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Columbia CT Series, Installation, Operation And Maintenance Manual

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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

Summary of Contents for CT Series

Page 1: ...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 ...

Page 2: ...CT BOILER WITH PARTIAL SECTION Figure 1 ...

Page 3: ...TER TREATMENT 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 ...

Page 4: ...pt 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 ...

Page 5: ...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 ...

Page 6: ... 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 _______________________________________________________...

Page 7: ...low 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 fo...

Page 8: ...y 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 col umn 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 min imum will cause...

Page 9: ...5 15 20 Std Elbow 2 7 3 7 4 5 5 5 6 1 8 11 FM 148 COLUMBIA BOILER COMPANY REV 6 06 6 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 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 wil...

Page 10: ...f this manual ELECTRICAL SUPPLY Connect the electric supply to the boiler and condensate return system as shown in the wiring diagrams Separate electrical services and disconnects must be provided for both the boiler and the return system If both 110 volts AC and 220 volts AC are needed sep arate disconnects should be provided The wiring must be installed in accordance with the National Electrical...

Page 11: ...the proper boiler water chemical balance See the WATER TREATMENT section for important information regarding the proper chem ical water treatment required to insure satisfactory service life of the boiler On long horizontal runs of piping it is best to maintain the piping as level as possible Avoid high spots that will collect air and lead to erratic pumping Install a check valve to prevent the bo...

Page 12: ... 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 ...

Page 13: ...FM 148 COLUMBIA BOILER COMPANY REV 6 06 10 Figure 4 BLOWDOWN PIPING ...

Page 14: ...THESE CHEMICALS THE CAUSTIC SODA IS EXTREMELY CORROSIVE TO SKIN AND CLOTHING DO NOT PERMIT EITHER THE DRY MATERIAL OR THE CONCENTRATE ED SOLUTION TO CONTACT SKIN OR CLOTHING 3 Mix the chemicals with water and pour into the boiler through any convenient opening in the boiler 4 Start the firing equipment 5 Boil the water for at least five hours 6 Stop the firing equipment 7 Drain the boiler to a loc...

Page 15: ... the boiler and all cover plates enclosures and safety devices must be installed at all times except while per forming maintenance and service The fuel supply should not be turned on until the combustion chamber has been vented and the pilot light if gas ignited checked for proper operation All blowdown valves including water column drain valves gauge glass drain valves and gauge cocks should be c...

Page 16: ...ler 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 sect...

Page 17: ... 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 capa ble of the...

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 Hig...

Page 19: ...e 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 VENT SIZE INTAKE SIZE BOILER MODEL DIAMETER INCHES DIAMETER INCHES CT 6 6 6 C...

Page 20: ...t 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 horizon tal foot of run All sections of flue pipe should be joined...

Page 21: ...ion 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 out side 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...

Page 22: ... to be left open This air is necessary to insure complete combus tion a clean fire and to prevent nuisance shutdowns due to excessively dirty burner parts Air from the outside may be provided through ducts fixed louvers or motorized louvers WARNING WITHOUT SUFFICIENT MAKE UP AIR THE BOILER WILL NOT OPERATE PROPERLY AND BURNER COMPONENT DAMAGE COULD OCCUR To calculate the required fresh air opening...

Page 23: ... 26 35 1 470 000 735 28 X 28 32 50 2 100 000 1050 33 X 33 38 Housekeeping Provide adequate space around the boiler for inspection and service Do not allow the boiler room to become a storage room Fire protection apparatus and fire prevention procedures for boiler room areas shall conform to the recommendations of NFPA and all local codes WARNING DO NOT STORE OR USE GASOLINE OR ANY OTHER FLAMMABLE ...

Page 24: ...obe L and high probe H to operate the pump When the water level in the boil er 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 ...

Page 25: ...ped 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 differen tial This switch opens on pressure rise It should be set at the maximum operating pressure desired...

Page 26: ... 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 ...

Page 27: ...ust 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 diagram...

Page 28: ...en 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 ...

Page 29: ... this manual 3 Check piping and wiring of all interlocks and shut off valves 4 Internal boiler plate inspection Remove hand hole assemblies use new gaskets when replacing covers Annual Boiler Check Maintenance List 1 Check operating Pressuretrol 2 Check high limit Pressuretrol 3 Test safety valves 4 Remove the Warrick Series DF Low Water Cut Off and clean inside casting 5 Oil fired clean replace o...

Page 30: ... gaskets on each end of the gauge glass 6 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 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...

Page 31: ...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 n...

Page 32: ... 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...

Page 33: ...nnections 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 sug gested that the soot be brushed down to the bottom and vacuumed out by push ing a long hose or pipe down between the baffles 9 Clean the baffle area as desired 10 Place the new millboard refr...

Page 34: ...FM 148 COLUMBIA BOILER COMPANY REV 6 06 31 MAINTENANCE LOG ...

Page 35: ...FM 148 COLUMBIA BOILER COMPANY REV 6 06 32 MAINTENANCE LOG ...

Page 36: ...el 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 burn er circuit is making and the b...

Page 37: ... depress the 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 Con...

Page 38: ...essure 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 A...

Page 39: ...ing 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 Pil...

Page 40: ...lot 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 w...

Page 41: ...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 open ing 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 g...

Page 42: ... promotes corrosion Phosphates 30 100 ppm Prevent scale formation Total Hardness 0 50 ppm Prevents scale formation Chlorides 60 200 ppm A measure of proper blow down Total Dissolved Solids 2000 ppm Maximum High solids may cause surging Sulfites 20 30 ppm A good oxygen scavenger Specific Conductance 700 micro ohms cm A measure of proper blowdown Oxygen 007 mg liter Prevents corrosion and pitting pp...

Page 43: ... 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 ...

Page 44: ...tain 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 boiler...

Page 45: ...ith 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 assem bly The water level in this tank is maintained at a level near the center of t...

Page 46: ... 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 outle...

Page 47: ... 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...

Page 48: ...APPENDICES ...

Page 49: ...REPLACEMENT PARTS FOR CT BOILERS WITH PANEL BOX WARRICK DF LWCO WITH PRESSURETROLS IN ON PANEL BOX PART OF CT 35 CT 50 W OIL BURNER ONLY ...

Page 50: ...PANEL BOX INSIDE VIEW DWG CT 546 A FOR USE WITH REPLACEMENT PARTS LIST WARRICK PROBE ASSEMBLY CT SERIES DWG CT 415 ...

Page 51: ...____________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ _...

Page 52: ...ERMINALS 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 5 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 1...

Page 53: ... FEEDWATER 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...

Page 54: ...AS 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 6 10 BOILER w POWER FLAME JR15A 10 3 4 GAS BURNER ...

Page 55: ...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 ...

Page 56: ...COCK NONE 1 8 1 8 1 8 1 8 66 PLUG NONE 1 4 1 4 1 4 1 4 68 SOLENOID GAS VALVE NONE HONEYWELL HONEYWELL HONEYWELL HONEYWELL V48A 1618 V48A 1626 V48A 1634 V48A 1634 70 UNION NONE 1 1 1 4 1 1 2 1 1 2 72 BALL VALVE HONE 1 1 1 4 1 1 2 1 1 2 74 COUPLING 1 8 NONE NONE NONE NONE 75 REDUCER 1 8 X1 4 NONE NONE NONE NONE 76 PILOT SHUTOFF COCK 1 4 1 4 1 4 1 4 1 4 78 PILOT PRESSURE REGULATOR 1 4 1 4 1 4 1 4 1 4...

Page 57: ...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 59: ...WARRICK CONTROLS ONE COWLES ROAD PLAINVILLE CT 06062 1198 PHONE 860 793 4579 FAX 860 793 4580 DIMENSIONAL DIAGRAM Either G tab can be used for reference probe ...

Page 60: ...OPERATION OF WARRICK DUAL FUNCTION CONTROLS 5 95 PRINTED IN U S A ...

Page 61: ...INSTALLATION OF WARRICK SERIES 3C 3K ELECTRODE FITTINGS ...

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Page 63: ...OPERATION OF WARRICK SERIES 26 CONTROLS 5 93 ...

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Page 70: ..._______________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ________________________________...

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Page 72: ...PRINTED IN U S A CC 6427 500 7 08 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 ...

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