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TABLE OF CONTENTS

SUBJECT

PAGE

PACKING LIST

3

SPECIFICATIONS  WL 60 / L 24

4-6

BOILER CONTROLS

9

BOILER FLAME & BRICK INSTALLATION INSTRUCTIONS

10-11

CONTROL LOCATIONS  &  PORTS WL 60

13

NOTES

17

CONTROL LOCATIONS  &  PORTS L 24

18-19

COIL INSTALLATION L24/WL60

20

BASIC BOILER & RADIANT HEAT INFORMATION 

21

CABINET / JACKET ASSEMBLY

23

WATER TREATMENT

23-25

BOILER MAINTENANCE and MODEL 24 SWING DOOR OPERATION

26-28

BURNER / PUMP / CHIMNEY , AIR & OIL SUPPLY

28-34

ELECTRICAL / WIRING DIAGRAMS

34

START UP

40

BURNER MAINTENANCE

42

TROUBLE SHOOTING GUIDE

49

PARTS

51

APPENDICIES A/B : WARRANTIES 

A/B  

ATTACHMENTS  : OEM CONTROLS INSTRUCTIONS  

Summary of Contents for L-24

Page 1: ...00 to find the distributor for your area Date Installed ____________________________ WARRANTY NOTICE Use of Columbia Boiler Company equipment on equipment not manufactured or designed for use by Columbia Boiler VOIDS the warranty property or personal damage could occur Sizing of the boiler is the responsibility of the purchaser A complete heat loss calculation for the structure or process is neces...

Page 2: ......

Page 3: ... PORTS L 24 18 19 COIL INSTALLATION L24 WL60 20 BASIC BOILER RADIANT HEAT INFORMATION 21 CABINET JACKET ASSEMBLY 23 WATER TREATMENT 23 25 BOILER MAINTENANCE and MODEL 24 SWING DOOR OPERATION 26 28 BURNER PUMP CHIMNEY AIR OIL SUPPLY 28 34 ELECTRICAL WIRING DIAGRAMS 34 START UP 40 BURNER MAINTENANCE 42 TROUBLE SHOOTING GUIDE 49 PARTS 51 APPENDICIES A B WARRANTIES A B ATTACHMENTS OEM CONTROLS INSTRUC...

Page 4: ...ed 1 Water Level Gauge glass When boiler ordered as steam 1 Boiler Manual 1 3 4 X 1 2 FPT Swivel 1 Shenandoah Logo Label white 1 Electric Junction Box w inner Bracket and Cover 1 Terminal Strip 1 Model Label WL 60 L 24 white 1 1 4 x 1 4 x 1 8 tee 1 1 4 NPT Hex Nipple 1 1 4 Nipple 1 1 2 Nipple 1 Suction Screen 1 Oil Filter w Gage 1 3 4 Check Valve 1 Vac Air Gage 1 Oil Pump 24 Fire Brick 12 Split Fi...

Page 5: ...ciated with overheated fossil fuel mixtures 5 Access shall be provided to easily remove the gun assembly and allow routine maintenance without removing the burner 6 Burner shall be supplied to fire at the input rate specified 7 Burner shall have a non condensing exhaust 8 Air for atomization must be designed to connect into an existing pressurized air source 9 A quick disconnect cord shall be prov...

Page 6: ... 7 Burner shall have three indicator lights to monitor burner operation 8 A thermostat shall be provided to allow convenient space temperature control and must be of the mercury type with on off switch 9 An oil transfer pump shall be available to meet the following minimum requirements 18 GPH 35 psi minimum 1 4 hp heavy duty 10 High range oil and air gauges shall be provided These shall be interch...

Page 7: ...on and nozzle plugging associated with overheated fossil fuel mixtures 5 Access shall be provided to easily remove the gun assembly and allow routine maintenance without removing the burner 6 Burner shall be supplied to fire at the input rate specified 7 Burner shall have a non condensing exhaust 8 Air for atomization must be designed to connect into an existing pressurized air source 9 A quick di...

Page 8: ...re covered the first year for full part replacement WASTE OIL FIRED BOILERS SPECIFICATIONS SUMMARY MODEL 24 MODEL 60 Waste Oil GPH approx 1 25 to 2 5 1 68 to 5 7 Gross BTUH Input approx 175 000 to 350 000 to 350 000 hour 800 000 hour Gross HP 4 to 8 6 to 20 Water Volume in Shell Gallons 55 133 GPM Single Coil Temp Rise 100 F 4 4 Max 6 5 Max GPM 2 Coils Temp Rise 100 F x 13 Max Width w o Controls C...

Page 9: ...ISTICS OF BURNING USED OIL IN A BOILER A Accumulation of ash produces numerous adverse affects 1 Reduced heat transfer U S Bureau of Mines Research by the U S Bureau of Mines has determined that 1 32 inch of soot coating causes 9 5 loss of boiler efficiency The following table shows how soot thickness effects efficiency 1 32 inch of soot 9 5 loss of efficiency 1 16 inch of soot 26 loss of efficien...

Page 10: ...n alarm or water feed switch N O between no s 2 4 and a burner shut down switch N C between 5 and 2 The LWC control box can mount anywhere near or on the boiler and the remote sensor threads into any 3 4 port in plates on front of boiler Additional Model 767 or 764 float LWC may be ordered for special applications or codes Provided w CWH water boilers L4006A Aquastat Operating 8 0 amp at 120 cycle...

Page 11: ...ng Valve allows hot water from boiler to accurately mix with returning cool water to make desired water ready to go to the application The hot water should be at least 20 degrees warmer than the return water for smooth operation Water Circulator used to circulate boiler water Expansion Tank used to absorb expanding water when heating it Water and Flame Locations In Boilers ...

Page 12: ...11 Brick Lining Location In WL 60 ...

Page 13: ...r Controllers Steam 750 LWC probe C 3 1 Relief Valve pr temp gauge D 4 1 1 2 Return water or condensate E 1 1 1 4 Relief Valve alternate F 1 2 1 2 Optional 764 767 LWC G 1 4 Heated water or steam to application H 2 1 Optional tankless coil w boilers upper rear of boiler Note that the above is suggested uses of the ports As can be seen in our photos there are many acceptable ways to install the pip...

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Page 18: ...17 Notes ...

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Page 20: ...19 PRESSURE GAUGE AQUASTATS LWC SENSOR ELEC BOX ...

Page 21: ... and rubber gasket s on the boiler to add coils Coil Removal Reverse the directions for installing a coil Contact your dealer if you need dummy fittings for the Model L24 to plug the two holes Coil Gasket Replacement 1 Remove the old gasket and thoroughly clean the boiler surfaces and the plate surfaces 2 Place the new gasket over the boiler studs making sure that it fits evenly 3 Using the correc...

Page 22: ...on pipe stress is minimized with continuous circulation 80 to 100 degree F water may be circulated to the radiant floor A floor too warm is uncomfortable thus the water temperature is kept to a minimum Steel boilers can withstand thermal shock from cool return water but internal sweating could occur even when the burner is firing Water temperature returning to the boiler of 140 degrees or greater ...

Page 23: ...ing Greater human comfort vs forced air heating Even air temperatures through elevation in room Cleaner no dust blowing Used in paint shops and other dust sensitive areas Concrete floor thermal mass allows quicker temperature recovery in heated space if doors or bays are opened frequently Better zoning control Tubing for In floor Heating Carries water to areas needing heat Three styles are commonl...

Page 24: ...portions 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 allow the dry material or the concentrated solution to contact with skin or clothing 3 Mix the chemicals with water and pour into the boiler 4 Replace the safety valve pipe if it was removed for adding the compound 5 Start ...

Page 25: ...dic enough to dissolve the steel boiler plates Under these condi tions the steel gradually becomes thinner and thinner until its destruction At a PH between 5 and 9 4 pitting of steel plates will occur at a rate depending on the dissolved oxygen in the boiler Dissolved Oxygen Dissolved oxygen is caused by the solubility of atmospheric oxygen into the supply water Aeration of city water supply is f...

Page 26: ...concentra tion of phosphates in the water to 30 50 p p m in order for complete reaction of the phosphates with the calcium hardness entering the boiler through the feed water 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 ...

Page 27: ...lame detection device Check boiler room floor drains for proper operation Inspect combustion air inlets of boiler room Clean ash from inside boiler s heating surfaces and chimney Frequent cleaning will extend boiler life Ash produces acids harmful to metals and prevents clean combustion Check draft in chimney Test low water cut off Check coil plate seals gaskets and piping for leaks Check temperin...

Page 28: ...eet first proceed to brush down the tubes from the front starting at the top and working down 3 Brush the side wall of the firebox through the burner opening 4 Carefully scoop or vacuum the soot and scale which is now lying in the chamber of the boiler Refractory material can become soft and brittle after firing and can be subject to damage from harsh handling Draining A clean properly maintained ...

Page 29: ...t Port 1 4 FNPT 40 60 PSI Pressure Range 20 40 PSI 6 GPH Max Flow 18 GPH 1725 RPM Speed 1725 RPM 1 4 HP 1 4 CW Shaft End Rotation CW Shaft End 20î Hg Max Operating Vacuum 20 Hg 10í Vertical Maximum Suggested Lift 10 Vertical 3 4 pipe Horizontal Suction Piping 30 Ft 3 4 pipe 1 pipe Horizontal Suction Piping 30 Ft 1 pipe INTRODUCTION Purchase of a Coulmbia Shenandoah waste oil boiler is a wise inves...

Page 30: ...il Burning Equipment This burner is recommend for burning 2 fuel oil used motor oil automatic transmission fluid hydraulic oil vegetable oil and gear oil mixed not to exceed 50 SAE Such oils may contain gasoline and specific precautions on the handling and storage of waste oils are to be observed Do Not add to oil supply or burn unknown garbage oils gasoline naptha chlorinated cleaning solvents or...

Page 31: ...ew holding the electrode clamping plate Adjust electrodes as shown Re tighten clamp screw Do not over tighten or insulation on electrodes may crack Examine electrode position after tightening to be sure position has not changed Replace hole plug 3 The electrodes should not touch surrounding metal parts or be within 3 16 as they will short the arc and not light the oil spray 4 Attach burner to boil...

Page 32: ...L FIRING RATE WITH THE B 10 BURNER CONSULT FACTORY OR DISTRIBUTOR FOR ASSISTANCE 4 If permanent masonry chimney is not available use appropriate diameter multi wall manufactured chimney and collars listed for use with oil fired boilers per UL 103 or All Fuel Class A Locate for easy connec tion to the boiler and install per manufacturers instructions and local building and fire codes Normal operati...

Page 33: ...ea If water is present take all measures to remove it The air solenoid may stick and other components may rust and fail 3 SERVICE TIP 80 of service problems can be avoided by keeping contaminants like rust chips water pipe dope insects from reaching burner through the air and oil lines OIL PUMP MOUNTING 1 Consult your dealer for best plumbing methods before starting Mount the pump as near the oil ...

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Page 35: ... to allow the burner door to swing open w o having to dis connect the oil line tubing Do not connect oil line to valve at the burner until after the oil line is purged of dirt and air Suggestion To ease future oil line purges adding a tee and drain cock near the burner allows dirt and air to be purged without disconnecting the line from the burner ELECTRICAL CONNECTIONS All electrical wiring must ...

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Page 39: ...38 B10 DUAL NOZZLE BURNER INTERNAL WIRING ...

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Page 41: ...ner is firing 6 Adjust B 5 burner oil pressure to 2 5 psi or B 10 burner 3 7 psi oil pressure Fine tune pressure setting based on the instructions on the following page 7 Adjust air pressure regulator on burner to approximately 12 14 psi on a B 5 single nozzle burner and 15 17 psi on a B 10 dual nozzle burner The preheated oil and air are mixed at the nozzle and the fuel is atomized as the electro...

Page 42: ...On B 10 models less than 600 000 BTUs spin the air adjustment plate CCW to allow a 3 4 inch gap between the plate and the burner to start On B 10 models greater than 600 000 BTUs spin the air adjustment plate CCW to allow a 1 1 2 inch gap between the plate and the burner to start Add just enough air to allow clean combustion Excess secondary air will reduce efficiency and make ignition more diffic...

Page 43: ...has failed lens is dirty or retention head is dirty 3 The retention head fins are not allowing light to pass to the cad cell 4 The cad cell receptacle is not making good contact with the cell 5 The primary control is defective allowing the reset button to pop too easily ROUTINE BURNER MAINTENANCE Weekly Maintenance A flame inspection mirror is useful for a routine check of the nozzle ignition and ...

Page 44: ... disassemble it into 3 pieces Clean thoroughly and reassemble Be sure small distributor is seated properly in the ferrule or the cap will mash it when screwed on Another option to clean the nozzle is to remove the slide gun assembly from the burner 1 Disconnect aluminum air line from underside of slide gun using 1 2 inch wrench 2 Disconnect oil line if it is not flexible 3 Loosen mount screw on le...

Page 45: ...44 Assembly of Nozzle O RING 57186 FERRULE DISTRIBUTOR CAP For a more thorough service the following burner components can be cleaned as a preventative yearly maintenance ...

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Page 47: ...ood flame is a indicator block passages may be restricted How quickly a block becomes restricted varies with hours of use and oil quality Block cleaning is a skilled service that inexperienced persons should not undertake Improper methods could dam age threads or passageways Consult your dealer if you think this operation is needed on your burner ...

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Page 50: ...Check oil pressure it should hold constant and not fluctuate or drift up and down 2 Be sure a spray of oil is going into chamber if not find obstruction Cleaning the nozzle oil solenoid or regulator may be required A fine mist can look like adequate oil is being sprayed but there may be inadequate volume to establish a flame Determine whether the fuel supply is combustible Antifreeze paint or wate...

Page 51: ...5 Electrodes improperly adjusted broken shorting or ash covered 6 Centrifugal switch in burner motor failing green light flickers or will not come on Primary Control Locks Out On Safety 1 The cad cell electronic eye detects a reduced dirty or no flame for over 30 seconds A signal measured in ohms is communicated between the cad cell and the primary control F F connections A poor or absent flame pr...

Page 52: ...s plugged with ash 3 Exhaust fan in building reverses draft in chimney 4 Cold building at night creates down draft in chimney 5 Height of chimney insufficient or pipe cap plugged or blown off 6 Lack of make up air for combustion 7 Install a draft inducer if reverse draft is present due to cold building or exhaust fans ...

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Page 54: ... x 1 2 HEX Washer Head TEK Screw G 57197 1 8 x 1 4 Male Brass Bushing 57198 Diaphragm for Norgren Oil Regulator 57127 Regulator Seat Gasket 57111 Oil Regulator Flow Seat Large Hole H 57190 57191 Oil Air Solenoid I 57176 B10 Aluminum Preheat Block with Plugs 57175 B5 Aluminum Preheat Block with Plugs J 57178 1 8 NPT Steel Plug with Vibraseal K 57195 1 4 copper Tube 4 Inch L 57196 1 8 x 3 1 5 inch G...

Page 55: ...ll 60 Leads Honeywell Z 57205 B5 Air Tube with Flange AB 57116 B5 Stainless Steel Flame Retention Head 57117 B10 Stainless Steel Flame Retention Head 57204 B5 Blower Wheel 15839 B10 Blower Wheel 57220 32303 B5 1 7 HP Motor for Burner 57201 57227 B10 1 2 HP Motor for Burner 56974 B5 Air Inlet Restrictor Disc w Bolts 52321 B5 Air Shutter for Burner Has Pointer Finger 57230 B10 Air Inlet Plate 57280 ...

Page 56: ...unger Zinc Plated w Spring 57139 Plunger Nickel Plated w Spring and Spacer 57212 1 8 Brass Street Elbow 57213 1 8 Galvanized Street Elbow 56400 Suction Screen 3 4 Tank 56405 Check Valve 56415 56416 Large O Ring for Metal Filter Combu 56410 Oil Filter with Base Assembly 33 micron Spin On 57155 Lenz Oil Filter Asm 100 mesh with Gauge 57151 Lenz Replacement Element with O ring 57153 Lenz O Ring betwe...

Page 57: ...c Cement pint 102665 Mastic Cement gallon 24088 Brick 9x4 5x2 5 12701 Brick 9x4 5x1 25 56917 Rope Gasket 1 2 diameter per foot 56638 Aquastat Operating Control 56639 Aquastat Hi Limit Control 58520 Well for Aquastat 3 4 x 3 58530 Safety Valve Relief 1 Water 58531 Safety Valve Relief 1 Steam 58522 Low Water Cutoff Manual Reset Electronic Type 58535 Low Water Cutoff Manual Float Type Auto Reset 5855...

Page 58: ...57 Notes ...

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Page 60: ...CC 6532 01 08 250 ...

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