, 1” CT-50 570118 14A FEEDWATER SPRING CHECK VALVE, 1/2” CT-6 THRU –15 579150 14B FEEDWATER SPRING CHECK VALVE, 3/4” CT-20 THRU – 35 579160 14C FEEDWATER SPRING CHECK VALVE, 1” CT-50 579170 PLUG, 1-1/4” (FOR OPTIONAL SURFACE BLOWDN.) ALL 328250 HANDHOLE ASSY. 3” X 4”, COMPLETE CT-6 970680 16A PLATE, #35 CT-6 970610 16B YOKE CT-6 970650 16C GASKET ALL 480210 16D BOLT, 5/8” – 11 C 3” SQ. HD. CT-6 311150 16E NUT, 5/8” – 11 HEAVY HEX CT-6 310250 16F WASHER, 5/8” FLAT, PLAIN CT-6 312210 17 HANDHOLE ASSY. 3” X 3-3/4, COMPLETE CT-10 THRU –50 970670 17A PLATE, #36B CT-10 THRU –50 970620 17B YOKE CT-10 THRU –50 970650 17C GASKET ALL 480210 17D BOLT, 5/8” – 11 X 3” SQ. HD. CT-10 THRU –50 311150 17E NUT, 5/8" - 11 HEAVY HEX CT-10 THRU –50 310250 17F WASHER, 5/8” FLAT, PLAIN CT-10 THRU –50 312210 18 SYPHON, 1/4”, 90° ALL 559312 19 BRASS FITTING, 1/4” NPT X 3/8” FLARE FITTING ALL 322720 20 BRASS FITTING, 3/8” NPT X 3/8” FLARE ALL 322750 15 >>> 16 (SEE. DWG. CT-385 FOR ITEMS 16 & 17 REFERENCE NUMBERS ABOVE REFER TO DWG. CT-545 EXCEPT REFERENCE NO. 4 SERIES REFERS TO DWG. CT-546. WHEN ORDERING PARTS, SUPPLY THE BOILER MODEL NUMBER, SERIAL NUMBER, AND THE SIX DIGIT ITEM NUMBER. CTPRTSLSTMY03.wpd REV. MAY 2006 GAS TRAIN PIPING DIAGRAM for CT-6/10 BOILER w/POWER FLAME JR15A-10 (3/4") GAS BURNER GAS TRAIN PIPING DIAGRAM for CT-15 BOILER w/POWER FLAME JR15A-10 GAS BURNER & CT-20 BOILER w/POWER FLAME JR30A-12 GAS BURNER GAS TRAIN PIPING DIAGRAM for CT-25 BOILER w/POWER FLAME JR30A-12 GAS BURNER & CT-35 BOILER w/POWER FLAME JR50A-15 GAS BURNER GAS TRAIN PIPING DIAGRAM for CT-50 BOILER w/POWER FLAME JR50A-15 GAS BURNER PRESSURE TAP BUSHING (OR REDUCER) BALL VALVE GAS VALVE CSD-1 LEAKAGE TEST COCK ELBOW BUSHING CSD-1 LEAKAGE TEST COCK PLUG SOLENOID GAS VALVE UNION BALL VALVE COUPLING REDUCER PILOT SHUTOFF COCK PILOT PRESSURE REGULATOR PILOT SOLENOID VALVE UNION TEE PRESSURE TAP 53 54 56 58 60 62 63 65 66 68 70 72 74 75 76 78 80 82 84 85 1/8" 1/4" 1/4" 1/4" 1/4" 1/4" 1/8"X1/4" 1/8" HONE NONE NONE NONE NONE NONE NONE 1/4" COMBINATION 1/8" 1/4" 1/4" 1/4" 1/4" 1/4” NONE NONE 1" 1" HONEYWELL V48A-1618 1/4" 1/8" 1/4" X 1/8" 1/4" NONE HONEYWELL V4943B-1019 HONEYWELL 1" NONE 1/4" 1" CT-15 w/ P.F. JR15A-10 CT-20 w/ P.F. JR30A-12 VR8305M-4009 3/4" NONE 1/4" 1 X 1 X 3/4 CT-6/10 w/ P.F. JR15A-10 (3/4") 1/8" 1/4" 1/4" 1/4" 1/4" 1/4" NONE NONE 1-1/4" 1-1/4 HONEYWELL V48A-1626 1/4" 1/8" 1/4" X 1/8" 1/4" NONE V4943B-1051 HONEYWELL 1-1/4" 1-1/4 X 1 1/4" 1" CT-25 w/ P.F. JR30A-12 CT-20 w/ P.F. JR30A-12 SIZE OR IDENTIFICATION CTGTPL01 REV. MAY 2006 1/8" 1/4" 1/4" 1/4" 1/4" 1/4" NONE NONE 1-1/2" 1-1/2 HONEYWELL V48A-1634 1/4" 1/8" 1/4" X 1/8" 1/4" NONE V4943B-1035 HONEYWELL 1-1/2" 1-1/2 X 1-1/4 1/4" 1" CT-35 w/ P.F. JR50A-15 †REFERENCE NUMBERS ABOVE REFER TO DWG. CT-549A. ‡WHEN ORDERING PARTS, SUPPLY THE BOILER MODEL NUMBER, SERIAL NUMBER, A ND THE DESCRIPTION AND SIZE, OR MFRS’ ITEM NUMBER. ORIFICE TEE DESCRIPTION‡ 52 REF. No.† 150 PSI w/Panel Box & Warrick LWCO/Pump Control GAS TRAIN COMPONENTS FOR CT SERIES BOILERS 1/8" 1/4" 1/4"’ 1/4" 1/4" 1/4" NONE NONE 1-1/2" 1-1/2 HONEYWELL V48A-1634 1/4" 1/8" 1/4" X 1/8" 1/4" NONE V4943B-1035 HONEYWELL 1-1/2" 1-1/2 X 1-1/4 1/4" 1" CT-50 w/ P.F. C2-G-20A CT-50 w/ P.F. JR50A-15 BOILER WIRING DIAGRAM SEE THE BURNER SECTION IN THE BOILER MANUAL BINDER FOR THE APPLICABLE WIRING DIAGRAMS FOR THIS BOILER. DIMENSIONAL DIAGRAM Either “G” tab can be used for reference probe. WARRICK CONTROLS • ONE COWLES ROAD • PLAINVILLE, CT 06062-1198 PHONE: (860) 793-4579 • FAX: (860) 793-4580 OPERATION OF WARRICK DUAL FUNCTION CONTROLS 5/95 PRINTED IN U.S.A. INSTALLATION OF WARRICK SERIES 3C & 3K ELECTRODE FITTINGS OPERATION OF WARRICK SERIES 26 CONTROLS 5/93 CT SPECIFICATIONS AND DATA MODEL NO. CT-6 CT-10 CT-15 CT-20 CT-25 CT-35 CT-50 ___________________________________________________________________________ RATINGS: ___________________________________________________________________________ Horsepower 6 9.5 15 20 25 35 50 ___________________________________________________________________________ Gas INput (BTU per hour) 252,000 399,000 630,000 840,000 1,050,000 1,470,000 2,100,000 ___________________________________________________________________________ Oil Input (Gals. per hour) 2.00 2.85 4.50 6.00 7.50 10.50 15.00 ___________________________________________________________________________ Output (BTU per hour) 201,600 320,000 504,000 672,000 840,000 1,176,000 1,680,000 ___________________________________________________________________________ Output (Lbs. steam per hour) 207 320 517 690 862 1207 1725 ___________________________________________________________________________ Maximum Allowable Working Pressure 150 150 150 150 150 150 150 ___________________________________________________________________________ Water Capacity (Gals.) 16 27 37 43 59 90 240 ___________________________________________________________________________ Steam Release Surface Area 183 sq. in. 262 sq. in. 389 sq. in. 501 sq. in. 627 sq. in. 817 sq. in. 1,402 sq. in. ___________________________________________________________________________ Hand Hole Sizes (3) 3 x 4 (3) 3 x 3-3/4 (3) 3 x 3-3/4 (4) 3 x 3-3/4 (4) 3 x 3-3/4 (4) 3 x 3-3/4 (4) 3 x 3-3/4 ___________________________________________________________________________ BOILER DIMENSIONS: ___________________________________________________________________________ A Boiler Height (includes piping) 70" 78" 84" 88" 92" 96" 103" ___________________________________________________________________________ B Boiler Diameter 34" 36" 40" 41" 42" 43" 56" (left to right, packaged including M & M) ___________________________________________________________________________ C Boiler Diameter 27" 30" 34" 37" 40" 43" 56" (left to right, less trim & piping) ___________________________________________________________________________ D Burner to Flue Outlet (approx.) 47" 48" 54" 58" 62" 71" 94" ___________________________________________________________________________ E Flue Outlet (diameter) 6" 6" 8" 8" 10” 12” 12" ___________________________________________________________________________ F Flue OUtlet to Floor (centerline) 48-1/4" 55" 60" 63-1/2" 65-1/2" 69" 76-1/4" ___________________________________________________________________________ G Steam Outlet (IPS) 3/4" 3/4" 1" 1" 1-1/4" 1-1/4" 2" ___________________________________________________________________________ H Feedwater Inlet 1/2" 1/2" 1/2" 3/4" 3/4" 3/4" 1" ___________________________________________________________________________ I Feedwater Inlet to Floor (centerline) 22-3/8" 24-3/8" 24-3/8" 27-3/8" 28-3/8" 13-1/2" 15-1/2" ___________________________________________________________________________ J Blowdown Outlet (IPS) 1" 1" 1" 1" 1" 1" 1-1.4" ___________________________________________________________________________ K Normal Water Line to Floor 46-3/4" 54-1/2" 60-1/2" 65" 69" 71-1/2" 81-1/2" ___________________________________________________________________________ Approx. Floor space 3' x 5' 3' x 5' 3-1/4' x 5' 3-1/2' x 5-1/2' 4' x 6' 5' x 8' 6' x 10' ___________________________________________________________________________ CRATED DIMENSIONS: ___________________________________________________________________________ Left to Right 38" 41" 43" 44" 44" 45-1/2" 56" ___________________________________________________________________________ Front to Rear 53" 56" 62" 66" 66" 77" 96" ___________________________________________________________________________ Height 73" 81" 86" 95" 95" 95" 104" ___________________________________________________________________________ Approx. Shipping Wt. (skidded & crated) 1580 lb 1900 lb 2450 lb 3075 lb 3400 lb 4650 lb 6200 lb America’s Most Trusted Name in Industrial, Commercial and Residential Boilers COLUMBIA® BOILER COMPANY P.O. Box 1070, Pottstown, PA 19464 • Phone (610) 323-2700 • FAX (610) 323-7292 CC-6427 500 - 7/08 PRINTED IN U.S.A.