Transcription

COLUMBIAMULTI-PASS HORIZONTAL BOILERMPH SERIESINSTALLATION,OPERATION andMAINTENANCE MANUALCOLUMBIA BOILER COMPANYPOTTSTOWN, PENNSYLVANIA

Table Of ContentsPARTS WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3SERVICE POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5BOILER ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5JACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6BURNER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6BOILER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7FUEL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9CLEANING AND FILLING A NEW STEAM BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14OPERATING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16STARTING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17STOPPING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17BURNER START UP AND TEST INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18CONTROL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Daily Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Weekly Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Monthly Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Semiannual Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Annual Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

IMPORTANT1. Read and familiarize yourself with this installation, operation, and maintenance manual before installing, operating, or servicing your boiler.2. All cover plates, enclosures, and safety devices must be installed at alltimes except 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 recommendations givenin this manual.5. Columbia Boiler performed testing on the MPH boiler line using specificmakes and models of burners. Should you choose to supply your own burner, please contact the burner manufacturer to confirm compatibility with theMPH boiler design.6. A barometric damper or draft regulator is required on MPH installations. Adraft regulating device is required on all multiple boiler installations wherethe boilers utilize common breaching. One regulator is required per boiler.Regulators can be installed in each individual boiler breach (Location A) orin the common breach, just upstream of each connection between the boiler breach and the common breach. (Location B) One regulator (Location C)is not acceptable. Set draft to -.02 to -.05 in the breach.7. A completed burner start up report (page 18) is required for all warrantyclaims.1MPH COLUMBIA BOILER COMPANY

LIMITED PARTS WARRANTYThe Columbia Boiler Company (hereinafter Columbia) warrants the burner componentsand controls installed on its boiler/burner units to be free from defects in material and workmanship under normal use and service for 12 months from the date of installation or 18months from the date of manufacture, whichever date occurs first, and is subject to warrantyapproval by the manufacturer of the specific components. This warranty does not extend toequipment subjected to misuse, neglect, accident or improper installation. Equipment whichis defective in material or workmanship and is removed within 12 months from the date ofinstallation will be repaired or replaced as follows:a. Motors, fuel units, controls, and transformers should be sent for repair or replacementto an authorized service point or distributor of the manufacturer of such componentwhen reasonably available in Customer’s locality.b. Where such local service is not available with respect to the above listed components, orwhere other components are involved, such defective equipment should be returned afterreceiving authorization from your dealer, freight prepaid, to the Columbia Boiler Co.,390 Old Reading Pike, Pottstown PA 19464. The use of the Columbia returned goodsform is mandatory when returning defective material.c. Columbia is not responsible for any labor cost for the removal and replacement ofequipment.d. Equipment which is repaired or replaced will carry a warranty equal to the unexpiredportion of the original equipment warranty.e. If inspection by Columbia does not disclose any defect covered by this warranty, theequipment will be repaired or replaced at the expense of the Customer, and Columbia’sregular charges will apply.THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE,AND PROVIDES EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHERREMEDIES. ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TOANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, ARE EXCLUDED. IN NO EVENT WILL COLUMBIABOILER CO. BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE. Columbia neither assumes nor authorizes any person to assumefor Columbia any other liability or obligation in connection with the sale of this equipment.Columbia’s liability and Customer’s exclusive remedy being limited to repairs or replacementas set forth above.March 10, 1997MPH COLUMBIA BOILER COMPANY2

INTRODUCTIONSeries MPH Modified Scotch BoilerThe Columbia Multi-Pass Horizontal (MPH) boiler is a modified scotch boilerdesigned for hot water, and/or low pressure steam applications. The pressure vesselis available as a welded pipe boiler or a rolled tube boiler. These units are manufactured to the specifications set forth by Section IV of the ASME Boiler and PressureVessel Code. Boilers are inspected and stamped for conformity to requirements ofthe National Board of Boiler and Pressure Vessel Inspectors. All boilers are designedto be fired using No. 2 fuel oil, and/or natural, manufactured, or liquid propane (LP)gas, methane or biogas, and are powered by standard AC electrical service.Columbia MPH hot water and low pressure steam boilers can be shipped knockeddown (unassembled), but are also available factory packaged. All boilers are furnished with a burner and boiler trim (the jacket is factory installed). Boiler trim consists of the operating and limit controls, pump control and/or low water cut off(LWCO) controls, and a safety valve. Factory packaged boilers are fully assembledand test fired.*Please note: All MPH burners are removed for shipping to prevent damage in transit, unless boiler is shipped on a flatbed truck or customer assumes all liability fordamage.3MPH COLUMBIA BOILER COMPANY

SERVICE POLICYSteam and hot water boilers are routinely serviced by the installer or another boilermaintenance company. Occasionally the service technician may be unable to determine the cause of the problem. In this situation, the dealer or service organizationshould contact the selling distributor for help.Should the problem persist, the distributor will contact the sales representative forassistance. Depending on the extent of the problem, the representative may requesttechnical assistance from the factory.If the problem cannot be resolved by the representative, the representative or serviceman should contact the Technical Service/Engineering Department at the factory.The following information will be needed. It is essential that this information be available to assure prompt service.Boiler Model and Size (HP)Boiler Serial NumberBoiler National Board NumberDate InstalledBurner Type and ModelPrimary Burner Control TypeInstaller's Name Phone ( )AddressDistributors Name Phone ( )AddressSales Representative Phone ( )AddressSpecific Problem - DetailedStartup ReportMPH COLUMBIA BOILER COMPANY4

INSTALLATIONBEFORE BEGINNING INSTALLATION, CAREFULLY STUDY THESEINSTRUCTIONS AND ALL CHARTS, DRAWINGS, AND DIAGRAMSSHIPPED WITH THE BOILER.Installation must follow all state and local code requirements, Fire and Underwriters regulations,and standard plumbing practices. The electrical installation shall be in accordance with theNational Electrical Code.Remove all boiler components from packaging and inspect prior to assembly to ensure thatdamage has not occurred in shipping.BOILER ROOMLocate the boiler in a well lit area on a noncombustible, level floor. Make available a convenientwater supply and allow adequate drainage, including unobstructed floor drains, for flushing andfilling the boiler. Provide sufficient make-up air for combustion at all times. See section on“Combustion Air” later in this manual. Power the boiler using a properly rated electrical service.Include fused disconnects for control circuits, blower motor circuits, and feed pump circuits thatrequire a motor contactor or motor starter relay.Reference local codes for clearances around the boiler. In lieu of local code, use 36" on allsides.Where possible, place the boiler on a 3 inch concrete pad. Allow adequate clearance betweenthe boiler and any walls or obstructions to permit inspection and service on burner, boiler piping, controls, or combustion vent.DO NOT install exhaust fans in or near the boiler room. Exhaust fans consume available makeup air during burner operation. More importantly, when the boiler cycles off, exhaust fans pullhot flue gases back through the burner causing burner parts to deteriorate, and possibly fail.Maintain a positive pressure in the boiler room at all times. Refer to the combustion air sectionof this manual for additional information.Do not allow your boiler room to become a storage room.VENTINGLocate the boiler as close as possible to the chimney or other approved exhaust vent. Attach allflue piping to the round flue connection and make each connection secure. The flue pipe shouldnot be inserted beyond the inside wall of the chimney.DO NOT REDUCE THE SIZE OF THE FLUE OUTLET OR FLUE PIPING.Columbia Boiler recommends the use of galvanized “B” Type vent for stack connections suitable for temperatures to 550F. The flue pipe should be pitched upward at least 1/4" per foot ofrun. Avoid the use of tees, sharp bends, and long horizontal runs. Install a draft regulator ifrequired. See page 1 for draft regulator installation on multiple boilers with common breaching.5MPH COLUMBIA BOILER COMPANY

All Columbia boiler models utilize a pressure fired burner and need only to be properly vented.For situations where unusual conditions may exist, consult the factory for proper venting.COLUMBIA BOILER COMPANY OF POTTSTOWN SHALL NOT BE HELD LIABLE FORDAMAGE TO THE BOILER CAUSED BY INCORRECT VENT CONDITIONS AND/ORINSUFFICIENT BURNER MAKEUP AIR.JACKET ASSEMBLYThe jacket for the MPH boiler is factory installed and should not have to be removed for installation of the boiler.BURNER MOUNTINGIf the burner is to be installed on site, first apply a flame resistant gasket or gasketing materialbetween the burner flange and the burner mounting plate to seal the burner. Wet insulation isthe preferred gasketing material because it compresses into a flat gasket which conforms to andfills any and all voids. Secure the burner in the boiler using the four bolts supplied with the burner. See the Burner Section of this manual for proper electrical wiring, and fuel supply piping.Figure 1MPH COLUMBIA BOILER COMPANY6

BOILER CONNECTIONSDrainsAll Columbia Boiler MPH units have (2) 1-1/2" drains. These are located in the front and rear ofthe boiler below the fire chamber. Install a pipe nipple and ball valve in a least one for use as adrain. If a drain is not needed, plug it by using the proper size nipple and a pipe cap. DO NOTuse a pipe plug.Low Water Cut-OffsAll Columbia boilers are supplied with at least one low water cut-off (LWCO) as standard equipment. Some boiler applications may require a secondary LWCO. The standard equipment is asfollows:Hot Water Boilers - McDonnell & Miller 750-MT-120 Probe Type Low Water Cut-Off with RemoteSensor - Thread the Remote Sensor into the 3/4" NPT fitting located on top of the boiler. Mountthe Control Box near the top of the side jacket panel.Steam Boilers - Warrick 3K3B3L Low Water Cut-Off/Pump Control - Install this device withequalizing piping into the 1" NPT welded couplings found on the top and either side of the boiler. Only two of the three 1" NPT will be used. The water column can be piped to either side ofthe boiler.Secondary Low Water Cut-OffsSecondary LWCO’s may be required to meet local codes or CSD-1 requirements. A Warrick26C1D1C Probe Type Low Water Cut-Off is used in steam applications to me