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Columbia CT-10 Installation, Operation And Maintenance Manual

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CT SERIES BOILERS
CT-10
CT-25
INST LL TION, OPER TION and
M INTEN NCE M NU L
COLUMBI
CT-15
CT-35
BOILER COMP NY
POTTSTOWN, PENNSYLV NI
CT-20
CT-50

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  • Page 1 CT SERIES BOILERS CT-10 CT-15 CT-20 CT-25 CT-35 CT-50 INST LL TION, OPER TION and M INTEN NCE M NU L COLUMBI BOILER COMP NY POTTSTOWN, PENNSYLV NI...
  • Page 2 W RNING 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. The absence of adequate external and internal treatments can lead to oper- ational upsets or total boiler failure that is not covered under warranty.

  • Page 3: Table Of Contents

    Table Of Contents P RTS W RR NTY ........... 2 SERVICE POLICY .
  • Page 4 –.02 to –.04 draft when the burner has cycled off, and a –.06 to –.10 draft when firing. (Draft measured in inches of water column) COLUMBIA BOILER COMPANY, REV 2-17 - 1 -...

  • Page 5: P Rts W Rr Nty

    RE EXCLUDED. IN NO EVENT WILL COLUMBI BOILER CO. BE LI BLE FOR NY INCIDENT L OR CONSEQUENTI L D M GES OF NY N TURE. Columbia neither assumes nor authorizes any person to assume for columbia any other liability or obligation in con- nection with the sale of this equipment.

  • Page 6: Service Policy

    Burner Type and Model ________________________________________________________ Installer’s Name ____________________________________ Phone (_____) ______________ ddress ______________________________________________________________________ Distributor’s Name __________________________________Phone (_____) ______________ ddress ______________________________________________________________________ Sales Representative ________________________________ Phone (_____) ______________ ddress ______________________________________________________________________ Specific Problem - Detailed COLUMBIA BOILER COMPANY, REV 2-17 - 3 -...

  • Page 7: Inst Ll Tion

    INST LL TION 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 designed to operate using No. 2 fuel oil and/or natural, manufactured, or liquid propane (LP) gas, and to be powered by standard C electrical service.
  • Page 8 4 elbows maximum. 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. COLUMBIA BOILER COMPANY, REV 2-17 - 5 -...
  • Page 9 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. COLUMBIA BOILER COMPANY, REV 2-17 - 6 -...
  • Page 10 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. dditional gas piping information is included in the burner section of this manual. COLUMBIA BOILER COMPANY, REV 2-17 - 7 -...
  • Page 11 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 independ- ently supported at the pump. COLUMBIA BOILER COMPANY, REV 2-17 - 8 -...
  • Page 12 Install a check valve to prevent the boiler water from back feeding into the service water supply. EQUIPMENT REQUIRING STE M STE M PIPING igure 3 COLUMBIA BOILER COMPANY, REV 2-17 - 9 -...
  • Page 13 W RNING: NEVER REDUCE THE VENT SIZE OF THE BLOWDOWN T NK. 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. COLUMBIA BOILER COMPANY, REV 2-17 - 10 -...
  • Page 14 4 BLOWDOWN PIPING COLUMBIA BOILER COMPANY, REV 2-17 - 11 -...

  • Page 15: Cle Ning Nd Filling New Ste M Boiler

    BOILER C USTIC SOD MODEL TRISODIUM PHOSPH TE 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. COLUMBIA BOILER COMPANY, REV 2-17 - 12 -...

  • Page 16: Oper Ting The Boiler

    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.

  • Page 17: St Rting The Boiler

    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. COLUMBIA BOILER COMPANY, REV 2-17 - 14 -...

  • Page 18: Burner St Rt Up Nd Test Inform Tion

    LWCO ____________________ Flame Safeguard _______________ Safety Limit____________________ Low Gas Pressure ______________ Ignition Failure Low Water Cut Off______________ High Gas Pressure ______________ Flame Failure Comments ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ COLUMBIA BOILER COMPANY, REV 2-17 - 15 -...

  • Page 19: Boiler Room

    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.
  • Page 20 W RNING: W W W RNING: DO NOT STORE OR USE G SOLINE OR NY OTHER FL MM BLE LIQUIDS ND V PORS IN THE VICINITY OF THE BOILER OR BOILER ROOM. COLUMBIA BOILER COMPANY, REV 2-17 - 17 -...

  • Page 21: Description Of Boiler Components

    Motor Contactor is provided as standard equipment on the CT-9.5 thru CT-25 Boilers, and a Motor Starter is provided as standard equipment on the CT-35 and CT-50 Boilers. COLUMBIA BOILER COMPANY, REV 2-17 - 18 -...
  • Page 22 The burner will not start until the situa- tion is corrected and the reset button is pushed. The high limit of the Safety limit must be set above the operating pressure control setting. COLUMBIA BOILER COMPANY, REV 2-17 - 19 -...
  • Page 23 Manual Reset Pushbutton and Control Board is available. This pushbut- ton, when installed, must be pressed and held for 10 seconds to start burner operation after a low water condition has been corrected. COLUMBIA BOILER COMPANY, REV 2-17 - 20 -...
  • Page 24 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. COLUMBIA BOILER COMPANY, REV 2-17 - 21 -...

  • Page 25: M Inten Nce

    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. COLUMBIA BOILER COMPANY, REV 2-17 - 22 -...
  • Page 26 9. Gas fired - check drip leg/strainer. 10. Oil fired - check for refractory hold in. 11. Check utomatic Change Over Control if equipped. 12. Gas fired - perform valve leakage test. COLUMBIA BOILER COMPANY, REV 2-17 - 23 -...
  • Page 27 It will be necessary to completely drain the unit prior to placing it on-line and to treat the water during operation according to the recommendation of the boiler water treatment company employed. COLUMBIA BOILER COMPANY, REV 2-17 - 24 -...
  • Page 28 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. COLUMBIA BOILER COMPANY, REV 2-17 - 25 -...
  • Page 29 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 G SKET OF H NDHOLE PL TE igure 7 COLUMBIA BOILER COMPANY, REV 2-17 - 26 -...
  • Page 30 February 1991 you will also need an upper hand hole gasket, part number 480210. Contact the factory and tell them your boiler serial number. They will advise the correct part number for millboard for your boiler. Instructions for installing the millboard will be included. COLUMBIA BOILER COMPANY, REV 2-17 - 27 -...

  • Page 31: M Inten Nce Logs

    M INTEN NCE LOG COLUMBIA BOILER COMPANY, REV 2-17 - 28 -...
  • Page 32 M INTEN NCE LOG COLUMBIA BOILER COMPANY, REV 2-17 - 29 -...

  • Page 33: Testing Of Boiler Components

    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- 2 and TB2-3. COLUMBIA BOILER COMPANY, REV 2-17 - 30 -...
  • Page 34 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 ter- minals “P2” and Ground should remain broken. COLUMBIA BOILER COMPANY, REV 2-17 - 31 -...
  • Page 35 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. COLUMBIA BOILER COMPANY, REV 2-17 - 32 -...
  • Page 36 3. If lift lever does not activate and there is no evidence of valve discharge, shut down equipment immediately and replace the valve. djust operating and high limit controls to their normal settings. COLUMBIA BOILER COMPANY, REV 2-17 - 33 -...

  • Page 37: W Ter Tre Tment

    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. COLUMBIA BOILER COMPANY, REV 2-17 - 34 -...
  • Page 38 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 con- COLUMBIA BOILER COMPANY, REV 2-17 - 35 -...
  • Page 39 If oil does get into the boiler, the boiler should be taken out of service immediately, and thoroughly cleaned. COLUMBIA BOILER COMPANY, REV 2-17 - 36 -...

  • Page 40: Return Systems

    This make-up valve is built into the boiler feedwater return tank. The maximum allowable pressure to the make-up valve is 40 PSI. Pressures in excess of this value must be reduced. COLUMBIA BOILER COMPANY, REV 2-17 - 37 -...

  • Page 41: Blowdown Sep R Tor

    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 SEP R TOR igure 9 COLUMBIA BOILER COMPANY, REV 2-17 - 38 -...

  • Page 42: Troubleshooting

    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. COLUMBIA BOILER COMPANY, REV 2-17 - 39 -...

  • Page 43: Ppendices

    PPENDICES...
  • Page 45 NOTES __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________...
  • Page 46 REPL CEMENT P RTS FOR CT SERIES BOILERS 150 PSI w/ Panel Box with Pressure Controls & Pump Control REF. No.† DESCRIPTION BOILER MODEL ITEM NUMBER BURNER – CONSULT F CTORY SEE P RTS LIST BOILER BLOWDOWN 1” Y-V LVE LL X/C CT-50 579005 BOILER BLOWDOWN 1-1/4”...
  • Page 47 NUT, 5/8” – 11 HE VY HEX CT-6 310250 W SHER, 5/8” FL T, PL IN CT-6 312210 H NDHOLE SSY. 3” X 3-3/4, COMPLETE CT-10 THRU –50 970670 PL TE, #36B CT-10 THRU –50 970620 YOKE CT-10 THRU –50...
  • Page 50 BOILER WIRING DI GR M SEE THE BURNER SECTION IN THE BOILER M NU L BINDER FOR THE PPLIC BLE WIRING DI GR MS FOR THIS BOILER.
  • Page 53 C T S P E C I F I C AT I O N S A N D D ATA CT-10 CT-15 CT-20 CT-25 CT-35* CT-50* RATINGS: Horsepower Gas Input (BTU per hour) 399,000 630,000 840,000 1,050,000 1,470,000 2,100,000 Oil Input (Gals. per hour) 2.85...
  • Page 56 Low Gas Pressure ______________ Ignition Failure Low Water Cut Off______________ High Gas Pressure ______________ Flame Failure Comments ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ COLUMBIA ® BOILER COMPANY P.O. Box 1070, Pottstown, PA 19464 • Phone (610) 323-2700 • FAX (610) 323-7292 MET-6427 2.17...

This manual is also suitable for:

Ct-15Ct-20Ct-25Ct-35Ct-50

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