Columbia CT Series Installation, Operation And Maintenance Manual
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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

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  • 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: Table Of Contents

    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...
  • Page 4 Normal burner cycling is required. Continuous oper- ation will eventually damage the boiler, voiding the warranty. Wrapping the CT Boiler with insulation will cause the boiler to overheat, voiding the warranty. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 1 -...

  • Page 5: Parts Warranty

    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 the unexpired por- tion of the original equipment warranty.

  • Page 6: Service Policy

    Burner Type and Model ________________________________________________________ Installer’s Name ____________________________________ Phone (_____) ______________ Address ______________________________________________________________________ Distributor’s Name __________________________________Phone (_____) ______________ Address ______________________________________________________________________ Sales Representative ________________________________ Phone (_____) ______________ Address ______________________________________________________________________ Specific Problem - Detailed FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 3 -...

  • Page 7: Installation

    In the absence of local codes, it is recommended that the above stated clearances be fol- lowed. FLUE The CT series boilers are pressure fired steam boilers, and need only to be properly vent- ed. Consult the factory for proper venting of the boiler for any unusual conditions that may exist at the job-site.
  • Page 8 The flue pipe must not be inserted beyond the inside wall of the chimney. Columbia Boiler approves the use of galvanized “B” type vent that is suitable for 550°F stack temperature as proper and safe for this application, but any and all codes take prece- dence.
  • Page 9 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. Additional gas piping information is included in the burner section of this manual. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 6 -...
  • Page 10 Connect the feedwater supply from the condensate return tank to the boiler inlet feedwa- ter connection. See Figure 2 and Piping Layout PL-098 in Appendix. Columbia Boiler Company provides one spring type check valve in the feedwater piping. An additional swing type check valve should be installed in the feed line as close to the pump as possi- ble.
  • Page 11 Avoid high spots that will collect air and lead to erratic pumping. Install a check valve to prevent the boiler water from back feeding into the service water supply. STEAM PIPING Figure 3 FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 8 -...
  • Page 12 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 9 -...
  • Page 13 Figure 4 BLOWDOWN PIPING FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 10 -...

  • Page 14: Cleaning And Filling A New Steam Boiler

    MODEL TRISODIUM PHOSPHATE CT-6 5 1/3 oz. 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 11 -...

  • Page 15: Operating The Boiler

    OPERATING THE BOILER NOTE: Although your new Columbia Boiler has been test fired at the factory, it must be “set up” for the conditions at your location. Improper combustion settings may cause the burner to operate erratically, resulting in boiler shutdowns, lost time, and unnecessary service expenses.

  • Page 16: Starting The Boiler

    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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 13 -...
  • Page 17 If the gas pressure is below seven inches water column con- tact your local gas company. If the local gas company is unable to help, contact the facto- ry for assistance. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 14 -...

  • Page 18: Burner Start Up And Test Information

    Flame Safeguard _______________q Safety Limit____________________q Low Gas Pressure ______________q Ignition Failure q Low Water Cut Off______________q High Gas Pressure ______________q Flame Failure q Comments ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 15 -...

  • Page 19: Sidewall Venting

    Equipment (Available with Power Flame Burners Only) Note: All Columbia boilers ordered for Sidewall Venting will be provided with a Combustion Air Intake Adapter. CT-6 Boiler with Power Flame JR15A-10 Burner...
  • Page 20 Installation The Columbia Model CT Direct Vent Series Steam Boiler is furnished completely piped, wired, and assembled. It has been test fired at the factory and is ready for installation. This steam boiler is designed to operate with natural gas, and is suitable for standard AC elec- trical service.
  • Page 21 Combustion Vent. Important Note: Surface discoloration of the building may occur due to improper boiler/burner adjustment and maintenance. Columbia Boiler Company will not accept any liability for such discoloration. FM-148 COLUMBIA BOILER COMPANY, REV 6-06...

  • Page 22: 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 23 NFPA and all local codes. WARNING: DO NOT STORE OR USE GASOLINE OR ANY OTHER FLAMMABLE LIQUIDS AND VAPORS IN THE VICINITY OF THE BOILER OR BOILER ROOM. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 20 -...

  • Page 24: Description Of Boiler Components

    See Table of Contents for location of applicable drawing and/or specification sheet. PANEL BOX WITH WARRICK SERIES 3K ELECTRODE FITTING The standard control circuit for the CT Series Boilers consists of probe type, primary and secondary low water cut off and pump controls enclosed in a panel box; and typical oper- ating and safety limit pressure controls.
  • Page 25 Adjust the differential set point for the desired cut in pressure by turning the adjusting screw on top of the case until the differential setting indicator is at the desired setting. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 22 -...
  • Page 26 The gauge glass protector is provided to guard against personnel injury and component damage in the event of a breakage of the sight glass. The gauge glass protector must be properly installed prior to operation of the boiler. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 23 -...
  • Page 27 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 24 -...

  • Page 28: Maintenance

    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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 25 -...
  • Page 29 9. Gas fired - check drip leg/strainer. 10. Oil fired - check for refractory hold in. 11. Check Automatic Change Over Control if equipped. 12. Gas fired - perform valve leakage test. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 26 -...
  • Page 30 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 27 -...
  • Page 31 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 GASKET OF HANDHOLE PLATE Figure 7 FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 28 -...
  • Page 32 If your boiler was built after February 1991 you will also need an upper hand hole gasket, part number 480210. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 29 -...
  • Page 33 14. Reinstall the top jacket fiberglass insulation strip. Replace this insulation strip with a new one if necessary. 15. Reinstall the top jacket and secure it to the top cover and to itself with the seven (7) screws that were removed. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 30 -...

  • Page 34: Maintenance Logs

    MAINTENANCE LOG FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 31 -...
  • Page 35 MAINTENANCE LOG FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 32 -...

  • Page 36: 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-A2 and TB2-3. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 33 -...
  • Page 37 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 34 -...
  • Page 38 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 35 -...
  • Page 39 2. Connect a Honeywell W136A tet meter, or equivalent microammeter, in series with the flame rod. Connect a standard electrical meter, set for 24 volt range, to terminals MV-MV on the control. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 36 -...
  • Page 40 9. repeat the entire turndown test until the flame is established promptly in step number 6. 10. Turn the pilot up to full flame at the completion of the test. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 37 -...
  • Page 41 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 go through a normal operating cycle. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 38 -...

  • Page 42: Water Treatment

    The pH should be maintained between a minimum of 10.5, and a maximum of 11.0 to prevent acidic corrosion of boiler tubes and plates, and to provide FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 39 -...
  • Page 43 The chloride test is unsuitable for feedwater with low incoming concentrations and the concentrations in the feedwater must be averaged over time for accuracy. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 40 -...
  • Page 44 If oil does get into the boiler, the boiler should be taken out of serv- ice immediately, and thoroughly cleaned. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 41 -...

  • Page 45: Return Systems

    This make-up valve is built into the boiler feedwater return tank. The maximum allowable pressure to the make-up valve is 50 PSI. Pressures in excess of this value must be reduced. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 42 -...

  • Page 46: Blowdown Separator

    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 SEPARATOR Figure 9 FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 43 -...

  • Page 47: 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. FM-148 COLUMBIA BOILER COMPANY, REV 6-06 - 44 -...

  • Page 48: Appendices

    APPENDICES...
  • Page 49 PART OF CT-35 & CT-50 W/OIL BURNER ONLY. REPLACEMENT PARTS FOR CT BOILERS WITH PANEL-BOX & WARRICK DF LWCO, WITH PRESSURETROLS IN/ON PANEL BOX...
  • 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 NOTES __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________...

  • Page 52: Replacement Parts For Ct Series Boilers

    REPLACEMENT PARTS FOR CT SERIES BOILERS 150 PSI w/ Panel Box with Pressure Controls & Warrick LWCO/Pump Control REF. No.† DESCRIPTION BOILER MODEL ITEM NUMBER BURNER – CONSULT FACTORY SEE PARTS LIST BOILER BLOWDOWN 1” Y-VALVE ALL X/C CT-50 579005 BOILER BLOWDOWN 1-1/4”...
  • Page 53 REPLACEMENT PARTS FOR CT SERIES BOILER 150 PSI w/ Panel Box with Pressure Controls & Warrick LWCO/Pump Control REF. No.† DESCRIPTION BOILER MODEL ITEM NUMBER SECONDARY LWCO PROBE ROD, 16” 558908 SEC. LWCO RUBBER BOOT – PROBE PLUG 558930 SAFETY VALVE, 150 PSI, 3/4” X 3/4”...
  • Page 54 GAS TRAIN PIPING DIAGRAM for CT-6/10 BOILER w/POWER FLAME JR15A-10 (3/4") GAS BURNER GAS TRAIN PIPING DIAGRAM for CT-15 BOILER w/POWER FLAME JR15A-10 GAS BURNER & CT-20 BOILER w/POWER FLAME JR30A-12 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 57: Boiler Wiring Diagram

    BOILER WIRING DIAGRAM SEE THE BURNER SECTION IN THE BOILER MANUAL BINDER FOR THE APPLICABLE WIRING DIAGRAMS FOR THIS BOILER.
  • Page 59 DIMENSIONAL DIAGRAM Either “G” tab can be used for reference probe. WARRICK CONTROLS • ONE COWLES ROAD • PLAINVILLE, CT 06062-1198 PHONE: (860) 793-4579 • FAX: (860) 793-4580...

  • Page 60: Warrick Dual Function Controls

    OPERATION OF WARRICK DUAL FUNCTION CONTROLS 5/95 PRINTED IN U.S.A.
  • Page 61 INSTALLATION OF WARRICK SERIES 3C & 3K ELECTRODE FITTINGS...
  • Page 63 OPERATION OF WARRICK SERIES 26 CONTROLS 5/93...
  • Page 70 CT SPECIFICATIONS AND DATA MODEL NO. CT-6 CT-10 CT-15 CT-20 CT-25 CT-35 CT-50 ___________________________________________________________________________ RATINGS: ___________________________________________________________________________ Horsepower ___________________________________________________________________________ Gas INput (BTU per hour) 252,000 399,000 630,000 840,000 1,050,000 1,470,000 2,100,000 ___________________________________________________________________________ Oil Input (Gals. per hour) 2.00 2.85 4.50 6.00 7.50 10.50 15.00...
  • Page 72 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 CC-6427 PRINTED IN U.S.A. 500 - 7/08...

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