ct series boilers - columbia ct series manual.pdf · ct series boilers ct-6 ct-10 ct-15 ct-20...

Download CT SERIES BOILERS - Columbia CT Series Manual.pdf · ct series boilers ct-6 ct-10 ct-15 ct-20 ct-25…

Post on 05-Jun-2018

229 views

Category:

Documents

4 download

Embed Size (px)

TRANSCRIPT

  • CT SERIES BOILERSCT-6 CT-10 CT-15 CT-20

    CT-25 CT-35 CT-50

    INSTALLATION, OPERATION andMAINTENANCE MANUAL

    COLUMBIA BOILER COMPANYPOTTSTOWN, PENNSYLVANIA

  • CT BOILER WITH PARTIAL SECTION

    Figure 1

  • Table Of Contents

    PARTS WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

    SERVICE POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4CLEANING AND FILLING A NEW STEAM BOILER . . . . . . . . . . . . . . . . . . . . . . . . . 11

    OPERATING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12STARTING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13STOPPING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13BURNER START UP AND TEST INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15SIDEWALL VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16BOILER ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19DESCRIPTION OF BOILER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

    MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25MAINTENANCE LOGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31TESTING OF BOILER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

    RETURN SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

    BLOWDOWN SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

    TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

    APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Replacement Parts for CT Series BoilersPanel Box - Inside View - Replacements PartsWarrick Probe Assembly - Replacement PartsReplacement Parts List for CT Series BoilersGas Train Piping DiagramsGas Train ComponentsBoiler Wiring DiagramSafety Valve Piping, typicalWarrick Dual Function ControlsWarrick Series 3K Electrode FittingsWarrick Probe Series 26 ControlsTubular Gage Glasses - Use and CareDanfoss Pressure ControlsTypical CT Boiler Piping Layout - Drawing PL-098

  • FM-148 COLUMBIA BOILER COMPANY, REV 6-06

    - 1 -

    IMPORTANT

    1. Read and familiarize yourself with this installation, oper-ation, 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 recom-mendations given in this manual.

    5. NOTE: The CT Boiler is not designed for continuous, nonstop operation. Normal burner cycling is required. Continuous oper-ation will eventually damage the boiler, voiding the warranty.

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

  • FM-148 COLUMBIA BOILER COMPANY, REV 6-06

    - 2 -

    LIMITED PARTS WARRANTYThe 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 undernormal use and service for 12 months from the date of installation or 18 months from the date ofmanufacture, whichever date occurs first, and is subject to warranty approval by the manufactur-er 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 workman-ship and is removed within 12 months from the date of installation will be repaired or replaced asfollows:

    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 Customers 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 columbias 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 APARTICULAR PURPOSE OR USE, ARE EXCLUDED. IN NO EVENT WILL COLUMBIA BOILER CO. BELIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE. Columbia neitherassumes nor authorizes any person to assume for columbia any other liability or obligation in con-nection with the sale of this equipment. Columbias liability and Customers exclusive remedy beinglimited to repairs or replacement as set forth above.

  • FM-148 COLUMBIA BOILER COMPANY, REV 6-06

    - 3 -

    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 theservice 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 technicalassistance from the factory.

    If the problem cannot be resolved by the representative, he should contact the TechnicalService/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 ________________________________________________________

    Installers Name ____________________________________ Phone (_____) ______________

    Address ______________________________________________________________________

    Distributors Name __________________________________Phone (_____) ______________

    Address ______________________________________________________________________

    Sales Representative ________________________________ Phone (_____) ______________

    Address ______________________________________________________________________

    Specific Problem - Detailed

  • FM-148 COLUMBIA BOILER COMPANY, REV 6-06

    - 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 designedto 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 ALLCHARTS, DRAWINGS, AND DIAGRAMS SHIPPED WITH THE BOILER.

    Installation must follow all state and local code requirements. The electrical installation mustbe in accordance with the National Electrical Code.

    CLEARANCES

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

    Underwriters Laboratories (UL) approved clearances:

    Side: 18 inchesTop: 18 inchesFront: 48 inchesChimney 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 muchharder for qualified technicians to perform routine maintenance in and around yourboiler.

    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

    The CT series boilers are pressure fired steam boilers, and need only to be properly vent-ed. Consult the factory for proper venting of the boiler for any unusual conditions that mayexist at the job-site.

    For boilers vented into a chimney, be certain the chimney i

Recommended

View more >