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Columbia CT-10 Installation, Operation And Maintenance Manual Download Page 25

COLUMBIA BOILER COMPANY, REV 2-17

- 22 -

MAINTENANCE

RECORD KEEPING

                                                

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

General

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

                       DISCONNECT ALL INCOMING ELECTRICAL POWER BEFORE SERVICING THE 
                       BOILER. USE EXTREME CAUTION AROUND BOILER PIPING AND THE WAR-
                       RICK SERIES DF LOW WATER CUT OFF SINCE THEY MAY BE VERY HOT.

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

Daily Boiler Check & Maintenance List

    1.  Water Level Controls and Cut Offs are operating normally.
    2.  Instrument and equipment settings are normal.
    3.  Gauge glass is clean and protector is installed. If leaks are detected, replace glass, 

         gaskets,  and  brass  washers  immediately.  When  replacing  gauge  glass  use  only 
         5/8" O.D. x 10-1/4" long Pyrex red line, high pressure, high temperature, glass 
         tubing,  with  fire  polished  ends.  See  gauge  glass  maintenance  section  for  proper 
         method when installing this gauge glass.

    4.  Boiler water at proper operating level.
    5.  Blow down boiler as instructed under BLOWDOWN.
    6.  Blow down probe type low water cutoff.

Weekly Boiler check & Maintenance List

    1.  Check flame failure detection system.

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

                                  timing.

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

    2.  Check fuel valves. Open limit switch and make aural and visual check.
    3.  Check ignition system flame signal.

WARNING

Summary of Contents for CT-10

Page 1: ...CT SERIES BOILERS CT 10 CT 15 CT 20 CT 25 CT 35 CT 50 INSTALLATION OPERATION and MAINTENANCE MANUAL COLUMBIA BOILER COMPANY POTTSTOWN PENNSYLVANIA ...

Page 2: ...es 20 30 ppm A good oxygen scavenger Specific Conductance 700 micro ohms cm A measure of proper blowdown Oxygen 007 mg liter Prevents corrosion and pitting ppm parts per million Recommended Guidelines for Boiler Water Treatment WARNING Have your water tested by a local waer treatment specialist Proper Water Chemistry is essential to prevent scale or other deposits and corrosion with in the boiler ...

Page 3: ...MPONENTS 30 WATER TREATMENT 34 RETURN SYSTEMS 37 BLOWDOWN SEPARATOR 38 TROUBLESHOOTING 39 APPENDICES 40 Replacement Parts for CT Series Boilers Panel Box Inside View Replacements Parts Probe Assembly Replacement Parts Replacement Parts List for CT Series Boilers Gas Train Piping Diagrams Gas Train Components Boiler Wiring Diagram Safety Valve Piping typical Typical CT Boiler Piping Layout Drawing ...

Page 4: ...roduct Failure to do so can result in serious injury or death You have just purchased a quality steam boiler designed to the ASME Boiler Code and registered with the National Board of Boiler Inspectors Treat this industrial equipment with care and respect It is safe when installed maintained and used properly Read the instruction carefully and contact the factory if you have any questions This man...

Page 5: ...uld 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 ...

Page 6: ...formation 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 __________________________________________________________...

Page 7: ...allation 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...

Page 8: ...of boiler assemblies for which sidewall venting may be utilized This includes No 2 fuel oil natural gas or combination No 2 fuel oil and natural gas sizes 9 5 to 50 H P The following criteria is required for installa tions using sidewall venting 1 Flue vent piping shall be pitched upward at 1 4 per foot of length 2 A U L Approved draft fan must be installed to provide sufficient draft minimum 02 t...

Page 9: ...ire 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 th...

Page 10: ...0 12 0 13 5 15 20 Std Elbow 2 7 3 7 4 5 5 5 6 1 8 11 COLUMBIA BOILER COMPANY REV 2 17 7 REQUIRED INPUT CUBIC FEET OF GAS PER HOUR GAS TYPE CT 10 CT 15 CT 20 CT 25 CT 35 CT 50 NATURAL 399 630 840 1050 1470 2100 PROPANE 160 252 336 420 735 840 Vent lines if required are to be run outside the building stopping clear of windows or fresh air intakes The vent should terminate in a way that will not allo...

Page 11: ... ELECTRICAL SUPPLY Connect the electric supply to the boiler and condensate return system as shown in the wiring diagrams Separate electrical services and disconnects must be provided for both the boiler and the return system If both 110 volts AC and 220 volts AC are needed sep arate disconnects should be provided The wiring must be installed in accordance with the National Electrical Code and any...

Page 12: ...r water chemical balance See the WATER TREATMENT section for important information regarding the proper chem ical water treatment required to insure satisfactory service life of the boiler On long horizontal runs of piping it is best to maintain the piping as level as possible Avoid high spots that will collect air and lead to erratic pumping Install a check valve to prevent the boiler water from ...

Page 13: ...f 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 B...

Page 14: ... COLUMBIA BOILER COMPANY REV 2 17 11 Figure 4 BLOWDOWN PIPING ...

Page 15: ...E CHEMICALS THE CAUSTIC SODA IS EXTREMELY CORROSIVE TO SKIN AND CLOTHING DO NOT PERMIT EITHER THE DRY MATERIAL OR THE CONCENTRATE ED SOLUTION TO CONTACT SKIN OR CLOTHING 3 Mix the chemicals with water and pour into the boiler through any convenient opening in the boiler 4 Start the firing equipment 5 Boil the water for at least five hours 6 Stop the firing equipment 7 Drain the boiler to a locatio...

Page 16: ...boiler and all cover plates enclosures and safety devices must be installed at all times except while per forming maintenance and service The fuel supply should not be turned on until the combustion chamber has been vented and the pilot light if gas ignited checked for proper operation All blowdown valves including water column drain valves gauge glass drain valves and gauge cocks should be closed...

Page 17: ...tlines in the burner section of this manual to set up the burner for proper operation New CT boilers will normally expel a vapor from joints and openings in the jacket This is a temporary condition caused by moisture evaporating out of the refractory insulation behind the jacket and will eventually disappear STOPPING THE BOILER To stop the boiler turn the main disconnect to the OFF position INLET ...

Page 18: ...________________________ Measured INput Rate BTU HR High Fire __________________ W C CO2 Low Fire ________________________ High Fire________________________ Bachrach Scale Smoke Number Low Fire ________________________ High Fire________________________ Over Fire Draft Low Fire___________________ W C High Fire __________________ W C Aux LWCO ____________________q Low Gas Pressure ______________q Hi...

Page 19: ...en This air is necessary to insure complete combus tion a clean fire and to prevent nuisance shutdowns due to excessively dirty burner parts Air from the outside may be provided through ducts fixed louvers or motorized louvers WARNING WITHOUT SUFFICIENT MAKE UP AIR THE BOILER WILL NOT OPERATE PROPERLY AND BURNER COMPONENT DAMAGE COULD OCCUR To calculate the required fresh air opening to the outsid...

Page 20: ...28 32 50 2 100 000 1050 33 X 33 38 Housekeeping Provide adequate space around the boiler for inspection and service Do not allow the boiler room to become a storage room Fire protection apparatus and fire prevention procedures for boiler room areas shall conform to the recommendations of NFPA and all local codes WARNING DO NOT STORE OR USE GASOLINE OR ANY OTHER FLAMMABLE LIQUIDS AND VAPORS IN THE ...

Page 21: ...ies 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 conti...

Page 22: ...ll restart The differential should be set at a value as large as pos sible to keep the unit from short cycling The pressure control must be level in order to operate accurately It is level when the level ing indicator hangs freely with its pointer directly over the index mark inside the back cover of the case The upper operating or cut off pressure is determined by the main scale set point while t...

Page 23: ...nimum 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 t...

Page 24: ...table time switch makes one circuit and breaks another simultaneously at as many intervals every 24 hours as required See wiring diagrams enclosed When used for On Off operation one side of the circuit is connected in series with the pressure control The other side is not used On dual pressure operation an additional pres sure control is connected in series on one side of the time switch ...

Page 25: ...ose who are responsible for maintenance A log of the following items should be maintained in the boil er room at all times Daily Boiler Check Maintenance List 1 Water Level Controls and Cut Offs are operating normally 2 Instrument and equipment settings are normal 3 Gauge glass is clean and protector is installed If leaks are detected replace glass gaskets and brass washers immediately When replac...

Page 26: ...anual 3 Check piping and wiring of all interlocks and shut off valves 4 Internal boiler plate inspection Remove hand hole assemblies Use new gaskets when replacing covers Annual Boiler Check Maintenance List 1 Check operating Pressure Control 2 Check high limit Pressure Control 3 Test safety valves 4 Remove the Warrick Series DF Low Water Cut Off and clean inside casting 5 Oil fired clean replace ...

Page 27: ...or 1000 gallon capacity may be placed on trays inside the boiler to absorb moisture from the air The hand holes should be closed and all connections on the boiler be tightly blanked The effectiveness of the materials for such purposes and need for their renewal may be determined through regular internal boiler inspections Wet Storage Wet Storage is preferable when boilers are to be paced in storag...

Page 28: ... each end of the gauge glass 6 Insert glass tube into top gauge valve and lower the glass tube into the bottom gauge valve which contains a seat Then raise glass 1 16 Do not allow glass to rest directly on the valve 7 Hand tighten the lower glass nut and then the upper nut While tightening these nuts be sure to keep the red line opposite the viewing side 8 With a wrench snug up the bottom nut and ...

Page 29: ...trol 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 numb...

Page 30: ...Under normal operating conditions the flue passages do not need to be cleaned If soot has built up on the flue passages due to improper burner set up or poor combustion the following procedure can be used to clean the boiler Before cleaning have your boiler tech nician check the stack temperature and combustion efficiency to make sure that cleaning is necessary Do not disassemble the jacket top ri...

Page 31: ... COLUMBIA BOILER COMPANY REV 2 17 28 MAINTENANCE LOG ...

Page 32: ... COLUMBIA BOILER COMPANY REV 2 17 29 MAINTENANCE LOG ...

Page 33: ...n 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 burn er circuit is making and the burner would...

Page 34: ... Probe Reset switch on the front of the panel box The burner should start operating nor mally 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 Test...

Page 35: ...ssure 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 Safety Limit Pressure Control Testing while in operation 1 Adjust the...

Page 36: ...GE 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 neces sary 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 f...

Page 37: ...fication The following terms and guidelines are to be used in conjunction with the advice of a water treatment specialist RECOMMENDED ANALYSIS COMMENTS RANGE pH 10 11 Low pH promotes corrosion Total Alkalinity 200 700 ppm Low promotes corrosion Phosphates 30 100 ppm Prevent scale formation Total Hardness 0 50 ppm Prevents scale formation Chlorides 60 200 ppm A measure of proper blow down Total Dis...

Page 38: ...ly related to the quantity of dissolved oxygen in the boiler water Elimination of the corrosive effect of dissolved oxygen can be accom plished 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...

Page 39: ...0 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...

Page 40: ...with the pump The motor starter will take the electrical load off the 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 assem bly The water level in this tank is maintained at a level near the center of the tank...

Page 41: ... 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 in...

Page 42: ...mes 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 bo...

Page 43: ...APPENDICES ...

Page 44: ......

Page 45: ...____________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ _...

Page 46: ...PPLIED IN 3 TERMINAL UNITS ALL 558864 4G TERMINAL BLOCK MOUNTING END ALL 558866 4H DUAL FUNCTION CONTROL MODULE ALL 558800 4J PROBE LWCO MODULE 26C1C0 C ALL 558885 4K MOTOR CONTACTOR ALL 554165 4M MOTOR STARTER 3 PHASE CT 35 CT 50 901716 5 WARRICK LWCO PUMP CONTROL ALL 558840 5A HIGH PROBE PUMP OFF 6 ALL 558950 5B LOW PROBE PUMP ON 7 1 2 ALL 558951 5C PRIMARY LOW WATER CUT OFF PROBE 9 ALL 558952 6...

Page 47: ...ATER SPRING CHECK VALVE 1 CT 50 579170 15 PLUG 1 1 4 FOR OPTIONAL SURFACE BLOWDN ALL 328250 SEE DWG CT 385 FOR ITEMS 16 17 16 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 97...

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Page 50: ...BOILER WIRING DIAGRAM SEE THE BURNER SECTION IN THE BOILER MANUAL BINDER FOR THE APPLICABLE WIRING DIAGRAMS FOR THIS BOILER ...

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Page 53: ...BTU per hour 320 000 504 000 672 000 840 000 1 176 000 1 680 000 Output Lbs steam per hour 320 517 690 862 1207 1725 Maximum Allowable Working Pressure 150 150 150 150 150 150 Water Capacity Gals 52 70 86 5 110 90 240 Steam Release Surface Area 389 sq in 389 sq in 501 sq in 627 sq in 817 sq in 1402 sq in Hand Hole Sizes 3 3x3 3 4 3 3x3 3 4 4 3x3 3 4 4 3x3 3 4 4 3x3 3 4 4 3x3 3 4 BOILER DIMENSIONS ...

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Page 56: ...ngs Pilot____________________________ CO2 High Fire________________________ CO High Fire________________________ Measured INput Rate BTU HR High Fire __________________ W C CO2 Low Fire ________________________ High Fire________________________ Bachrach Scale Smoke Number Low Fire ________________________ High Fire________________________ Over Fire Draft Low Fire___________________ W C High Fire _...

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