Do you have a question about the EO-100-1M and is the answer not in the manual?
Questions and answers
Debele Muntas Mamo
April 22, 2025
how to give service for steam generator
1 comments:
Mr. Anderson
May 11, 2025
To service the Clayton EO-100-1M steam generator, follow these detailed steps:
1. Before Starting: - Close: - Soot blower valve [28] (for oil or oil/gas units) - Steam discharge valve [47] - Coil drain valve [25] - Drain cock at base of water pump - Open: - Water supply to the hotwell - Coil feed valve [26] - Valve to steam trap [35]
2. Washing the Coil (when soot buildup is suspected): - Set switch [S01] to position 2 (pump mode) and run the generator for 15 minutes to cool it. - Disconnect and remove the stack section above the heater cover. - Remove the burner manifold. - Place a trough under the burner volute to collect wash water. - Use a 20 mm hose (minimum 20 L/min flow) without a nozzle. - Insert hose through the stack opening and under the heater cover. - Move the hose to evenly wash the coil top surface. - Dark water in the trough indicates soot removal.
3. Operation Notes: - The generator reaches full pressure within 5 minutes from a cold start. - It includes safety devices for water failure, burner failure, overpressure, and electrical overload. - Automatic controls manage feedwater flow and burner modulation. - Regular attention and maintenance by trained personnel is required.
Failure to follow these instructions may void the warranty.
This answer is automatically generated
wubshet solomon
April 18, 2025
i need the picture of bag "castable insulation ( Clayton order nr. : M011297 )
CHAPTER 1 : INTRODUCTION This manual is intended to be used as instruction to operate the Clayton Steam Generator, providing maximum safety, efficiency, and to guaranty reliable operation over an extended lifetime. Read this manual carefully before commissioning the Steam Generator, so that the equipment is safely and correctly installed, operated and serviced from the beginning.
(pressures, temperatures, time settings, etc.) shall be durably marked. Any modification on the steam generator shall only be performed in agreement with Clayton Industries, and under supervision of authorized, competent personnel. The owner is responsible for maintaining the unit in a safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation.
: injury from falling down or tripping over. Check out the situation before taking actions and inform other workers accordingly. Make sure to have the proper equipment available if you need to work on heights. Clayton Steam Generator model EO-100-1M PAGE 7 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 8
: The pump (1 or 2 depending on the model) is fed with hot water from the hotwell. Frost : Do maintenance if a generator is not used during cold periods, ice can be formed in the parts containing water Clayton Steam Generator model EO-100-1M PAGE 8 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 9
: Make sure to cut the power of the frequency controller and motor(s) of the pump(s) Human error : A Clayton pump is fairly complex. Make sure to foresee operator and maintenance training. Automation : the generator and pumps can be operated via a remote control 2.4.3 COIL AND STEAM / WATER SEPARATOR...
Page 10
: Make sure to cut the power from all the motors, ventilators and oil pumps Automation : Generator ,fuel and air hook-up can be started via remote control. 2.4.5 CERTIFICATION The Clayton steam generator is designed and manufactured in compliance with: Pressure Equipment Directive (PED) 97/23 EC Machine Directive...
3.1 GENERAL The Clayton steam generator will deliver its rated output of 99% quality steam (containing less than one percent moisture). The generator will develop its full rated pressure within five minutes from a cold start. Standard equipment includes safety devices for protection against water failure, burner failure, excessive pressure, and electrical overload.
Page 13
When the alarm condition is corrected the generator must be manually restarted. Temperature sensor mounted in the wall of the heating unit Clayton Steam Generator model EO-100-1M PAGE 13 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
CHAPTER 4 : ELECTRICAL SYSTEM & MAIN COMPONENTS 4.1 DESCRIPTION OF MAIN COMPONENTS For the description of the main components, we refer to the electrical drawing(s). in the Clayton Binder The last pages of these electrical drawings contain the function of the components.
Page 17
H-47 stops the unit in case of minimum fuel pressure / burner failure End Chapter - 4 Clayton Steam Generator model EO-100-1M PAGE 17 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Add the tri-sodium phosphate mixture to the receiver. • Operate the steam generator & feedwater system (plant) for at least one hour. • Blowdown the plant. • Clayton Steam Generator model EO-100-1M PAGE 18 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 19
• Blowdown the plant again as instructed • This should completely clean the system of all construction and installation residues. End Chapter - 5 Clayton Steam Generator model EO-100-1M PAGE 19 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Rising pressure registered on the steam pressure gauge indicates that water has reached the steam separator. If plant is wet shut-down, burner can be started immediately • Clayton Steam Generator model EO-100-1M PAGE 20 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Protection of generators, exhaust gas boilers or others parts during fabrication and/or storage, (that is before they are incorporated in an installation) is described in a Clayton procedure BASE AND REFERENCE DOCUMENTS -- Clayton installation manual -- Clayton instruction manual...
Page 22
If needed bring alkalinity up to normal level while • running feedpumps. Close off supply water to feedwater tank and check for leakages in system. • Clayton Steam Generator model EO-100-1M PAGE 22 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 23
If low-level alarm occurred during the shut down period, run feedpumps and/or circulation pumps for two hours to fill up the system. Fired Clayton generators and exhaust gas boilers can be equipped for fully automatic wet shut down •...
Page 24
Then open steam outlet valves, water supply valve and automatic blow down valves and start • generator and/or exhaust gas boiler. End Chapter - 6 Clayton Steam Generator model EO-100-1M PAGE 24 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
- Ensure waterpump is dischar- ging at normal capacity Steam trap discharge pressure registers fixed pressure reading - Check for possible malfunc- tioning of steam trap Clayton Steam Generator model EO-100-1M PAGE 25 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
- Air leak in supply line - Suction line must be air tight causing loss of pressure and air pockets eliminated - Fuel pump failure - Replace fuel pump Clayton Steam Generator model EO-100-1M PAGE 26 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 27
Burning or fluttering flame after burner - Oil solenoid valve does not - Check and clean oil solenoid stop during automatic operation close completely valve Clayton Steam Generator model EO-100-1M PAGE 27 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 28
- Dirt on UV-cell - Clean glass UV-cell occurs about 2 seconds after initial start (inadequate flame signal) - UV-cell defect - Replace UV-cell Clayton Steam Generator model EO-100-1M PAGE 28 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Before reset and attempting to restart, check position of coded disc, as referred to the Burner Controller A1 (LAL2 inside electrical panel). This information will help to diagnose the exact cause of burner failure Clayton Steam Generator model EO-100-1M PAGE 29 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 30
(solenoid valves, control valve, pressure regulator) - too high combustion air pressure, - check air damper (air/ oil ratio) blowing out main-flame Clayton Steam Generator model EO-100-1M PAGE 30 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 31
Clayton Steam Generator model EO-100-1M PAGE 31 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 32
Clayton Steam Generator model EO-100-1M PAGE 32 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 33
End Chapter - 7 Clayton Steam Generator model EO-100-1M PAGE 33 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
CHAPTER 8 : PERIODIC MAINTENANCE. 8.1 GENERAL Like any other piece of mechanical equipment, the CLAYTON steam generator must receive periodic inspection and attention to maintain the efficiency and service it is designed to perform. The following service recommendations require a few minutes each day and will maintain the efficiency of the unit and minimize repairs and replacements.
3000 - 6000 ppm. If this level is exceeded, perform a manually blow down to re- establish the correct TDS level and re-adjust the automatic blow down valve. Clayton Steam Generator model EO-100-1M PAGE 35 / 70...
After check, replace cell and reset plant. 8.5.5 DRAINING AND CLEANING OF THE HOTWELL To remove sludge, accumulated at the bottom of the hotwell. Clayton Steam Generator model EO-100-1M PAGE 36 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
The operation and setting of all alarm and operating switches, as well as setting and operation of safety and relief valves should be checked by a qualified Clayton technician Clayton Steam Generator model EO-100-1M PAGE 37 / 70...
1 week. Because of the very low, almost un-existing risks to create a steam explosion with a Clayton type steam generator (with all safety devices removed, Clayton did practical firing tests which resulted in a complete...
Page 39
Clayton, preferably without changing original set points. When this is not possible, set-points may only be changed in presence of the AIA and/or a qualified technician of Clayton and the broken seal(s) shall be replaced after testing and readjusting to the original settings Restarting the generator after a shut down by a safety device is only allowed and possible after the anomaly is solved and the reset button is activated.
Page 40
Operation modes to EN12952-7/8: EN-AT=attended; EN-24=max.24h continuous unattended ; EN-1W= max.1 week unattended Col 8->10 : Devices for specific mode: X=standard installed; XC=supplemental installed by Clayton; XM=generator model dependant; XS=special device; O=optional device (sold as an option); OM=optional device generator model dependant. Col 11->14 : Testing: V=visual check;...
Page 41
Operation modes to EN12952-7/8: EN-AT=attended; EN-24=max.24h continuous unattended ; EN-1W= max.1 week unattended Col 8->10 : Devices for specific mode: X=standard installed; XC=supplemental installed by Clayton; XM=generator model dependant; XS=special device; O=optional device (sold as an option); OM=optional device generator model dependant. Col 11->14 : Testing: V=visual check;...
Stud pump Gskt cap brg, 0.005" thick Diaphragm Cap bearing Washer diaphragm Screw cap Spring return diaphragm Washer lock spring Head pump Plate assy cover Clayton Steam Generator model EO-100-1 PAGE 42 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 43
Scale may be removed from inside of check valve housings by filling the housings and pump columns • with a solution of two parts water and one part Clayton Manufacturing Company KLEENKOIL other properly inhibited scale removing acid. Scale on springs and discs may be removed by immersing in the same solution.
Page 44
After installation, operate plant normally for at least 24 hours. Then shut down plant and allow to completely cool. Retighten all pump head nuts while pump is cold to take up set in diaphragms and prevent leakage. Clayton Steam Generator model EO-100-1 PAGE 44 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 45
Assemble and secure main gear to crankshaft. Screws must be tightened securely. Press cone sections • of bearings on ends of crankshaft. Clayton Steam Generator model EO-100-1 PAGE 45 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 46
Oil level switch Bottom mounting screw Top mounting screw Calibration mark Arm position with correct oil Switch extension arm level Lever arm Calibration mark Housing Float Clayton Steam Generator model EO-100-1 PAGE 46 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 47
When reassembling, make sure that the spring washers are not cocked in the housing. • Clayton Steam Generator model EO-100-1 PAGE 47 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 48
Top housing Insert retainer Rubber insert Bottom housing Fig 8.7 : Waterpump discharge snubber END Section waterpump Clayton Steam Generator model EO-100-1 PAGE 48 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Volute(in burner base) Bolt Anchor Burner base insulations Water wall Air passage Heating coil Coil insulation cloth Coil insulation blok Lifting eye Sensor coil temp Clayton Steam Generator model EO-100-1 PAGE 49 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 50
THE CLAYTON COIL The coil of a Clayton Steam Generator is of a unique design which has been developed for optimum heat transfer at all steam output levels. The coil is a single water tube which is stacked in spirally wound layers in the upper section of the Clayton Steam Generator and forms a ‘water wall’...
Page 51
9.2.2 REMOVAL OF EXCESSIVE SOOT FROM HEATING COIL -An authorized Clayton technician should supervise this operation Where the steam generator has been operated with improper air adjustment for any period of time of where uniform periodical soot blowing has not been followed, it may be necessary to wash the coil with water to remove the excessive soot accumulation.
Page 52
9.2.3 HEATING COIL REMOVAL -An authorized Clayton technician should supervise this operation Removal of the heating coil from the burner base is done as follows : Remove inspection covers and remove thermocouple.
Page 53
8.9 item 6 [ ** kg ] vermiculite insulation ( Clayton order nr.: M018506 ) < max.temperature : 1000°C ; • density : 450 kg/m³ > Do not finish the surface too slippery to secure a good adhering with te castable insulation ( item 7 ) •...
Page 54
MODEL E-60 E-80/100/125/185 Insulation cement (Clayton part number - M018506 ) 2 kg 4 kg Refractory cement (Clayton part number - M011297 ) 15 kg 65 kg Fig.8.9 : Burner base. Heating coil Insulation retaining ring Burner base Coil insulation...
For maximum steam output, the pressure regulator setting may range from bar fuel pressure. *** See QC-1039 test sheet Locknut Adjusting screw fig.8.12 : Fuel pressure regulator. Clayton Steam Generator model EO-100-1 PAGE 55 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 56
The burner capacity depends also on the combustion air pressure. Check this pressure first before regulation of the fuel pressure Clayton Steam Generator model EO-100-1 PAGE 56 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 57
Spacer manifold burner Electrode ignition E-100 Nozzle 9.5GPH -- 90° qty 1 Nut lock electrode E-100 Nozzle 4.5 GPH -- 80° qty 2 FOR THIS ORDER Clayton Steam Generator model EO-100-1 PAGE 57 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 58
Fig 8.13 a : Oil burner ( ignition electrodes) Drawing 0160555 Clayton Steam Generator model EO-100-1 PAGE 58 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Page 59
9.3.2 CLEANING AND ADJUSTING THE OIL BURNER MANIFOLD -An authorized Clayton technician should supervise this operation Disconnect ignition wires (attached to item 16) from burner manifold. Disconnect fuel lines. • Unscrew nuts which attach manifold to burner volute and remove manifold...
– DO NOT RETURN SCREW “leave on Nr ( 0) 4 Mounting plate motor E-100 MOUTING PLATE “UB70330 “ 5 Belimo motor 24v “0204920” Clayton Steam Generator model EO-100-1 PAGE 60 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Turning the screw clockwise increases pressure, counterclockwise decreases. After regulating LF & HF note the tension of the potentiometers for further Reference. Clayton Steam Generator model EO-100-1 PAGE 61 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
= nominal stack temperature at max. firing-rate + 15 C for stack [A95]; xxx = saturation temperatuur + 15 C for separator [A31]. Clayton Steam Generator model EO-100-1 PAGE 62 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
"override" during abrupt drop in steam load. If set to low, steam pressure will not be maintained at high level during heavy loads. The way of adjustment of the switch is identical to the one for the steam pressure switch. Clayton Steam Generator model EO-100-1 PAGE 63 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Remove cover of pressure switch. Turn external ring with scale to the value which corresponds to • 80% of normal volute pressure. An indication arrow is provided on the internal ring. End Chapter - 9 Clayton Steam Generator model EO-100-1 PAGE 64 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
• When replacing standard Clayton oils by oils for food industries that are not mentioned in above table, please contact your local supplier for the correct replacement procedure.
Point loads on the body can lead to serious deformation. Transport and storage below the freezing point (0°C) are not allowed. (Freezing risk of un-drainable remaining water in the pressure equipment). Clayton Steam Generator model EO-100-1 PAGE 66 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Safety accessories :Suitable safety devices shall be installed to prevent that the maximum allowable operating parameters are exceeded in case of failing limiting devices. Clayton Steam Generator model EO-100-1 PAGE 67 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
In the latter case, precautions shall be made to prevent internal corrosion e.g. by putting and maintaining the pressure system under inert gas pressure of 0,5 to 1 barg. Clayton Steam Generator model EO-100-1 PAGE 68 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
(e.g. where there are no block valves installed or allowed). Check surface temperatures Clayton Steam Generator model EO-100-1 PAGE 69 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
The repair must be inspected as required by the authorized inspector and local jurisdiction. Only original parts may be used. End Chapter - 11 END MANUAL PSC 04-02-2014 Clayton Steam Generator model EO-100-1 PAGE 70 / 70 Instruction Manual, doc.nr.: MAN18206 Rev A PSC...
Need help?
Do you have a question about the EO-100-1M and is the answer not in the manual?
Questions and answers
how to give service for steam generator
To service the Clayton EO-100-1M steam generator, follow these detailed steps:
1. Before Starting:
- Close:
- Soot blower valve [28] (for oil or oil/gas units)
- Steam discharge valve [47]
- Coil drain valve [25]
- Drain cock at base of water pump
- Open:
- Water supply to the hotwell
- Coil feed valve [26]
- Valve to steam trap [35]
2. Washing the Coil (when soot buildup is suspected):
- Set switch [S01] to position 2 (pump mode) and run the generator for 15 minutes to cool it.
- Disconnect and remove the stack section above the heater cover.
- Remove the burner manifold.
- Place a trough under the burner volute to collect wash water.
- Use a 20 mm hose (minimum 20 L/min flow) without a nozzle.
- Insert hose through the stack opening and under the heater cover.
- Move the hose to evenly wash the coil top surface.
- Dark water in the trough indicates soot removal.
3. Operation Notes:
- The generator reaches full pressure within 5 minutes from a cold start.
- It includes safety devices for water failure, burner failure, overpressure, and electrical overload.
- Automatic controls manage feedwater flow and burner modulation.
- Regular attention and maintenance by trained personnel is required.
Failure to follow these instructions may void the warranty.
This answer is automatically generated
i need the picture of bag "castable insulation ( Clayton order nr. : M011297 )