CSMG-15/30/40 - Clayton Industries · 3 Compact Burner, Weishaupt 4 Steam Outlet 5 Exhaust Outlet 6...

STEAM MASTER SERIES

USER MANUAL

Cover

CSMG-15/30/40

R027880B-20190603

For your convenience, enter your unit’s specific model and serial number in the space below. The model and serial number are located on the right-hand side of the electronic controls cabinet.

MODEL: _______________________ SERIAL NUMBER: _____________________

SAFETY SUMMARYEMERGENCY STOPIn the case of an emergency, immediately press the EMERGENCY STOP pushbutton (S101). Turn the main disconnect switch (S10), located directly below emergency stop pushbutton, to the OFF position. Turn off main fuel supply.

HIGH PRESSURE VESSELHeating section of the steam generator/fluid heater is under pressure when the unit is in operation. Perform a complete shut down of the unit and relieve all the pressure from the heating section and piping before disassembling piping, pump, coil, and pressure and temperature devices for maintenance and repair.

HOT SURFACES! Allow the unit to cool down before performing disassembly.

DANGEROUS VOLTAGES230/460 volts in the electronic control box. Use extreme care when accessing the control box for maintenance. Disconnect and lock out main power circuit switch before performing any disassembly of the steam generator.

Disconnect main power and properly lockout disconnect switch (S10) before working on any electrical component inside the electrical control panel.

High voltage and moving parts hazards exists around the blower and feedwater pump motors and pulley systems.

Equipment may start automatically at any time.

HEARING PROTECTIONElevated ambient noise levels exist in the facility where the steam generator is installed. Extended exposure to elevated noise levels may result in long-term hearing damage.

CORROSIVE LIQUIDSWear face shield, protective apron, protective boots, and protective glove at all times when handling corrosive liquids. Hydrochloric Acid (HCl) and KleenKoil Inhibitor™ used for heating coil descaling procedure.

Risk of death or serious bodily injury if the directions in this note is not followed. Take appropriate precautions while working on all machines.

Risk of machine damage if the directions in this note is not followed. The loss of machine operating effectiveness may lead to bodily injury or death.

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Personnel must become thoroughly familiar with all aspects of safe and proper operating and maintenance procedures before attempting to operate or maintain this machine.

IF A STRONG SMELL OF GAS IS DETECTED, IMMEDIATELY OPEN DOORS ANDWINDOWS AND EXTINGUISH ANY OPEN FLAMES. STAY AWAY AND DO NOT TOUCHANY ELECTRICAL SWITCHES AND SIMILAR DEVICES. IMMEDIATELY EVACUATE ALLPERSONNEL FOR BUILDING. IMMEDIATELY CONTACT THE FIRE DEPARTMENT.

IN ACCORDANCE WITH OSHA STANDARDS, ALL MACHINES MUST BE LOCKED OUTAND WORK AREA SECURED PRIOR TO PERFORMING WORK ON THE MACHINE.

FAILING TO INSTALL, OPERATE, AND MAINTAIN MACHINERY ACCORDING TOMANUFACTURE’S INSTRUCTIONS COULD RESULT IN HAZARDOUS WORKINGCONDITIONS THAT LEAD TO BODILY HARM OR DEATH.

ALL SERVICING OF MACHINERY MUST BE PERFORMED BY A QUALIFIED AND FULLYTRAINED SERVICE TECHNICIAN.

VERIFY ALL STEAM GENERATOR ELECTRONIC EQUIPMENT ARE DISCONNECTEDPRIOR TO THE STEAM GENERATOR INSTALLATION. DAMAGE TO ELECTRONICEQUIPMENT NOT COVERED BY THE CLAYTON WARRANTY MAY RESULT FROMINSTALLATION ACTIVITIES IF THIS ACTION IS NOT TAKEN.

Steam generator electronics cabinet devices are rated to function properly at typical boilerroom temperatures not exceeding 122°F (50°C). For boiler room installations wheretemperatures are expected to exceed 122°F (50°C), an electronics cabinet cooling kit isrequired.

MACHINE STORAGE: Store your Clayton Steam Generator and all ancillary equipment in adry place where the temperature and humidity is relatively stable and the environment is freefrom frost. Generally, your Clayton Steam Generator, as delivered from Clayton, is covered fora storage period of three months. For storage periods that may exceed three months, followthe storage instructions described in the equipment documentation package. Contact ClaytonIndustries for clarity if documentation package instructions is unclear or missing from thedelivered equipment. Failing to follow the equipment storage instructions properly will voidyour Clayton warranty.

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IMPORTANT INFORMATION

PLEASE READ THIS PAGE CAREFULLY

1. READ THIS INSTRUCTION MANUAL AND THE INSTALLATION MANUAL CAREFULLY BEFORE INSTALL-ING, OPERATING, OR SERVICING THE STEAM GENERATOR UNIT. KEEP ALL INSTRUCTIONS IN LEGIBLE CONDITION AND POSTED NEAR THE STEAM GENERATOR FOR REFERENCE BY OWNER AND SERVICE PERSONNEL.

2. All steam generator units must be installed in accordance with ASME, national, state, and local plumbing, heating, and electrical codes and regulations. Consult the proper authorities having jurisdiction over the installation site prior to installing any steam generator.

IN ALL CASES, REFERENCE SHOULD BE MADE TO THE FOLLOWING STANDARDS:

USA BOILERS

A. Current edition of the American National Standard ANSI Z223.1/NFPA54, National Fuel Gas Code, or ANSI/NFPA 31, “Installation of Oil Burning Equipment,” for clearances between heating unit, vent connector, and combustible material.

B. Current edition of the American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances,” for Chimney requirements, types of venting material and clearances between vent connector pipe and combustible materials.

C. Current edition of the American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for Automatically Fired Boilers,” for assembly and operations of controls and safety devices.

CANADA BOILERS

A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equip-ment,” for recommended installation practices.

B. The equipment shall be installed in accordance with the current installation code for gas burning appliances and equipment, CGA B149, and applicable provincial regulations for the class, which should be followed in all cases. Consult the proper authorities having jurisdiction over the installation site prior to installing any steam generator.

3. Heating systems should be designed by licensed contractors, only. Installation of a steam generator should be performed only by persons qualified in the layout and installation of boiler systems (including ASME code).

4. The steam generator must be properly vented in accordance with the National Fuel Gas Code and local codes. Failure to adhere to these codes may result in serious property damage.

5. The Contractor will be responsible for verifying that all operating and safety controls are correctly installed and are functioning properly before signing off on a project.

6. Do NOT tamper with the steam generator or its controls. To assure the steam generator is maintained properly, only qualified service personnel should perform adjustments and maintenance on the equipment.

7. KEEP THE AREA AROUND THE STEAM GENERATOR FREE AND CLEAR OF ALL FLAMMABLE MATE-RIAL; SUCH AS, RAGS, PAPERS, AND WOOD SCRAPS, AT ALL TIMES.

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RECEIVING AND UNPACKING

Your Clayton Steam Master Steam Generator arrives anchored to a shipping pallet. It is typically packaged in protective plastic wrap—unless otherwise specified (See below.).

Properly-rated lifting equipment MUST be used to move your steam generator.

IT IS YOUR RESPONSIBILITY TO INSPECT YOUR UNIT BEFORE UNPACKING AND AFTER UNPACKING FOR DAMAGES THAT MAY HAVE OCCURRED DURING SHIPPING.

The steam generator is anchored to the pallet by two bolts. One of the two anchor bolts is located at the front-left corner of the unit inside the front-left door. The second of the two bolts is located at the right-rear corner of the unit (See below.)

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Overview of Unit FeaturesThe following pages describe the controls and other features of the Clayton Steam Master.These pages are only a general overview. The controls and features may differ depending onthe unit’s size and specifications.

See page viii for description of unit features.

v

The controls and features may differ depending on the unit’s size and specifications.

vi

The controls and features may differ depending on the unit’s size and specifications.

vii

Description of Unit Features

1 Gas Train, Main Gas Supply

2 Gas Inlet, Main

3 Compact Burner, Weishaupt

4 Steam Outlet

5 Exhaust Outlet

6 OIU (Operator Interface Unit)

8 Condensate Return, Steam Trap

9 Economizer Drain

10 Blowdown Drain

11 Separator

12 Exhaust Duct/Economizer

13 Pump and Motor Assembly

14 Heating Coil

20 Water Inlet, Pump

24 Feedwater Pressure Gauge

25 Maintenance Drain Valve

26 Coil Feedwater Valve

29 Test Valve

30 Safety Relief Valve

32 Separator Drain Valve

38 Steam Pressure Gauge

41 Steam Trap Pressure Gauge

47 Steam Outlet Valve

48 Steam Trap

B24 Pressure Transducer (OPX1)

B29 Temperature Transmitter

F21 Temperature Switch (LPS)

F31 Thermocouple

F95 Temperature Switch

Y15 Blowdown Valve, Manual

S10 Main Switch

S101 Emergency Stop Button

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ASME Conformance Statement

A Clayton Steam Generator is manufactured in conformance with the ASME (Ameri-can Society of Mechanical Engineers) Power Boiler Code, Section I. Construction and inspection procedures are regularly monitored by ASME certification officials and by authorized inspectors commissioned by the jurisdiction and the NBBI (National Board of Boiler and Pressure Vessel Inspectors). The NBBI is responsible for enforcement of all ASME code sections applicable to steam boiler manufactur-ing.

The NBBI is a nonprofit organization. Its chief boiler and pressure vessel inspectors are responsible for administering the boiler and pressure vessel safety laws of their jurisdiction.

Clayton Steam Generators are designed with electrical and combustion safeguards which comply with UL (Underwriters Laboratories) and other such agency require-ments as specified in a customer's order.

NBBI certification and UL compliance assures that a Clayton Steam Generator is reliable and capable of producing the high quality steam it was designed to deliver. All Clayton Steam Generators are built to conform to the rules and practices for safety and durability of the highest recognized regulatory authority.

CLAYTON INDUSTRIES17477 Hurley Street

City of Industry, California 91744-5106USA

Phone: +1 (626) 435-1200Fax: +1 (626) 435-0180

Internet: www.claytonindustries.comEmail: [email protected]

© Copyright 2018 Clayton Industries. All rights reserved.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopy, recording, or otherwise) without written permission from Clayton Industries.

The descriptions and specifications shown were in effect at the time this publication was approved for printing. Clayton Industries, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or

change specifications or design without notice and without incurring any obligation.

FACTORY DIRECT SALES AND SERVICEUNITED STATES OFFICES

ATLANTA • CHICAGO • CINCINNATI • CLEVELAND • DALLAS • DETROITKANSAS CITY • LOS ANGELES • NEW ENGLAND • NEW JERSEY

NORTHERN CALIFORNIA

LICENSEES, AFFILIATES, SALES and SERVICE DISTRIBUTORS WORLDWIDE

SPECIFICATIONS

Units of Measure-

mentCSM-15 CSM-15-SE CSM-30 CSM-30-SE CSM-40 CSM-40-SE

Boiler Horsepower bhp 15 15 30 30 40 40

Heat Input: Gas Btu / hr 619,907 590,735 1,239,815 1,181,471 1,653,086 1,575,294

Net Heat Output Btu / hr 502,125 502,125 1,004,250 1,004,250 1,339,000 1,339,000

Equivalent Output (From and at 212 °F feedwater and 0 psig steam.)

lbs / hr 518 518 1,035 1,035 1,380 1,380

Design Pressure (See Note 1.) psig 150 150 150 150 150 150

Steam Operating Pressure psig 65 – 125 65 – 125 65 – 125 65 – 125 65 – 125 65 – 125

Gas Consumption — at maximum steam output (See Note 2.)

ft3 / hr 620 591 1,240 1,182 1,653 1,575

Burner Controls (modulating gas) 4:1 turndown 4:1 turndown 4:1 turndown 4:1 turndown 4:1 turndown 4:1 turndown

Efficiency (gas fired) % 81 85 81 85 81 85

Electric Motors — design pressure 150 psi hp Blower = 0.67Pump = 0.5

Blower = 0.67Pump = 0.5





Electric FLA — based on 230 vac(See Note 3.)

vac 10 10 11 11 15 15

Gas Supply Pressure Required psig 2 2 2 2 2 2

Water Supply Required gph 133 133 265 265 353 353

Heating Surface ft2 78.6 110.9 141.0 199.1 152.8 228.2

Customer Connections:

Feedwater Inlet in. 1.5 1.5 1.5 1.5 1.5 1.5

Steam Trap Discharge in. 1.0 1.0 0.75 0.75 1.0 1.0

Separator Blowdown in. 1.0 1.0 0.75 0.75 1.0 1.0

Economizer Drain in. 1.0 1.0 1.0 1.0 1.0 1.0

Supply Gas Inlet in. 0.75 0.75 0.75 0.75 1.0 1.0

Steam Discharge Outlet in. 1.5 1.5 1.0 1.0 1.5 1.5

Safety Relief Valve in. 1.0 1.0 1.0 1.0 1.0 1.0

Exhaust Gas Outlet in. 7.88 7.88 9.88 9.88 9.88 9.88

Overall Rough Dimensions

length in. 69 69 77 77 85 85

width in. 50 50 56 56 56 56

height in. 82 82 89 89 97 97

Weight

Installed (wet) lbs 2,502 2,689 3,328 3,548 3,567 3,791

Shipping lbs 2,424 2,601 3,152 3,350 3,350 3,593

NOTE:

1. Design pressure is currently l imited to 150 psig.

2. Based on natural gas with a high heat value (HHV) of 1,000 Btu /ft3.

3. Continuous running 230 vac / 1 ph / 60 Hz power supply required.

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Table of Contents

Safety Summary ..................................................................................................................................... i

Important Information .......................................................................................................................... iii

Receiving and Unpacking .................................................................................................................... iv

Overview of Unit Features .................................................................................................................................... v

ASME Conformance Statement ............................................................................................................ ix

Specifications ...................................................................................................................................... xi

Section 1 Using This Manual ............................................................................................................. 1-1

1.2 General ....................................................................................................................... 1-1

1.3 Feedwater Treatment .................................................................................................. 1-2

Section 2 Description ........................................................................................................................ 2-1

2.2 Water and Steam System ............................................................................................ 2-1

2.2.1 Flow ................................................................................................................... 2-1

2.2.2 Feedwater Pump ................................................................................................ 2-1

2.2.3 Heating Coil ........................................................................................................ 2-1

2.2.4 Steam Separator ................................................................................................. 2-3

2.2.5 Steam Trap ......................................................................................................... 2-4

2.3 Control Devices ........................................................................................................... 2-4

2.3.1 Group Motor Protectors (GMP) ........................................................................... 2-4

2.3.2 Gas Pressure Switch - High (GPSH) ................................................................... 2-4

2.3.3 Gas Pressure Switch - Low (GPSL) .................................................................... 2-4

2.3.4 Limit Pressure Switch (LPS) ............................................................................... 2-5

2.3.5 Main Gas Valve (MGV) ....................................................................................... 2-5

2.3.6 Power Supply ..................................................................................................... 2-5

2.3.7 Stepdown Transformer (115 VAC) ....................................................................... 2-5

2.3.8 Variable Speed Drive (VSD) ................................................................................ 2-5

2.4 PLC (Programmable Logic Controller) ......................................................................... 2-5

Section 3 Safety Precautions ............................................................................................................ 3-1

3.1.1 Hot Components ................................................................................................. 3-1

3.1.2 Poorly-vented Boiler Rooms ................................................................................ 3-1

3.1.3 Frost ................................................................................................................... 3-1

3.1.4 Moving Parts ...................................................................................................... 3-1

3.1.5 Protruding Parts ................................................................................................. 3-1

3.1.6 Sharp Parts and Rough Edges ............................................................................ 3-1

3.1.7 Welding and Grinding ......................................................................................... 3-1

3.1.8 Uneven Surfaces and Physical Obstructions ....................................................... 3-1

3.1.9 Pressurized Gases and Liquids ........................................................................... 3-1

3.1.10 Heavy or Loose Parts ......................................................................................... 3-2

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3.1.11 Vacuum Created By Steam or Hot Water Cooling Down ...................................... 3-2

3.1.12 Water Hammer ................................................................................................... 3-2

3.1.13 Pre-stressed Springs .......................................................................................... 3-2

3.1.14 Electrical Parts ................................................................................................... 3-2

3.1.15 Chemicals .......................................................................................................... 3-2

3.1.16 Loud Excessive Noise ......................................................................................... 3-2

3.1.17 Human Error ....................................................................................................... 3-2

3.1.18 Automation ......................................................................................................... 3-3

3.2 Feedwater Pump ......................................................................................................... 3-3

3.2.1 Hot Surface ........................................................................................................ 3-3

3.2.2 Freezing Conditions ............................................................................................ 3-3

3.2.3 Fluid Under Pressure .......................................................................................... 3-3

3.2.4 Handling Heavy and Loose Parts ........................................................................ 3-3

3.2.5 Compressed Springs ........................................................................................... 3-3

3.2.6 Electrical Parts ................................................................................................... 3-3

3.2.7 Human Error ....................................................................................................... 3-3

3.2.8 Automation ......................................................................................................... 3-3

3.3 Heating Coil and Steam Separator ............................................................................... 3-3

3.3.1 Hot Fluids ........................................................................................................... 3-3

3.3.2 Hot Surfaces ....................................................................................................... 3-3

3.3.3 Freezing Conditions ............................................................................................ 3-3

3.3.4 Fluid Under Pressure .......................................................................................... 3-4

3.3.5 Water Hammer ................................................................................................... 3-4

3.3.6 Vacuum .............................................................................................................. 3-4

3.4 Fuel and Air Piping ...................................................................................................... 3-4

3.4.1 Poorly-vented Boiler Room ................................................................................. 3-4

3.4.2 Explosion Risk .................................................................................................... 3-4

3.4.3 Falling Risk ......................................................................................................... 3-4

Section 4 Operating Instructions ...................................................................................................... 4-1

4.2 Main Menu Screen ...................................................................................................... 4-1

4.3 Start up Auto Mode ...................................................................................................... 4-1

4.4 Start Mode .................................................................................................................. 4-2

4.4.1 Easy Start ........................................................................................................... 4-3

4.4.2 Operator Start ..................................................................................................... 4-3

4.5 Manual Mode Operation .............................................................................................. 4-3

4.5.1 Manual Fill Mode ................................................................................................ 4-3

4.5.2 Manual Firing Mode ............................................................................................ 4-4

4.6 Restart After Momentary Shut Down ............................................................................ 4-4

4.7 Intermittent Fill / Wet Lay-up ......................................................................................... 4-5

4.8 Dry Shut Down ............................................................................................................ 4-5

4.9 Advanced-Level Screens ............................................................................................. 4-6

4.9.1 Modify Set Point and Tune PID Screens .............................................................. 4-6

4.9.2 Calibration Screens ............................................................................................ 4-7

4.10 Alarm Screens ............................................................................................................. 4-8

4.10.1 Alarm Annunciation ............................................................................................. 4-8

4.10.2 Alarm History ...................................................................................................... 4-8

4.11 Maintenance Drain ...................................................................................................... 4-8

xiv

Section 5 Troubleshooting ................................................................................................................ 5-1

5.2 Water System .............................................................................................................. 5-2

5.3 Fuel System - Gas-fired Machines ............................................................................... 5-3

5.4 Electrical System ......................................................................................................... 5-4

5.5 Weishaupt Packaged Burner Unit ................................................................................ 5-5

Section 6 Periodic Maintenance ........................................................................................................ 6-1

6.2 Feedwater Treatment .................................................................................................. 6-1

6.3 Daily Service ............................................................................................................... 6-1

6.3.1 Record Operating/ Steam Pressure ..................................................................... 6-1

6.3.2 Trap Timing ........................................................................................................ 6-1

6.3.3 Test and Record Feedwater ............................................................................... 6-1

6.3.4 Manual Blowdown ............................................................................................... 6-1

6.3.5 Walk-Around Inspection ...................................................................................... 6-1

6.4 Weekly Service ........................................................................................................... 6-2

6.4.1 Steam Generator Unit ......................................................................................... 6-2

6.4.2 Hot-well Tank ...................................................................................................... 6-2

6.4.3 Belt Tension ........................................................................................................ 6-2

6.5 Monthly Service ........................................................................................................... 6-2

6.5.1 Check Coil Feed Pressure .................................................................................. 6-2

6.5.2 Flush Water Pump Heads And Columns .............................................................. 6-3

6.5.3 Check Dual Element Thermocouple Sensor ........................................................ 6-3

6.5.4 Check Main Temperature Limit Controllers (MTLC) ............................................. 6-4

6.5.5 Clean Strainers ................................................................................................... 6-5

6.5.6 Drain and Flush Hot-well Tank ............................................................................ 6-5

6.5.7 Inspect Intake Surge Chamber and Snubber ....................................................... 6-5

6.6 Semi-annual Service ................................................................................................... 6-6

6.7 Annual Service ............................................................................................................ 6-6

6.7.1 Replace Check-valves ........................................................................................ 6-7

6.7.2 Replace Feedwater Pump Diaphragms and Seals ............................................... 6-7

6.7.3 Test Steam Safety Valve ..................................................................................... 6-7

6.7.4 Service Compact Burner Unit ............................................................................. 6-7

6.8 Heating Coil Scale Removal ........................................................................................ 6-7

6.8.1 Setting Up Machine For Descaling ...................................................................... 6-7

6.8.2 Descaling The Machine ...................................................................................... 6-9

6.8.3 After Descaling Is Complete .............................................................................. 6-10

Section 7 Component Maintenance ................................................................................................... 7-1

7.2 Feedwater Pump Maintenance .................................................................................... 7-2

7.2.1 Check-Valve Maintenance ................................................................................... 7-2

7.2.2 Replacing Check-Valve Seats ............................................................................. 7-2

7.2.3 Diaphragm Replacement .................................................................................... 7-3

7.2.4 Pump Disassembly ............................................................................................. 7-5

7.2.5 Inspect and Repair Pump .................................................................................... 7-5

7.2.6 Pump Reassembly .............................................................................................. 7-5

7.2.7 Install High Strength Studs .................................................................................. 7-6

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7.3 Feedwater Pump Relief Valve ...................................................................................... 7-7

7.3.1 Adjustment ......................................................................................................... 7-7

7.4 Temperature Controllers (MTLC1, MTLC2) .................................................................. 7-7

7.4.1 Check Main Temperature Limit Controllers .......................................................... 7-7

7.5 Operating Pressure Switch (OPS) Adjustment ............................................................. 7-8

7.6 Limit Pressure Switch (LPS) Adjustment ...................................................................... 7-8

7.6.1 Adjustment ......................................................................................................... 7-8

7.7 Gas Pressure Switches ............................................................................................... 7-8

Steam Generator List of Parts ........................................................................................................... A-1

Fig. 01A - Main Heating Section – SM15 ............................................................................... A-2

Fig. 01B - Economizer Stack Outlet Kit – SM15 ..................................................................... A-4

Fig. 01C - Main Heating Section – SM30 .............................................................................. A-6

Fig. 01D - Economizer Coil – SM30 ...................................................................................... A-8

Fig. 01C - Main Heating Section – SM40 ............................................................................ A-10

Fig. 01D - Economizer Coil – SM40 (Sht 1 of 2) ................................................................. A-12

Fig. 02A - Steam Discharge and Separator Hookup — SM-15 ............................................. A-14

Fig. 02B - Steam Discharge and Separator Hookup — SM-30/40 ........................................ A-16

Fig. 02C - Steam Trap and Control Valve Hookup .............................................................. A-18

Fig. 02D - Safety Relief Valve Hookup ............................................................................... A-19

Fig. 02E - Pressure Indicating System ............................................................................... A-20

Fig. 04A - Feedwater Pump Hookup – C1 ........................................................................... A-22

Fig. 04B - Feedwater Pump Hookup – C2 ........................................................................... A-23

Fig. 05A - Pump Assy – C1 ................................................................................................. A-24

Fig. 05B - Pump Assy – C2 ................................................................................................. A-26

Fig. 06 - Check Valve ........................................................................................................ A-28

Fig. 07 - Relief Valve ......................................................................................................... A-28

Fig. 09 - Fuel Gas System ................................................................................................. A-29

Fig. 13 - Electrical Control Box .......................................................................................... A-30

Fig. 18 - Separator High Level Alarm Kit ............................................................................ A-31

Feedwater Skid Option List of Parts ................................................................................................. B-1

Fig. 01 - Vertical Hotwell ..................................................................................................... B-2

Fig. 02 - Water Softener Plumbing Hookup .......................................................................... B-2

Fig. 03 - Water Level Indication and Control ........................................................................ B-3

Fig. 04 - Water Temperature and Blowdown Tank Hookup .................................................... B-3

Fig. 05 - Sparger Tubes – Water Heating .............................................................................. B-4

Fig. 06 - TDS Control System — Equipment Option .............................................................. B-4

Fig. 07 - Circulation Pump Hookup - TDS System ................................................................ B-5

Fig. 08 - Booster Pump Hookup ........................................................................................... B-5

Fig. 09 - Sample Cooler / Water Sampling ............................................................................ B-5

Fig. 10 - Optional Sparger Tube – Water Heating .................................................................. B-5

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10/02/20

Section I USING THIS MANUAL

1.1 Graphic SymbolsThe following graphical symbols and their

definitions are used throughout this manual:

WARNING paragraphs provide information onpotentially hazardous conditions that maycause severe bodily injury if precautions are nottaken while working on the equipment.

CAUTION paragraphs provide instructions forproper handling of equipment to prevent dam-age or destruction of the equipment that maylead to loss of operating effectiveness.

These paragraphs warns of dan-

gerous voltage environments.Extreme care must used whenworking in these conditions to avoidbodily injury.

These paragraphs highlight operat-ing conditions, recommendations,and suggestions for efficient oper-ating procedures.

1.2 GeneralThis manual contains instructions for operat-

ing and maintaining a Clayton Steam Generator.Recommendations given herein result from manyyears of experience in the manufacture and serviceof this type of equipment. The efficiency and ser-

vice of your steam generator will depend upon strictadherence to these instructions. It is important thatthe operator study all sections of this manual to gaina working knowledge of the operation and mainte-nance requirements of the Clayton Steam Genera-tor.

The information contained in this manualapplies to gas-fired machines. Section II of thismanual acquaints you with the machine. This sec-tion provides an overview and descriptions of amachine’s systems, such as the water supply andfuel system. The machine overview includes a dis-cussion on the theory of operation of a ClaytonSteam Generator.

Before a new machine is placed into service,the residual mill scale and other contaminantsdeveloped during manufacturing must be purgedfrom inside the heating coil. This initial firing pro-cedure and other pre-startup requirements are dis-cussed in Section III. If this is your first experiencewith a Clayton Steam Generator, then you shouldfamiliarize yourself with its controls by reviewingSection IV. This section discusses machine startup,filling, wet shutdown, dry shutdown, and introducesthe Operator Interface Unit (OIU).

Section V provides some common trouble-shooting procedures for problems that may occurduring the machine’s operation. Section VI dis-cusses the scheduled maintenance requirements thatwill help maintain the efficiency and reliability,increase the operating life, and minimize the down-time of the machine. Section VII contain proceduresfor maintaining, repairing, or replacing componentsand assemblies on the machine.

The appendices at the end of this manual con-

18 1-1 Sect01_CSMG_a.fm

Steam Master Instruction Manual

tain supplemental instructions, reference tables andcharts, and the parts catalog, which is used forordering replacement parts. The parts catalog con-tains illustrations of steam generator assemblies andtheir corresponding parts list.

1.3 Feedwater TreatmentProper and adequate feedwater treatment must

be used from the time your Clayton steam generatoris commissioned. Suitable water treatment equip-ment should be installed before placing the steamgenerator into service. Daily treatment and care ofthe feedwater supply is the sole responsibility of theuser.

Continuous feedwater treatment is required atall times, even during the periods of wet lay-upshutdowns. Water testing must be conducted daily,even during the periods of wet lay-up shutdowns.

A separate feedwater treatment manual (part num-ber: R015216) is provided with every Clayton SteamGenerator. This manual covers the available watertreatment packages from Clayton, general guide-lines on scheduled feedwater maintenance, and theappropriate chemicals required for treatment to min-imize the down time of your machine.

Sect01_CSMG_a.fm 1-2 10/02/2018

04/19/20

Section II DESCRIPTION

2.1 GeneralThe Clayton steam generator will deliver its

rated output of 99 percent quality steam (containingless than one percent moisture) per hour from 60° F(16° C) feedwater. It will develop its full ratedsteam pressure within five minutes from a filledcoil, cold start condition.

Standard equipment includes safety devicesfor protection against water failure, burner failure,excessive pressure and electrical overload. Auto-matic controls regulate the flow of feedwater andmodulate the burner in accordance with steamdemand.

2.2 Water and Steam System(See Fig. 2-1.)

2.2.1 Flow

Makeup water, chemicals, and process con-densate returns blend in the hot-well tank and thenflow, either by gravity or by booster pump, into thefeedwater pump. Chemically treated feedwater ispumped directly into the heating coil, flowingthrough the spiral single-passage section of the coilin a direction opposite that of the combustion gases(counterflow principle). As the steam-water mixtureleaves the generating section, it passes into the sep-arating nozzle of the steam separator. Steam isdelivered from the discharge outlet of the steamseparator. The surplus liquid is returned to the hot-well tank through the steam trap mounted on thesteam separator.

2.2.2 Feedwater Pump

The Clayton positive displacement, dia-phragm-type, feedwater pump ensures a wet-tubeheating coil by delivering the required volume ofwater to the heating coil under all load conditions.

A reciprocating pump diaphragm displaces feedwa-ter through the discharge side of the check-valvehousing into the heating coil. Corrosion-resistantsprings, discs, and seats are used in the check-valvehousings.

Tubular water columns (standpipes) separatethe check-valve housings from the pump heads tokeep excessive temperature from the diaphragms.Discharge snubbers absorb pressure pulsations tostabilize feedwater delivery. Intake surge chamberson the pump suction help stabilize feedwater sup-ply. A relief valve protects the pump against over-pressure.

2.2.3 Heating Coil

The heating coil consists of a series of carbonsteel spirally wound tube sections (commonlyreferred to as pancakes or pancake sections). Theheating coil is constructed in a single-pass, mono-tube design. A counterflow method of fluid circula-tion, at controlled velocities, is used to providemaximum heat transfer. The combustion gases flowupward around the tubes of the heating coil whilethe fluid inside the tubes is circulating in a down-ward direction. The heating coil is constructed toallow free expansion.

19 2-1 Sect02_CSMG_b.fm


2.2.3.1 Main Temperature Limit Controller (MTLC2)

This over-temperature safety controller (see

Fig. 2-2) has a fixed trip-point1. It will interrupt themotor and burner control circuits on a severe over-temperature condition. It must be manually resetbefore normal operation can be resumed. This isdone through 010. A “STEAM COIL TEMP. -OVER LIMIT-” safety shutdown condition will beindicated on the OIU, and an audible alarm willsound.

Fig. 2-1. Water and Steam System (typical)

OPTIONAL ECONOMIZER

A

B

C

D

E

A– Steam Discharge Valve

B– Coil Feed Valve

C– Feedwater Pump

D– Feedwater Valve

E– Separator Drain Valve

F– Coil Drain Valve

F

1 See the Table of Reference Values in Appendix B for MTLC trip-point value.

Fig. 2-2. Thermocouple Assembly

Sect02_CSMG_b.fm 2-2 04/19/2019

Section II–Description

2.2.3.2 Thermocouple sensor

MTLC2 and MTLC1 each use one-half of adual-element thermocouple sensor. The sensor isinserted in the coil steam discharge outlet. See Fig.2-2.

2.2.4 Steam Separator

The steam separator is designed to expelexcess water from the steam-water mixture dis-charged from the heating coil. The steam-watermixture enters the separator at a high velocity andpasses through the nozzle vanes inside the separa-tor, which causes the steam-water mixture to swirl.The centrifugal action of the swirling forces theheavier water in the steam-water mixture to the sep-arator wall, where the water then cascades to the

bottom of the separator. What results is “dry” steambeing discharged from the steam separator outlet(A–Fig. 2-1).

The excess water in the separator is recircu-lated back to the hot-well tank when the fluid levelrises high enough to activate the inverted bucket inthe steam trap. This method of mechanical separa-tion prevents carry-over of liquid and chemicaltreatment into the steam system.

Under normal operating conditions, the indi-cated temperature should be close to the saturationtemperature relative to the pressure at the separator(See Pressure - Temperature Table 2-1.). A substan-t ia l tempera ture r i se above the sa tura t iontemperature for the corresponding operating pres-sure indicates a water shortage condition.

Table 2-1: Pressure-Temperature

GAUGE PRESSURE

PSIG TEMP F

GAUGE PRESSURE

kPa TEMP C

GAUGE PRESSURE

PSIG TEMP F

GAUGE PRESSURE

kPa TEMP C

GAUGE PRESSURE

PSIG TEMP F

GAUGE PRESSURE

kPa TEMP C

5 228 34.4 109 220 396 1,516.8 202 420 453 2,895.7 236

10 240 68.9 115 230 399 1,585.7 204 440 457 3,033.6 237

15 250 103.4 121 240 403 1,654.7 206 460 462 3,171.5 239

250 406 1,723.6 208 480 466 3,309.4 241

60 308 413.6 153 260 409 1,792.6 209 500 470 3,447.3 243

70 316 482.6 158 270 413 1,861.5 212 550 479 3,792.1 248

80 324 551.5 162 280 416 1,930.5 213 600 489 4,136.8 254

90 331 620.5 166 290 419 1,999.4 215 650 497 4,481.6 258

100 338 689.4 170 300 422 2,068.4 217 700 505 4,826.3 263

110 344 758.4 173 310 425 2,137.3 218 750 513 5,171.1 267

120 350 827.3 177 320 428 2,206.3 220 800 520 5,515.8 271

130 356 896.3 180 330 431 2,275.2 222 900 534 6,205.3 279

140 361 965.2 183 340 433 2,344.2 223 1000 546 6,894.8 286

150 366 1,034.2 186 350 436 2,413.2 224 1100 558 7,584.2 292

160 370 1,103.2 188 360 438 2,482.1 226 1250 574 8,618.4 301

170 375 1,172.1 191 370 441 2,551.1 227 1500 298 10,342.1 314

180 380 1,241.0 193 380 443 2,620.0 228 1750 618 12,065.8 326

190 384 1,310.0 196 390 445 2,689.0 229 2000 637 12,789.5 336

200 388 1,378.9 198 400 448 2,757.9 231 2250 654 15,513.2 345

210 392 1,447.9 200 410 450 2,826.9 234 2500 669 17,236.9 354

04/19/2019 2-3 Sect02_CSMG_b.fm


2.2.5 Steam Trap

The steam trap returns excess water from thesteam separator to the hot-well tank. Some trappingis necessary to ensure that a sufficient volume offeedwater is circulating through the heating coil andthat dissolved solids are being carried through theheating coil back to the hot-well tank. The actualamount of trapping depends on operating condi-tions, steam pressure, feedwater temperature, pumpconditions and firing rate.

A trap (discharge) pressure gauge is providedto indicate when the steam trap is either open orclosed. A rising pressure on the gauge indicates thatthe steam trap is discharging water. When the pres-sure begins to drop, the trap is closed. If the steamtrap is not opening and closing in the normal man-ner, this may indicate that one of the abovementioned variables has changed.

On initial start of the machine, after the cor-rect air-fuel rate has been established, the operatingtemperature and trap-open time should be recorded.These figures should be checked regularly to assurethat the machine is operating properly.

If the steam generator is connected to an open(hot-well) system where the feedwater temperatureis 180°–200° F (82°–93° C), the steam trap shouldbe open for 30–40 minutes (accumulated) of eachhour at high-fire operation (100% rate). At steadylow-fire operation (20% rate), the steam trap shouldbe open for six to eight minutes (accumulated) ofeach hour, or a proportionate length of time for anyintermediate firing rate.

Checking and recording for the duration thatthe steam trap remains open under normal operatingconditions helps to determine if a component, suchas the feedwater pump (which has a fixed pumpingrate), is malfunctioning.

A reduction in the firing rate due to a decreasein fuel pressure will increase the trapping time. Adecrease in the pump rate will decrease trappingtime. Trap-open time should not fall below twelveminutes per hour at high fire and four minutes perhour a t low f i re (accumula ted) under anyconditions.

2.3 Control Devices

2.3.1 Group Motor Protectors (GMP)

The group motor protectors function as a3-phase, manual, motor starter/protector for controland protection of their respective motor(s). Theseshort circuit protection devices are equipped withadjustable, phase loss sensitive, bimetallic overloadtrips and adjustable magnetic trips. If tripped, amanual reset is required.

2.3.2 Gas Pressure Switch - High (GPSH)

This normally-closed safety switch is con-nected in series with the combustion control circuit.It is situated between the main gas cock and modu-lating gas valve.

NOTE

The GPSH is located inside the gas burnerhousing. Gaining access to the GPSHrequires removal of the housing cover.

This switch will open to interrupt burner oper-ation in the event of high burner gas pressure. Amanual reset is required after each interruption. TheGPSH is factory set to actuate at approximately50% above the normal burner operating pressure atthe maximum firing rate.

2.3.3 Gas Pressure Switch - Low (GPSL)

There are two GPSL safety switches installedin series with the combustion control circuit. Thesenormally-closed safety switches will open in theevent of a low supply gas pressure, disruptingburner operation.

One of the two GPSLs is installed at the inletof the gas train, immediately upstream of the safetyshutoff valve (See Fig. 2-3.). This switch requires amanual reset following its actuation and at the timeof initial machine firing. A second GPSL isinstalled immediately downstream of the main gas,electro-hydraulic, actuator valve (MGV). Thisswitch does not require a manual reset followingactuation.

The GPSL is factory set to actuate at approxi-mately 50% below the normal burner operatingpressure at the maximum firing rate.

Sect02_CSMG_b.fm 2-4 04/19/2019

Section II–Description

2.3.4 Limit Pressure Switch (LPS)

This safety limit switch is connected in serieswith the holding circuit. In the event of excessivesteam pressure, the LPS will open, removing con-trol voltage from the holding circuit, shutting downthe machine. A manual reset is required before themachine can be restarted.

2.3.5 Main Gas Valve (MGV)

This valve is an electrically-operated,hydrometer gas valve. It is piped in series and wiredin parallel with the safety shutoff gas valve (SSGV).It has a built-in regulating function. It provides pos-itive gas shutoff within one second.

2.3.6 Power Supply

The power supply provides a filtered 24 VDCpower supply to the PLC.

2.3.7 Stepdown Transformer (115 VAC)

ST1 is a 230/115 vac step-down transformerthat supplies 115 vac to control circuit voltage. (SeeFig. 2-4 for connection points.)

2.3.8 Variable Speed Drive (VSD)

The VSD provides variable frequency input tothe feedwater pump motor(s), dictating the rpm ofthe feedwater pump(s). It is controlled by a4-20 mA reference voltage signal from the PLC.Detailed information on operation, programming,and troubleshooting is provided in VSD manufac-turer’s operators manual provided at time of initialstartup.

2.4 PLC (Programmable Logic Controller)

The PLC is responsible for the monitoring andmanaging a machine’s operation. The primary oper-ation that the PLC oversees is synchronization ofthe burner and feedwater pump. The proper feedwa-ter flow rate to firing rate is important for meetingthe steam load.

Another task the PLC performs is alarmannunciation. The PLC monitors the various safetydevices installed on the machine. When a safetyparameter is exceeded, the PLC causes an alarmcondition. Depending on the alarm, the PLC mayalso cause a machine shutdown.

During the ON fill cycle, a FILL CYCLE flag(at the bottom of the default OIU display) will flashindicating pump activation:

Fig. 2-3. Wiring diagram for a standard step-down transformer

Fig. 2-4. Wiring diagram for a standard step-down transformer

04/19/2019 2-5 Sect02_CSMG_b.fm



Sect02_CSMG_b.fm 2-6 04/19/2019

11/22/20

Section III SAFETY PRECAUTIONS

3.1 GENERAL SAFETY PRECAUTIONS

A steam generator and its parts are based onphysical processes, each with typical characteristicsand potential hazards. All necessary safetyprecautions were taken during the design andconstruction of the generator. However, duringcertain manipulations or maintenance, there are stillremaining risk factors. These are described below:

3.1.1 Hot Components

Fire injury let hot components cool down toambient temperature. Use insulating or heatrepellent protective clothing, especially gloves. Donot wear short sleeves.

3.1.2 Poorly-vented Boiler Rooms

Ambient temperature rise, lack of oxygen,dehydration, fainting, combustion gasesaccumulates in boiler room leading to suffocationand poisoning.

Construct permanent or temporary ventilationopenings in the wall or ventilators with sufficientcapacity. The generator must be able to functionnormally during ventilation. Insufficient oxygen canlead to poisonous CO gas.

3.1.3 Frost

Supercooling and exhaustion. Wear warmclothing. Contact with cold metals can lead to stiffand, hence, less sensitive hands, creating a greaterchance for hand injury.

3.1.4 Moving Parts

Injury to body or clothing. All rotating partsare screened off. If screens are removed formaintenance or repair, make sure to cut the electricalpower on this particular part. Use a lock or remove

the key from the switch. If you need to work on partswithout protective screens, make sure not to wearloose clothing such as ties, open coats, etc. Onlyauthorized personnel should be present near thegenerator.

3.1.5 Protruding Parts

Body/head injury. Wear a helmet to preventhead injuries.

3.1.6 Sharp Parts and Rough Edges

Rough edges from mechanical wear ordismantling of parts. Wear gloves and use the righttools.

3.1.7 Welding and Grinding

Hot metal sparks are inherent for theseoperations. Wear protective clothing, no shortsleeves. Wear a face mask with side shields andmake sure it has the appropriate color filter whenwelding. Glowing metal parts can cause fire. Makesure a second person is present with fire suppressionequipment on-hand. Make sure vital emergencycontact information is available and visible in caseof fire.

3.1.8 Uneven Surfaces and Physical Obstructions

Injury from falling down or tripping over.Evaluate the situation before taking actions andinform other workers accordingly. Make sure tohave the proper equipment available if you need towork on heights.

3.1.9 Pressurized Gases and Liquids

Skin penetration resulting in injuries,poisoning, and eye damage.

18 3-1 Sect03_CSMG_a.fm


Fluids or gases under pressure can causesevere skin or eye damage due to their impact whenflowing through fine openings. They can even enterthe body, resulting in poisoning. Evaluate thesituation before taking any action.

Wrap pieces of cloth around the parts that needto be opened so that possible fluids or gases getdiffused. Close off isolated areas, so the fluids can bedrained away and the pressure has dissipated.

3.1.10 Heavy or Loose Parts

Injuries by mechanical impact from twistingor carrying heavy weights.

Use pulleys and gloves when assemblingheavy parts. Save your strength. Use tools, such as,crowbars and hydraulic pumps as lever or powerintensifier. Appoint a coordinator when severalpersons are working on the same job. Watch out forinjuries from crushing during assembly work.

3.1.11 Vacuum Created By Steam or Hot Water Cooling Down

Injuries by under pressure. A vacuum can becreated in machine parts that are closed off from theatmosphere and are cooling down, after they werefilled with steam or hot water. By opening theseareas, severe suction can be created by underpressure. Make sure not to expose body parts tothese openings, since this could cause skin injury.

3.1.12 Water Hammer

Improper ratio of steam to water inside pipingcan create water hammer. This is a ball of waterblocking an entire section of the pipe. It movesforward via the steam against the steam speed. Atseams or curves in the pipes, this ball of water cancreate an impact or become a water-hammer. Pipingcan be so that the steam escapes and the fixing of thepiping gets damaged.

3.1.13 Pre-stressed Springs

Injuries by mechanical impact. Looseningparts with pre-stressed springs can cause injuries bya sudden position change of the parts. Check outhow these parts are interlinked first. Use accessories,such as, pins to disassemble parts with pre-stressedsprings.

Parts not strong enough to support heavyweights some parts can bend or break withoverloads. Parts can never be used as a platform,support or connector. Use ladders or platforms.

3.1.14 Electrical Parts

Death from electrocution. Lock out electricalpower before working on equipment.

Electrocution. Always cut the electrical powerbefore working on electrical components. This canbe done by locking the main switch or by removingits key, when there is one available. Should repair ormaintenance be needed when the equipment is undercurrent, use rubber gloves, isolated tools andisolation between the body and the earth.

3.1.15 Chemicals

Risk of poisoning and burning limbs frommishandling of chemicals.

Burns and poisoning. Wear face mask,chemical gloves and protective clothing whenmanipulating chemicals. Keep the technical data onall chemicals used available for persons workingwith them. Make sure to note down the phonenumber of the poison control center and local aidservices.

3.1.16 Loud Excessive Noise

Deafness and communication problems. Wearear protection. When working with multiplepersonnel in an excessively loud environment, makesure to communicate clearly. If required, exit theloud environment to communicate clearly soinstructions are not misinterpreted.

3.1.17 Human Error

Poor maintenance behavior ormisinterpretation of circumstances is a result ofhuman error. Human error can be avoided withproper training of personnel.

Sect03_CSMG_a.fm 3-2 11/22/2018

Section III - Safety Precautions

3.1.18 Automation

Potential unexpected automatic start ups canoccur if equipment is not secured properly. A steamgenerator and its parts can cause all of the safetyhazards explained above, during maintenance orinspection. Although this equipment is wellprotected, caution is needed at all times. Onlytrained personnel should operate or maintain thegenerator, its devices or parts.

An explanation of specific safety hazards ofequipment component assemblies are in thefollowing sections.

3.2 FEEDWATER PUMP

3.2.1 Hot Surface

The feedwater pump receives hot water fromthe hot-well. Allow feedwater pump to cool beforeattempting repair.

3.2.2 Freezing Conditions

Proper freeze protection maintenance isrequired if the feedwater pump will be placed understorage conditions. Ice will form within thefeedwater pump if moisture or water is present.

3.2.3 Fluid Under Pressure

Pressurized fluid may be present in thefeedwater pump. Potential high pressure fluiddischarge can occur when dismantling pump.

3.2.4 Handling Heavy and Loose Parts

The check-valve/standpipe subassembly ofthe feedwater pump is heavy. Make sure properlifting apparatus is used when performing feedwaterpump maintenance and repair. If required, seekadditional personnel for assistance.

3.2.5 Compressed Springs

The feedwater pump diaphragm springs areunder compression in the pumphead housing.Unseat pumphead housing carefully.

3.2.6 Electrical Parts

Lock out the main circuit power beforeworking on feedwater pump to prevent unexpectedmotor start.

3.2.7 Human Error

Only personnel who are properly trained towork on Clayton feedwater pumps should handle itsmaintenance and repair.

3.2.8 Automation

The feedwater pump operates automatically inrelation to feedwater requirements. The feedwaterstarts and stops automatically.

3.3 HEATING COIL AND STEAM SEPARATOR

Hearing loss will result from actuating safetyrelief valve. Wear hearing protection to protectagainst hearing loss.

3.3.1 Hot Fluids

Fluids draining from the heating coil andseparator is hot. Maintain a safe distance fromdischarging heating coil and separator fluid.

Serious burns will result from scalding fluids.Wear proper safety gear to avoid serious injury.

3.3.2 Hot Surfaces

Heating coil, separator, and plumbing surfacesare HOT! Although the heating coil, separator, andsome plumbing are insulated, treat these surfaceswith extreme caution.

Serious burns will result from hot surfaces.Wear proper safety gear to avoid serious burns.

3.3.3 Freezing Conditions

Evacuate the heating coil, separator, and allplumbing of fluid and moisture before long termstorage. Install a nitrogen flush as needed.

11/22/2018 3-3 Sect03_CSMG_a.fm


Damage to heating coil, separator, and otherparts will result from moisture or fluid inside thecoil and pipes.

3.3.4 Fluid Under Pressure

Pressurized fluid may be present in the heatingcoil and plumbing. Potential high pressure fluiddischarge can occur when dismantling heating unit.

3.3.5 Water Hammer

Improper ratio of steam to water inside pipingcan create water hammer. This is a ball of waterblocking an entire section of the pipe. It movesforward via the steam against the steam speed. Atseams or curves in the pipes, this ball of water cancreate an impact or become a water-hammer. Pipingcan be so that the steam escapes and the fixing of thepiping gets damaged.

3.3.6 Vacuum

A vacuum condition occurs when a heated coiland plumbing is tightly sealed and cools to ambienttemperature. This creates a strong suction at variousaccess point openings.

3.4 FUEL AND AIR PIPING

3.4.1 Poorly-vented Boiler Room

The heating coil is surrounded by an air coverunder a predefined over pressure. As a result,combustion gases can only exit the unit through anexhaust duct. However, if this “air cover” fails,combustion gases will escape into the boiler room.This problem could occur when the air supply to theventilator is blocked and, hence, no overpressure canbe built up. Also, poisonous CO gas can be formeddue to lack of oxygen. Therefore, always make sureto close the gas valve manually and secure it with alock, if maintenance or repair is needed.

3.4.2 Explosion Risk

Death from explosion. Electrical sparks willignite gas fumes.

Before performing electrical work on compactburner system, shut main gas supply valve(s). Purgegas from all gas lines. Purge gas from heating unit’scombustion chamber.

3.4.3 Falling Risk

Death or broken limbs from falling. Do not usepiping and ducting for support.

Gas piping, fluid piping, and ducts are notdesigned for supporting personnel. Do not lean,hang, or apply any additional weight on these parts.

Sect03_CSMG_a.fm 3-4 11/22/2018

11/15/20

Section IV OPERATING INSTRUCTIONS

4.1 GENERAL

The instructions in this section describe thestandard startup and shutdown procedures for yourClayton Steam Master steam generator.

Your Clayton Steam Master offer twooperating modes, auto mode and manual mode.These two operating modes are covered in thefollowing sections.

The manual operating mode is reservedfor more advanced, knowledgeableusers who are thoroughly familiar withthe Clayton Steam Master steamgenerator.

4.2 MAIN MENU SCREEN

The main menu provides basic Claytoncontact information, machine information, andaccess points to selected operation screens. Thisscreen is accessed by pressing the MAIN MENU

icon at the bottom-right corner of the variousoperating screens.

Not all icons will appear on the main menuscreen, as shown in Fig. 4-1. The icons will beeither active or inactive depending on the operatoraccess level. The advanced-level screens requireuser login. Once logged in, the icons for theadvanced-level screens will become active.

4.3 START UP AUTO MODE

The default start is auto mode. The unitmay be transferred into manual modeby the AUTO/MANUAL button on themain menu once the unit is started.

Manual mode operation requires the operatorto be present and actively monitoring the unitthroughout this period.

The start-up screen in Fig. 4-2 displays afterpower-on. Verify and set, as needed, the valvepositions as indicated on the screen. Acknowledgeeach valve on the screen following verification thatthe indicated valve is in the correct position; i.e.:the valve is either open or closed.

Once the final valve position has beenacknowledged, the unit will start to auto fill. Theunit will fill at a preprogrammed fill rate of 20%.

Fig. 4-1. Main Menu screen.

18 4-1 Sect04_CSM_a.fm


The fill mode screen that displays is in Fig.4-3. It displays a graphic depicting the fill rate andthe percentage the coil is filled. The fill durationand the fill rate are fixed.

Once the coil fill is complete, an operatorscreen will display (Fig. 4-4) prompting theoperator to set the control valves to the indicatedpositions. Once each valve is set and verified to bein the correct position, acknowledge that valve onthe screen.

The unit will start the light-off sequence. TheFIRING IN AUTO screen will display (Fig. 4-5).The burner unit will proceed through itspreprogrammed light-off sequence and light offwhen the sequence is completed.

The steam pressure, steam temperature, andfiring rate information is displayed on this screen.These values are fixed.

4.4 START MODE

The unit offers two start modes, easy start andoperator start. The start mode is selected from the

Fig. 4-2. Start up screen.

Fig. 4-3. Filling in auto screen.

Fig. 4-4. Firing in auto screen.

Fig. 4-5. Firing in auto screen.

Sect04_CSM_a.fm 4-2 11/15/2018

Section IV–Operating Instructions

main menu screen. Pressing the START MODEicon will display the start mode pop-up box (Fig.4-6). From the pop-up box, select EASY START orOPERATOR START.

4.4.1 Easy Start

Easy start requires the unit to have aBPR (back pressure regulator) installed.

Easy start enables the operator to start the unitand “walk-away.” The unit requires minimum userinteraction with easy start. The BPR will allow theunit to build up the required back pressure beforereleasing steam into the main header.

4.4.2 Operator Start

Operator start requires the operator to be atthe unit to open and close control valves duringfilling and light off periods. The operator startscreens will identify which valves are required to beopened or closed during operator start. See alsoSection 4.3, Start up Auto Mode.

4.5 MANUAL MODE OPERATION

The manual operating mode is reservedfor more advanced, knowledgeableusers who are thoroughly familiar withthe Clayton Steam Master steamgenerator.

Clayton recommends transferring overto manual mode operation ONLYAFTER the unit has completed its startprocess and is running normally.

Manual mode operation requires the operatorto be present and actively monitoring the unitthroughout this period.

Your Clayton Steam Master may be operatedmanually for maintenance, troubleshooting, andrepair purposes. Manual mode operation enablesthe operator to dictate the fill rate and firing rate ofthe unit.

4.5.1 Manual Fill Mode

To transfer the unit into manual fill mode, goto the main menu by pressing the MAIN MENUicon at the bottom-right corner of the screen. Pressthe AUTO/MANUAL icon. The manual fill screenwill display (Fig. 4-7).

Press the “%” icon on the screen to adjust thefill rate. A pop-up box will display where a newvalue can be entered.

The filling rate remains fixed at the rateentered until it is changed.

Fig. 4-6. Start mode selection.

11/15/2018 4-3 Sect04_CSM_a.fm


4.5.2 Manual Firing Mode

To transfer the unit into manual firing mode,while the unit is in manual fill mode, press theMAIN MENU icon at the bottom-right corner ofthe screen. The main menu will display.

On the main menu screen (See Fig. 4-1 onpage 4-1.), press the FILL TO RUN icon to transferto manual firing mode. The manual fire screen willdisplay (Fig. 4-8).

The firing rate may be adjusted by pressingthe “%” icon on the upper-right of the image on the

screen. A pop-up box will display where a newvalue can be entered.

The firing rate remains fixed at the rateentered until it is changed.

The unit may be transferred back tomanual fill mode at any time during themanual firing mode by returning to themain menu and selecting the RUN TOFILL icon.

4.6 RESTART AFTER MOMENTARY SHUT DOWN

A unit that had its operation disrupted by theoperator, or by an alarm condition, may still have afilled or partially-filled coil. In either case, theoperator has the option to skip the coil fill processor proceed with a coil fill upon restart.

To restart the unit bypassing the fill process,press the START SKIP FILL icon to the right on theoperator start screen. See A in Fig. 4-9.

To restart the unit with the fill process, pressthe START WITH FILL icon to the right on theoperator start screen. See B in Fig. 4-9.

Fig. 4-7. Filling in manual screen.

Fig. 4-8. Firing in manual screen.

Fig. 4-9. Restart with START SKIP FILL (A) and START WITH FILL (B) options.

Sect04_CSM_a.fm 4-4 11/15/2018


4.7 INTERMITTENT FILL/WET LAY-UP

Intermittent fill maintains a “wet” coil. Thisoperation is active when the unit is in wet lay-up.Wet lay-up is used when the unit will be shut downfor only a short period. The INTERMITTENTFILL WATER PUMP ON message appears on theleft of the screen (Fig. 4-10) while the unit is in wetlay-up.

The wet lay-up process is initiated by pressingthe AUTO SHUT DOWN icon on the main menuscreen (Fig. 4-1 on page 4-1).

Verify the bypass valve is open. Verify theheader valve, dry shut down valve, andmaintenance drain valve are tightly closed. Makesure feedwater quality is maintained throughout thewet lay-up period. Verify there are no leaksanywhere in the plumbing during wet lay-up.

4.8 DRY SHUT DOWN

The unit will develop rust or other forms ofoxidation inside the coil tubing if dry shut downis executed improperly.

A dry shut down should be performedby Clayton service personnel or otherpersonnel who are thoroughly trained inClayton steam generators.

A dry shut down maintains a “dry” coil whena unit will be shut down for a prolonged period—usually exceeding 14 days.

The dry shut down process is initiated bypressing the DRY SHUT DOWN icon on the mainmenu screen (Fig. 4-1 on page 4-1).

The “dry shutdown in progress” screen (Fig.4-11) will display and step through the shut downprocess.

The operator must be presentthroughout this process to performrequired operations as indicated on thescreen (Fig. 4-12) and verify andacknowledge the control valves duringthe dry shut down.

Fig. 4-10. Firing in manual screen.

Fig. 4-11. Dry shut down screen.

11/15/2018 4-5 Sect04_CSM_a.fm


4.9 ADVANCED-LEVEL SCREENS

Advanced-level screens are reserved forClayton personnel/technicians or Claytonauthorized personnel. Advanced-level screens arepassword protected, which require user login fromthe main menu screen (See Fig. 4-1 on page 4-1.).Once logged in, the icons for the advanced userlevel screens will become active.

4.9.1 Modify Set Point and Tune PID Screens

Fig. 4-12. Slowly close steam header valve to maintain pressure during dry shutdown.

Fig. 4-13. Modulation setpoints screen. Enter modulation setpoint, cut-out setpoint, and cut-in

setpoint from this screen.

Fig. 4-14. PID Parameters screen. The PID trend button will display a chart of the steam pressure, PID

setpoint, and PID control output

Fig. 4-15. PID Trend screen.

Sect04_CSM_a.fm 4-6 11/15/2018


4.9.2 Calibration Screens

The following calibration screens are ClaytonTechnician level access.

Fig. 4-16. PID Process Trend screen.

Fig. 4-17. Calibration Screen 1: machine hours, service telephone number, SPS limit setpoints, steam pressure transducer (OPX) scaling, rate turn down, and fill time

are entered from this screen.

Fig. 4-18. Calibration Screen 2: intermittent fill (layup, interfill, and fill rate), delay release temperature, delay

release pressure, delay rate, ramp release temperature, ramp release pressure, ramp release steam temperature Delta-T, ramp release time, and

stack temperature alarm setpoint can be entered on this screen.

Fig. 4-19. Calibration Screen 3: post fill temperature, post run temperature, water level relay delay time,

water level relay alarm time, water level relay temperature limit, maintenance drain interval (2–26

weeks), maintenance drain duration (01–99 seconds), and dry shutdown duration (0–99 seconds) are entered

from this screen.

11/15/2018 4-7 Sect04_CSM_a.fm


4.10 ALARM SCREENS

4.10.1 Alarm Annunciation

This screen displays the alarm condition. Thealarm condition must be corrected before pressingthe RESET icon.

4.10.2 Alarm History

This screen can be accessed by pressing theALARM HISTORY icon on the main menu screen(See Fig. 4-1 on page 4-1.).

4.11 MAINTENANCE DRAIN

The maintenance drain screen is typicallyused for maintenance procedures, such as TDScontrol.

Fig. 4-20. Alarm screen.

Fig. 4-21. Alarm history screen.

Fig. 4-22. Maintenance Drain screen.

Sect04_CSM_a.fm 4-8 11/15/2018

Sect05_

Section V TROUBLESHOOTING

5.1 ANNUNCIATOR SYSTEM

The following chart lists the primary safety shutdown conditions together with the cause and remedialprocedure to follow in the event a safety shutdown of the machine has occurred.

Trouble Possible Cause Remedy

Pump trouble Low NPSH to water inlet Check for a ruptured diaphragm in feedwater section of pump. Check for loose pump head stud nuts.

Pump failing to maintain proper feed volume to heating coil, causing thermostat interruption

Low NPSH to water pump inlet causing intermittent pump operation.

Correct the cause for inadequate water pump inlet pressure (NPSH).

Pump check-valves not operating properly. Clean and inspect check-valves (See Sect. 7.2.).

Pump relief valve leaking. Adjust to proper pressure (See Sect. 7.3.), or replace if faulty.

Feedwater pump not primed. Prime feedwater pump.

Strainer partially plugged. Hot-well tank drain open. Float valve strainer plugged.

Correct accordingly.

Thermostat Low water condition. Correct cause of low water or water failure condition. *Possible causes:1.Empty hot-well tank.2.Clogged inlet strainer.3.Worn check-valve seats and discs.4.Malfunctioning booster pump(s).

MTLCs fail to stop motor or burner

MTLCs or thermocouple are malfunction-ing.

Check and replace faulty MTLC (See Sect. 7.4.).Check, adjust, or replace thermocou-ple (See Sect. 6.5.3.).

Pump motor overload VSD over current (ground fault) or exces-sive current due to overload has caused the instantaneous or over current trip unit in the GMP to secure the VSD and burner.

Check for and correct cause of over-load in the VSD circuit. The GMP can be reset and the annunciator lamp will stop glowing after the overload element cools (2–3 min-utes) and is manually reset.

CSMG_a.fm 5-1 11/26/2018


5.2 WATER SYSTEM

VSD overload VSD over current (ground fault) or exces-sive current due to overload has caused the thermal or over current trip unit, in the GMP, to secure the VSD and Burner.

Check for and correct causes of overload in the VSD circuit. The GMP can be reset after the overload condition is removed and the ele-ment cools.

Limit pressure Excessive discharge pressure in the separa-tor caused LPS to actuate.

Relieve the separator pressure. Ver-ify LPS is functioning properly; ver-ify modulating motor are functioning properly; verify control valve in main header is functioning properly. LPS must be manually reset before machine can be restarted.

High/Low gas pressure GPSH or GPSL shuts down machine. Check for faulty GPSH/GPSL and gas pressure regulator. Replace faulty GPSH/GPSL switch or replace faulty gas pressure regulator.


Noisy feedwater pump operation

Feedwater pump intake surge chamber malfunctioning.

Check rubber insert deflection (Sect. 6.5.7) and replace intake surge cham-ber, if required.

Feedwater pump discharge snubber malfunctioning.

Check rubber insert deflection (Sect. 6.5.7) and replace discharge snubber, if required.

Worn bearings in crankcase. Replace bearings if necessary.

Restricted heating coil causing exces-sive back pressure.

Check feed pressure for coil restriction (See paragraph 6.5.1).

Feedwater boiling or too hot. Correct cause of excessive heat in con-densate return line from system. Inspect valves and traps on equipment.

Excessive pump vibration;Feedwater pressure gauge nee-dle jumping erratically

Intake surge chamber or discharge snubber malfunction.

Check rubber insert deflection (Sect. 6.5.7) and replace intake surge chamber/discharge snubber, if required.

Overheating hot-well tank Modulating system malfunction. Check and readjust modulating system controls for proper water rate or over firing.

Temperature regulator valve not work-ing properly.

Adjust temperature regulator for proper temperature.

Steam trap(s) locked open. Check and correct trap “blow-by.”


Sect05_CSMG_a.fm 5-2 11/26/2018

Section V–Troubleshooting

5.3 FUEL SYSTEM - GAS-FIRED MACHINES

REFER TO MANUFACTURER OPERATIONS AND MAINTENANCE MANUAL FOR TROU-BLESHOOTING PROCEDURES.

Steam trap pressure gauge reads zero pressure

Steam trap closed. Ensure feedwater pump is discharging at normal capacity.

Blowdown valve partially open. Close it.

Check for possible malfunctioning of steam trap.

Machine overfired. Check temperature on separator tem-perature gauge. Correct fuel input rate if necessary.

Trap gauge sensing line obstructed or trap gauge defective.

Clean sensing line. Replace gauge if defective.

Steam trap pressure gauge registers fixed pressure reading

Steam trap open. Ensure feedwater pump is discharging at normal capacity.

Check for possible malfunctioning of steam trap, or loss of trap prime.

Check modulating system controls.

Check burner operation for possible reduced heat input (under firing).

Weeping safety relief valve Valve seat or disc contamination. Replace valve. The valve seat/disc may be resurfaced if the damage is minor.

NOTE: Any safety relief valve repair should be performed ONLY by an authorized repair shop or authorized technician.


11/26/2018 5-3 Sect05_CSMG_a.fm


5.4 ELECTRICAL SYSTEM

WARNING

Observe all warning and caution labels to avoid electrical shock when working with elec-trical components.


Burner purge cycle fails to occur GPSL actuated. Reset GPSL. Check supply gas pressure. GPSL must be reset on any loss of gas pressure.

GPSH actuated. Reset GPSH. Be sure regulator is not hung open.

Motor fails to start, or stops during operation

Power failure or blown fuse. Check fuses in lines to machine.

Safety shutdown caused by thermal trip unit in the GMP.

Wait for elements to cool; then manually reset and restart. Check cause of overload. Check motor for overheat due to possible shorted or grounded winding.

System over-pressure or failed LPS. Replace LPS or correct cause of overpressure.

Check for low voltage. Correct cause.

Motor noisy or running hot Motor running single phase. Check for blown fuse in feeder lines.

Insufficient lubrication or bearing fail-ure.

Lubricate bearings. Check for worn bearings.

Excessive system pressure variation Modulating Pressure Setting Differen-tial out of adjustment.

Adjust based on existing steam load conditions.

Magnetic Controller fails to contact Operating coil failure. Also see trou-bles and remedies under “Motor Fails to Start.”

Replace coil. Be sure the coil is properly rated for the installation.

Contact failure caused by poor contact pressure, dirt, arcing, or low voltage.

Replace contacts.

Magnetic Controller fails to disconnect

Welded contacts, due to arc, or mechanical binding.

Replace contacts. Correct cause of binding.

Magnetic Controller noisy Poor alignment, wrong coil, mechani-cal binding, or gummy guide surfaces.

Check and clean magnetic control-ler.

Sect05_CSMG_a.fm 5-4 11/26/2018

Section V–Troubleshooting

5.5 WEISHAUPT PACKAGED BURNER UNIT

WARNING

Observe all warning and caution labels to avoid electrical shock when working with elec-trical components.

REFER TO MANUFACTURER OPERATIONS AND MAINTENANCE MANUAL FOR TROU-BLESHOOTING PROCEDURES.

Burner purge cycle fails to occur

Modulating motor, safety shut-off valve, ATS, or other upstream con-tacts open.

Modulating motor must be in low-fire position.

Be sure gas valve (SSGV or MGV) (proof-of-closure valve) is not hung open.

ESC locked out. Reset. Circuit complete when burner flame safeguard display reads “standby.”

Check for cause of burner lockout.


11/26/2018 5-5 Sect05_CSMG_a.fm


NOTES

Sect05_CSMG_a.fm 5-6 11/26/2018

04/22/20

Section VI PERIODIC MAINTENANCE

6.1 IntroductionPeriodic inspections and regularly scheduled

maintenance on the Clayton steam generator isessential for maintaining its peak performance andreliability. The following service recommendationsrequire only a few minutes each day to maintain theefficiency of the steam generator, as well as, mini-mize unscheduled repairs. A monthly maintenancelog sheet can also be found in the back of this man-ual. Proper use of these sheets provides an accuraterecord and serves as a daily reminder of the routinemaintenance requirements. Cumulative hours ofoperation can viewed from the OIU.

6.2 Feedwater TreatmentThe Feedwater Treatment Manual discusses

the importance of feedwater treatment. To preventinternal corrosion and to eliminate scale formation,proper control of feedwater must be given seriousconsideration before start-up.

6.3 Daily Service

6.3.1 Record Operating/ Steam Pressure

Record the operating pressure in the PeriodicMaintenance Log (R027906).

6.3.2 Trap Timing

(See paragraph 2.1.6 in Section 2 for details.)

Record the trap pressure in the Periodic Main-tenance Log.

6.3.3 Test and Record Feedwater

Record tested feedwater characteristics indi-cated in Periodic Maintenance Log.

Refer to Clayton Feedwater Treatment Man-ual, R015216, for details.

6.3.4 Manual Blowdown

A manual bleed blowdown is used to controldissolved solids and to remove suspended solidsand sludge. Manual bleed blowdown may be elimi-nated from daily operation if an automatic bleeddevice (optional equipment) is used and the feedwa-ter is tested daily for TDS (Total Dissolved Solids)content.

Adjust continuous bleed blowdown valveopening (See Fig. 6-1.) or auto TDS controls tomaintain desired TDS levels. See Feedwater Man-ual (R015216), Section 4.1 System Blowdown, fordetails.

6.3.5 Walk-Around Inspection

Check for leaks, unusual noise, stack smoke,and other visual items. Hot lines on manual blow-down discharge are an indication of valve leakage.

Fig. 6-1. Check pump belt tension weekly.



NITROGEN LAYUP– If unit is laid-up with anitrogen blanket, verify pressure is maintaining35 psig (240 kPa). Take appropriate action to rem-edy condition if a loss of pressure has occurred dueto system leakage.

6.4 Weekly Service

6.4.1 Steam Generator Unit

Purge sludge settlement at the steam generatorunit. Open the steam generator unit maintenancedrain valve fully for about one minute (may be donewhile in operation). This purges settlement buildupfrom low points in the steam generator system.

NOTEPurge process may be required more oftendepending on the application of the steamgenerator.

6.4.2 Hot-well Tank

Partially drain the hot-well tank. Open the hot-well tank drain valve fully for about one minute(may be done while in operation). This flushesloose solids from the tank. Make sure fluid isalways visible in the sight glass of the fluid levelgauge.

6.4.3 Belt Tension

Check the feedwater pump drive belt forproper tension. See Fig. 6-2.

Fingers will be crushed by spinning pump belt.Prevent losing fingers by cutting power to thefeedwater pump motor.

a. Remove the five Allen screws thatattaches the top cover to the feedwaterpump compartment.

b. Remove the top cover.

c. Check belt tension. Belt play, checkedmidway between the two pulleys, shouldbe no more than the thickness of the belt.

d. Adjust belt tension, as required. See Sec-tion 7.1 in Section 7 for procedure.

e. Replace the top cover when done.

6.5 Monthly Service

6.5.1 Check Coil Feed Pressure

Check the coil feed pressure at the high firerate. Record and compare with the original readingfor an indication of internal scaling.

The normal feed pressure may vary slightlywith each installation. It is advisable to make a noteof the feed pressure right after the steam generatorhas been installed. This will provide an accuratebase reference value to check for coil restriction forthe particular machine.

NOTEAlways note the feed pressure afterthe steam generator has operatedfor a period of time and is thoroughlyheated; and always note at the samefeed pressure, feedwatertemperature, and at full load.

Fig. 6-2. Check pump belt tension weekly.

Sect06_CSMG_b.fm 6-2 04/22/2019

Section VI–Periodic Maintenance

A constant steam pressure discharge must bemaintained under a steady load condition that willprevent burner modulation. To check the feed pres-sure, open the valve to the feed pressure gauge justenough to allow a steady reading on the gauge. Coilscaling is present if the feed pressure is 30 psi(2 bar) or more above the normal feed pressure basereference value (noted right after installation, orwhen the coil was completely clean). For example,it is noted that feed pressure was 300 psi (21 bar)when the machine was in the new condition. Coildescaling (Section 6.8) is required if the currentfeed pressure reading is 330 psi (22.8 bar), orhigher, for that same given steam pressure.

If rising feed pressure is noted within 10–30days after initial installation, take steps immediatelyto correct the cause and to prevent future trouble.Consider the following measures:

a. Carefully check to be sure the feedwatertreatment is adequate and is being usedproperly and consistently. See that thewater softener is regenerating at regularintervals. To be effective, feedwater treat-ment must be consistent and continuous.

b. Blowdown the machine more frequently.It is sometimes necessary to blowdownmore often than specified in this manual toremove solids that are precipitated in theform of sludge. The blowdown operationis not a cure-all, but it will remove somescale and thereby delay coil restriction.

NOTEThe Feedwater Treatment Manualcontains detailed information withregards to the importance offeedwater treatment and therecommended procedures andequipment necessary to preventscale and corrosion within the steamgenerator.

6.5.2 Flush Water Pump Heads And Columns

Open drain cocks at base of water pump untilclear water appears, if heavy accumulations ofsludge appears, repeat this operation more fre-

quently. If drain cocks are plugged, remove cocksand use a stiff wire to dislodge sediment. (Waterpump may be operated and coil feed valve throttledto provide pressure to purge cock if not severelyplugged.)

Stop machine before attempting to removedrain cocks.

6.5.3 Check Dual Element Thermocouple Sensor

The integrity of the dual element thermocou-ple sensor must be checked monthly. The sensor isinstalled in the steam discharge line at the top of thesteam generator unit. See Fig. 6-3. A temperaturetest meter/indicator is required. The thermocouplesensor check is conducted under two conditions,when the machine is in operation under load atoperating pressure and when the machine is in wetlay-up for at least two hours following a cease firingof the burner.

Fig. 6-3. The thermocouple sensor is installed in the steam discharge line at the top of the steam genera-

tor unit.

04/22/2019 6-3 Sect06_CSMG_b.fm


6.5.3.1 Steam temperature reading with steam generator in operation

a. Connect the test meter to the primary el-ement of the dual element thermocouplesensor.

b. Record the steam temperature. Removethe meter leads from the primary elementwhen temperature is recorded.

c. Connect the test meter to the secondaryelement of the dual element thermocou-ple sensor.

d. Record the steam temperature. Removethe meter leads from the secondary ele-ment when done.

e. Record the steam temperature readingfrom the separator thermometer.

f. Compare the recorded temperatures withthe reference temperatures in Table 2-1(Pressure-Temperature Table) inSection 2. Make a note of the differencesfor evaluation in paragraph 6.5.3.3.

6.5.3.2 Steam temperature reading with steam generator in wet lay-up

NOTEThe machine should be in wet lay-upfor at least two hours following aburner shut down. The cool-downtime may be reduced by increasingthe FILL rate.

a. Connect the test meter to the primary el-ement of the dual element thermocouplesensor.

b. Record the steam temperature. Removethe meter leads from the primary elementwhen temperature is recorded.

c. Connect the test meter to the secondaryelement of the dual element thermocou-ple sensor.

d. Record the steam temperature. Removethe meter leads from the secondary ele-ment when done.

e. Record the feedwater temperature read-ing on the thermometer on or near thefeedwater pump.

Alternatively, a feedwater temperaturereading from the thermometer on the hot-well tank may be used.

6.5.3.3 Evaluate recorded values

a. The results from steps 6.5.3.1b and6.5.3.1d should fall within 40 degrees ofthe recorded steam temperature or thevalue obtained from Table 2-1 Pressure/Temperature Table (in Section 2).

b. The results from steps 6.5.3.2b and6.5.3.2c should fall within 10 degrees ofthe recorded incoming feedwater tem-perature taken in step 6.5.3.2e.

c. If one of the coil temperature readings,from either the primary element or thesecondary element, exceed the acceptedtemperature range, then the correspond-ing element wiring or connections arefaulty.

d. If both coil temperature readings, fromeither the primary element or the second-ary element, exceed the accepted tem-perature range, and they are equal in theerror value, then it is likely that the ther-mocouple elements are not making suffi-cient contact with the sleeve that isinserted in the tube. (See Fig. 2-2 in Sec-tion 2.)

6.5.4 Check Main Temperature Limit Controllers (MTLC)

a. Remove on thermocouple lead wire fromthe MTLC.

b. Verify that a shutdown occurs and analarm is initiated within one minute.

c. Replace the thermocouple lead wire.

d. Repeat steps a, b, and c for other MTLC.

Sect06_CSMG_b.fm 6-4 04/22/2019


NOTEIf any of the MTLCs are suspected ofbeing faulty, remove it and conductfurther bench testing. Replace theMTLC if it is faulty.

6.5.5 Clean Strainers

Turn off the water supply to the strainer(s), ifapplicable. Remove the strainer cap and remove thescreen from strainer. Rinse the strainer screen thor-oughly with clean water, removing all the sludgeand solids. Reassemble screen and cap. Turn onwater supply, if applicable.

6.5.6 Drain and Flush Hot-well Tank

The hot-well tank should be drained andflushed monthly, or as determined by the feedwaterquality. The following water conditions must bemaintained in the feedwater (boiler water) at alltimes:

• Hardness: 0 ppm (4 ppm maximum)

• pH 10.5–11.5 (normal range), maximumof 12.5

• Oxygen free with an excess sulfite resid-ual of 50–100 ppm during operation(>100 ppm during wet lay-up)

• Maximum TDS of 8,550 ppm (normalrange 3,000–6,000 ppm)

• Maximum dissolved iron of 5 ppm

• Free of suspended solids

• Maximum silica of 120 ppm with theproper OH alkalinity

NOTEReview the Clayton IndustriesFeedwater Treatment ReferenceManual (P/N: R015216) foradditional feedwater qualityrequirements.

Secure the machine before performing thismaintenance procedure.

a. Open the drain valve at the base of thehot-well tank and allow the water to com-pletely drain.

b. Close the drain valve.

c. Fill the tank with clean potable water.

d. Open the drain valve to drain the tank.Verify the water draining from the tank isclean and free of sludge. Repeat the stepsabove until the rinse water runs clean.

e. Close the drain valve.

f. Fill the tank to the proper level with chem-ically treated water.

NOTEMake sure TDS is brought back tothe proper levels, see above, andoptimum feedwater conditions aremet before placing the machine backinto operation.

6.5.7 Inspect Intake Surge Chamber and Snubber

Inspect the intake surge chamber and dis-charge snubber (Fig. 6-4) on the feedwater pump.The rubber inserts inside the surge chamber andsnubber must be pliable to properly dampen thefeedwater pulsations.

The pliability of the rubber inserts can bechecked through the breather holes at the base ofthe surge chamber and discharge snubber housing.

a. Remove the top cover, right-side panel,and front panel of the pump compartmentto allow access to the discharge snubberand intake surge chamber.

04/22/2019 6-5 Sect06_CSMG_b.fm


b. Obtain a 3/16 in. x 6 in. (4 mm x 150 mm)rod, dowel, pencil, or similar device. Thisrod will be inserted through the breatherhole for testing.

POTENTIAL LOSS OF OFF FINGERS!Fingers caught between belt and pulley may becut off. This procedure is performed while thefeedwater pump is operating.

c. With the feedwater pump operating, insertthe rod into the breather hole in the base ofthe intake surge chamber/discharge snub-ber housing until it stops.

d. Verify the rod modulates in an up anddown motion. If the rod fails to do this,then the intake surge chamber/dischargesnubber requires replacement.

6.6 Semi-annual ServiceTest feedwater pump relief valve (Fig. 6-5)

operation. Slowly, close the coil feed valve until thefeedwater discharge pressure exceeds the reliefvalve’s set pressure, typically 275 psi (1,896 kPa).Verify relief valve is discharging properly and ver-

ify the drain lines are clear of blockage for properdraining. See Section 7.2 adjustment and mainte-nance procedures.

NOTEIncrease maintenance intervals tothree months on older feedwaterrelief valves.

Fully open the coil feed valve after feedwaterpump relief valve check is complete.

6.7 Annual Service

NOTEPerform this annual service semi-annually if the steam generator is inuse 24 hours a day, 7 days a week(or similarly continuous operation).

Fig. 6-4. Feedwater pump relief valve.

Fig. 6-5. Feedwater pump relief valve.

COIL FEED VALVE

Sect06_CSMG_b.fm 6-6 04/22/2019


6.7.1 Replace Check-valves

Replace check-valve seats and discs on boththe feedwater discharge check-valve and feedwaterpump check-valves. (See paragraphs 7.2.1 and7.2.2.)

6.7.2 Replace Feedwater Pump Diaphragms and Seals

Replace feedwater pump diaphragms every7,000 hours of operation or once a year, whicheveroccurs first, during scheduled preventative mainte-nance shutdowns (See paragraph 7.2.3).

NOTEFeedwater pump diaphragms mustbe replaced more often (than 7,000hours) in SCR (semi-closed receiver)applications.

Tighten pump head stud nuts regularly, asneeded. Torque pump head stud nuts to 200 lb-ft(271 N•m).

6.7.3 Test Steam Safety Valve

Set the Limit Pressure Switch (LPS) to exceedthe steam relief valve pressure setting. Allow pres-sure to increase (by throttling discharge valve) untilsteam safety relief valve actuates.

Hearing will be damaged from loud burst ofsteam discharging. Wear ear protection toprotect against potential hearing damage. Weareye protection to protect against potential hotwater spray from relief valve discharge.

If valve does not actuate after exceeding pres-sure setting, open separator discharge valveimmediately.

After test is accomplished, regulate steampressure to desired working pressure. Reset the LPSto its original settings. Fully open separator dis-charge valve. Service or replace steam safety valveif test fails.

6.7.4 Service Compact Burner Unit 1

Servicing must be performed by a well-qualifiedand experienced service technician only.

Standard maintenance of the -Weishaupt-compact burner unit to be performed once a yearby qualified and experienced personnel.

Servicing to be performed according to theguidelines outlined in the -Weishaupt- Installationand Operating Instructions Manual provided withyour Clayton Steam Master unit.

6.8 Heating Coil Scale RemovalImproperly treated feedwater often leads to

coil scaling—a mineral buildup inside the coils—over time. Coils must be descaled when this occurs.This section contains the procedures for descaling arestricted coil.

A “feed-and-bleed” process is used in the des-caling process. A large, open-top container isrequired in this procedure to facilitate the adding ofthe acid solution and the monitoring of the descal-ing progress. See Fig. 6-6A/B for hookup diagram.

NOTEThe heating coil maintenanceprocess requires 8–10 hours.

6.8.1 Setting Up Machine For Descaling

a. Start the machine in the FILL mode (with-out burner operation). Allow cold water tocirculate through the entire system until itis cooled. Stop the machine and close thefeedwater inlet valve (D).

b. Obtain a non-galvanized, acid-resistant,55-gallon (200 liter) container and place itnearby the feedwater pump. Make surethis container can withstand fluid tem-peratures above 150°F (65°C).

1 Weishaupt Installation and Operating Instructions Manual: Ch. 7.2 Service Plan; WG40.../1-A, vers. ZM-LN; 01/2004 (Certified US/Canada edition)

04/22/2019 6-7 Sect06_CSMG_b.fm


NOTELarger containers maybe required ifsevere scaling exists. Review thisentire descaling procedure todetermine if a larger container isneeded.

c. Elevate the container to provide a 12-inch(30 cm) gravity feed to the feedwaterpump. If possible, provide a pipe outlet 1–2 inches (2.5–5 cm) from the bottom ofthe container for acid suction.

d. Remove and replace the intake surgechamber with a suction hose. Make surethe hose is manufactured from acid-resis-tant materials.

e. Attach the opposite end of the suctionhose to the outlet at the bottom of the55-gallon (200 liter) container. If there is

no outlet at the bottom of the container,fasten a fine mesh screen over the end ofthe hose and place that end of the hoseinside the container. Secure the hose to thecontainer to prevent it from slipping out.

NOTEA shutoff valve may be installed atthe outlet of the container. This willaid in preventing any acid spillagefrom the container when the suctionhose is disconnected from thecontainer.

f. Fill the container with 4–5 inches (10–13 cm) of clean, potable water. Make surethe suction hose or suction outlet is belowthe water level.

Fig. 6-6A. Hookup diagram for steam generator descaling (shown with SE)

OPTIONAL ECONOMIZER

A

B

C

D

E

A– Steam Discharge Valve

B– Coil Feed Valve

C– Feedwater Pump

D– Feedwater Inlet Valve

E– Separator Blowdown Drain

F– Maintenance Drain Valve

F

DRAIN/RETURN HOSE

SUCTIONHOSE

55-gal.container

INTAKE SURGECHAMBER

Sect06_CSMG_b.fm 6-8 04/22/2019


g. Separate the separator blowdown drain(E) line at the union, which is locatedinside the feedwater pump compartment.

h. Attach a second acid-resistant type hose tothe separator blowdown line. A pipe unionadapter may have to be fabricated toattach the hose. This hose must be longenough to reach the containers.

i. Securely fasten the opposite end of thehose to the container so that it will not dis-lodge during the descaling operation.Considerable pressure can develop in thehose, which can cause it dislodge.

j. Close the separator blowdown valve andthe trap discharge valve.

NOTEThe completed hose hookups shouldcreate a closed loop systemconsisting of the heating unit,feedwater pump, and 55-gallon (200liter) container(s).

6.8.2 Descaling The Machine

a. Start the machine in the FILL mode (with-out burner operation).

b. Add or remove water from the containeruntil a steady circulation can be main-tained through the system and back to thecontainer, with about 4–5 inches (10–13 cm) of water remaining in the con-tainer. Be sure the feedwater pumphousings are primed.

Wear protective clothing. Mishandling of theacid may cause serious personal injury.

c. Mix 3 ounces (89 milliliters) of KleenKoilInhibitor to one gallon (3.8 liters) ofhydrochloric acid (HCl), or one can ofKleenKoil Inhibitor to 5 gallons (19 liters)of HCl.

d. SLOWLY add this acid solution to the con-tainer. Monitor the feedwater in thecontainer for foaming. Continue addingthe acid solution until foaming stops.

Adding the acid too rapidly can cause bubblingin the feedwater pump check-valve housing.This can lead to the loss of pump prime.

NOTEDepending on the severity of the coilscaling, this procedure can require50–100 gallons (190–380 liters) ofthe acid solution.

Initially add the acid solution slowly untilthe circulation can be maintained withoutexcessive bubbling from the dischargehose. For example, add about 1/2 cup(120 cc) and wait for the reaction to sub-side, then add another 1/2 cup (120 cc),repeat. As the cleaning operation pro-gresses, acid can be added in graduallyincreasing amounts. In extreme cases, it ispossible to completely block the passagethrough the coil with loosened scale ifacid is added too rapidly.

Fig. 6-6B. Descaling hookup connection points.

D FEEDWATERINLET VALVE

E SEPARATORBLOWDOWN

INTAKE SURGECHAMBER

COIL FEEDBVALVE

04/22/2019 6-9 Sect06_CSMG_b.fm


e. Continue the circulation for 4–6 hours. Alonger circulation time is required if bub-bling still occurs in the discharge solution.

NOTEDuring this period, frequently checkto be sure that the feedwater pump isprimed. The only way to make surethat the pump is primed is to slowlythrottle coil feed valve until thepressure rises on the feed pressuregauge. If the pressure fails to rise,the pump will require priming. Re-open the coil feed valve after check.

f. Test the acid at regular intervals by addinga pinch of sodium bicarbonate (bakingsoda) into the container. If no foamingreaction takes place, the acid has beenneutralized and it will be necessary toincrease the acid concentration in the acidsolution.

g. When the bubbling subsides, SLOWLYheat the solution by intermittently startingand stopping the burner until the solutiontemperature rises to a maximum of 150° F(65° C). Continue circulation for an addi-tional two hours, cycling the burnerwhenever necessary to keep the solutionhot.

Boiling acid solution will cause serious burnsand damage equipment. DO NOT allow acidsolution to boil.

h. Shut down the machine after the acid solu-tion has circulated for the two additionalhours.

6.8.3 After Descaling Is Complete

Acid solution will burn face, arms, and otherbody parts. Carefully disconnect hoses to avoidspilling acid solution. If a shutoff valve wasinstalled at the container, close the valve beforedisconnecting suction hose.

NOTEDischarging the acid solution into alocal sewage system may be inviolation of municipal codes andregulations. Verify with localgovernment regulatory agencies forthe proper method of disposal.

a. Carefully remove the drain/return hosefrom the container and direct it to a drain.

b. Carefully disconnect the suction hosefrom the feedwater pump and direct it to adrain.

c. Open the separator blowdown/drain valve.Allow as much of the solution to drainfrom the separator as possible.

d. Reinstall the feedwater pump intake surgechamber.

e. Close the separator blowdown/drain valveand open the feedwater intake valve.

f. With the discharge hose still directed tothe drain, start the machine without burneroperation and allow the machine to run forat least 10 minutes to flush the system ofthe acid solution. Flush the feedwaterpump standpipes by opening the draincocks to allow water to run until clear. Besure the feedwater pump remains primed.

g. Stop the machine and remove the dis-charge hose. Reinstall the coil drain valveand plumbing.

h. Open the separator blowdown valve andthe automatic dump isolation valve.

Sect06_CSMG_b.fm 6-10 04/22/2019


NOTEStart the machine and blowdown themachine thoroughly four to five times(See Section 4.8. of Section IV.)before resuming normal operation.This will dislodge and remove muchof the loosened scale.

04/22/2019 6-11 Sect06_CSMG_b.fm



Sect06_CSMG_b.fm 6-12 04/22/2019

04/26/20

Section VII COMPONENT MAINTENANCE

7.1 Feedwater Pump Belt Replacement

Fingers will be crushed by spinning pump belt.Prevent losing fingers by cutting power to thefeedwater pump motor. Lock out main electricalpower to prevent the machine fromautomatically starting.

The feedwater pump belt should be replacedapproximately every 7,000 hours of operation. Thefeedwater pump is located in the feedwater pumpcompartment on the right side of the heating sec-tion. Feedwater pump belt adjustment andreplacement is performed as follows:

a. Remove the five Allen bolts securing thetop cover and remove cover. (See View Ain Fig. 7-1.)

b. Remove the two Allen bolts securing theside cover and remove cover. (See View Bin Fig. 7-1.)

c. Loosen the four motor base adjusting nutsto lower the motor base. (See Fig. 7-2.)

d. Loosen each of the four adjusting nuts torelieve the belt tension.

e. Remove old belt and replace with newbelt.

f. Adjust each of the for nuts to raise thepump motor until the belt is taut. DO NOTOVERTIGHTEN.

g. Replace feedwater pump compartmentcovers.

Fig. 7-1. Remove covers for pump compartment. Fig. 7-2. Use of Clayton seat puller and seat driver



7.2 Feedwater Pump Maintenance

Avoid bodily injury. Always lock-out mainelectrical power to the machine to preventaccidental machine startup when repairing orperforming maintenance on the machine.

7.2.1 Check-Valve Maintenance

(See Fig. 7-3.)

a. Unscrew check-valve caps (3) fromcheck-valve housings and disassemblediscs (6) and springs (2 and 5) from caps.Remove scale and pits from discs by rub-bing them in a “figure 8” motion on apiece of fine sandpaper (wet-or-dry no.400 or finer) placed on plate glass. Discsmust be perfectly smooth and flat forproper water pump operation.

Remove and process check-valves oneat a time to avoid interchanging parts.

b. Inspect springs (2 and 5) for distortion andfor free length. Free length of dischargesprings (5) should be 3/4 inch; free lengthof intake springs (2) should be 1/2 inch.Replace broken or distorted springs.

c. Damaged seats (1) may be removed with ascrew extractor (E-Z Out). Turn extractorwhile lifting firmly until seat is removed.Drive replacement seats in place with aspecial seat driving tool (part no. UH-18389) to avoid damage to the seat face.

7.2.2 Replacing Check-Valve Seats

To replace valve seats, use a special seatpuller (Part No. UH-25257) and a special seat driver(Part No. UH-18389). A screw extractor (E-Z Out)may also be used when removing seats. Proceed asfollows:

a. Adjust puller stem counterclockwise untilretracted catch extends below valve seatwhen puller is inserted into check-valvehousing (Inset A, Fig. 7-4).

b. Extend catch and turn stem clockwise inbody until catch meets the bottom of thevalve seat (Inset B, Fig. 7-4)

Fig. 7-3. Pump Check-valve Maintenance

1. Check-valve Seat2. Intake Spring3. Check-valve Cap

4. Gasket5. Discharge Spring6. Check-valve Disc

PUMP ASSEMBLYINTAKE/DISCHARGE

CHECK-VALVE

FEEDWATERDISCHARGECHECK-VALVE

Sect07_CSMG_b.fm 7-2 04/26/2019

Section VII–Component Maintenance

c. Hold stem and turn jam nut clockwiseuntil valve seat is free of check-valvehousing (Inset C, Fig. 7-4).

d. Drive in seat using seat driving tool (InsetD, Fig. 7-4) using care to avoid damagingseat face.

e. After seats have been properly installed,assemble springs to check-valve caps withcheck-valve discs. Install correct springsand caps in proper ports of check-valvehousings.

7.2.3 Diaphragm Replacement

(Refer to Fig. 7-5 for parenthetical call-outs.)

a. Disconnect piping connected to the check-valve housing (1).

b. Remove the drain plug (18) at the base ofthe pump head (17) and allow the fluid todrain.

HOT pumphead fluid can cause scalding. Allowample time for pumphead fluid to cool beforedraining and disassembling pumphead.

c. Unscrew the eight attaching pumpheadhex nuts (15) and remove pumphead /check-valve assembly.

d. Unscrew the cap screw (14) and removethe top diaphragm washer (3) and the olddiaphragm (4). Note the orientation of thetop diaphragm washer as it is installed.

e. Install the new diaphragm and the top dia-phragm washer . Make sure the topdiaphragm washer is installed with thetapered-edge side facing the diaphragm(See Fig 7-6 on page 7-5.).

When installing the new diaphragm,apply a coating of gasket compound tothe joining surfaces of the connectingrod, diaphragm, and diaphragm washerbefore reassembly.

f. Install the diaphragm cap screw andwasher. Torque cap screw to 30 ft-lb (41N•m).

g. Install the pumphead/check-valveassembly over the pumphead studs.

h. Apply “Never-Seez” thread lubricant toeach stud.

Fig. 7-4. Use of Clayton seat puller and seat driver

04/26/2019 7-3 Sect07_CSMG_b.fm


1. Check-valve Housing2. Standpipe3. Diaphragm Washer, Top4. Diaphragm5. O-ring Packing6. Diaphragm Spacer7. Diaphragm Washer, Bottom8. Connecting Link9. Crankcase

10. Washer11. Screw

12. Retaining Plate13. Washer

14. Screw 1

15. Nut 2

16. Stud17. Pump Head18. Pipe Plug19. Bearing Spacer, End20. Washer

21. Connecting Link Bearing22. Crankshaft Bearing23. Crankshaft24. Check-valve Seat25. Intake Spring26. Check-valve Cap27. Gasket28. Discharge Spring29. Check-valve Disc30. Plug31. Check-valve Housing–ported

1 Torque 30 ft-lb2 Torque 35 ft-lb

Fig. 7-5. C2 feedwater pump assembly

Sect07_CSMG_b.fm 7-4 04/26/2019


i. Finger-tighten the stud nuts initially.Using a wrench, tighten each nut 1/2 to 3/4 turn. Make sure the next nut to be tight-ened is always opposite of the one thatwas just tightened. This is to ensure thatpressure will always be evenly distributedacross the pumphead. Maintain this pat-tern until all nuts are tight. Finally,continuing in the same tightening pattern,torque each nut to 45 ft-lb (61 N•m).

j. See Section IV for start up procedures.

7.2.4 Pump Disassembly

(Refer to Fig. 7-5.)

a. Remove the pump pulley from thecrankshaft.

b. Remove the pumpheads/check-valveassembly, diaphragms, and diaphragmwashers from the connecting link, asdescribed in paragraph 7.2.3.

c. Remove bearing retainer plates (12) fromeach side of the pump.

d. From the pulley end of the crankshaft,str ike the crankshaft with a heavy-weighted hammer to unseat the connect-ing link-bearing-crankshaft assemblyfrom the crankcase.

DO NOT strike crankshaft shaft directly.Striking the crankshaft end directly cancause flaring, which can interfere withthe pulley installation. Instead, place apiece of 2x4 lumber against the shaftend and strike the piece of lumber.

e. Remove the crankshaft bearing (22) that isfarthest from the pulley with a bearingpulling tool.

f. Remove the connecting link-bearing-crankshaft assembly from the crankcase.

g. Pull the remaining crankshaft bearing(22), connecting link (8), and bearing (21)from the crankshaft.

7.2.5 Inspect and Repair Pump

a. Spin the bearings by hand to check forroughness or grinding. Replace the bear-ing(s) if roughness is felt while spinningthe bearing, or if the bearings show wear.

b. Replace the crankshaft (23) or the con-necting link (8), or both, if they are scoredor damaged due to seized bearings.

c. Replace the diaphragm washers (3, 7) ifthey are damaged or if the face of thewashers are in a condition that will causethe diaphragm to chafe.

d. Check the diaphragm (4) for pliability.Replace the diaphragm if some rigidnessis evident. See paragraph 7.2.3 (page 7-3).

7.2.6 Pump Reassembly

a. Apply Loctite Bearing Mount-Grade B tothe inside surface of the connecting link.Press the bearing (21) into the connectinglink (8). Wipe off the excess Loctite fromthe connecting link surfaces.

Fig. 7-6. Use of Clayton seat puller and seat driver

04/26/2019 7-5 Sect07_CSMG_b.fm


b. Apply Loctite Bearing Mount-Grade B tothe inside surface of the bearing hole onthe crankcase (9). Press the connectinglink and bearings onto the crankshaft.Wipe off excess Loctite from the crank-shaft and bearing surfaces.

c. Position the crankshaft and connectinglink assemblies in the crankcase and pressthe crankshaft bearings (22) onto the endsof the crankshaft and into the crankcase.

d. Assemble the diaphragm and pumpheadas described in paragraph 7.2.3 (page 7-3).

e. Install the pump pulley onto thecrankshaft.

f. Align the pulley and install the drive belt.

g. Connect piping to the check valves.

h. Start and run the steam generator in thestandard mode of operation. Verify thepump is properly primed. Inspect all con-nections for leaks and retighten as needed.

7.2.7 Install High Strength Studs

Required tools:

• Torque wrench, 3/4 inch, ratchet drive, 0–300 ft.-lb (0–410 N•m).

• Stud driver (1-14 thread)

a. Thoroughly clean both the studs and thethreaded crankcase holes of all dirt, oil,and other debris. Use clean solvent.

b. Spray primer (Locquic “T” Primer) onlyon the short threaded end of the cleanedstud. Do not over prime. A very thin filmis best.

Inhaling primer fumes will cause loss ofconsciousness. Use primer in a well ventilatedarea.

c. Apply adhesive (Loctite # 242) at leadthreads in the threaded hole.

d. Spread Loctite to the rear of the threadswith a clean plastic tie wrap, or similardevice. (See Fig. 7-7.)

e. Apply Loctite to the stud (primed end).Fill ninety percent (90%) of the threadswith Loctite. Work with one stud at atime.

f. Hand thread the stud into the crankcaseseveral rotations clockwise, then reversethe direction counterclockwise allowingany entrapped air to escape. Repeat thisprocedure until the stud is fully seated inthe case. Wipe away all excess Loctite.

g. Double-nut the stud and tighten intocrankcase. DO NOT OVER TIGHTEN.Torque the stud to 250 lb-ft (338 N•m).Repeat this process for all studs.

h. Install pump head as described in steps g –i in paragraph 7.2.3 (page 7-3).

Fig. 7-7. Apply Loctite to stud hole threads.

Sect07_CSMG_b.fm 7-6 04/26/2019


7.3 Feedwater Pump Relief ValveExcessive leakage from the relief valve will

result in insufficient water to the heating coil andwill result in overheating. The relief valve (Fig. 7-8)is factory preset for the following pumps:

• C2 pump .................... 275 psi

7.3.1 Adjustment

Under certain conditions, when startingthe machine, the feed pressure maysurge sufficiently to cause the reliefvalve to release a small amount ofwater. The feed pressure will return tonormal, however, after the machineheats and the system becomesstabilized.

a. Start the machine in the FILL position andslowly close the coil feed valve until therelief valve begins to discharge. When thedischarge begins, check the pressure onthe feed pressure gauge.

b. To raise the pressure adjustment, turn theadjusting screw clockwise. Similarly, tolower the pressure adjustment, turn theadjusting screw counterclockwise. Securethe adjusting screw with the lock nut afteradjustment process.

It is best to make these pressureadjustments while the feedwater pumpis off. A feedwater pump that is runningplaces more resistance against theadjusting nut.

c. Fully open the coil feed valve. Regularlyinspect the relief valve for leakage duringnormal operation.

7.4 Temperature Controllers (MTLC1, MTLC2)

The MTLCs are installed in the electricalcontrol box.

7.4.1 Check Main Temperature Limit Controllers

a. Remove one thermocouple lead wire fromthe MTLC. See Fig. 7-9 below.

b. Verify that a shutdown occurs and analarm is initiated within one minute.

Fig. 7-8. Feedwater Pump Relief Valves

Fig. 7-9. Test MTLCs in electrical control box.

04/26/2019 7-7 Sect07_CSMG_b.fm


c. Replace the thermocouple lead wire.

d. Repeat steps a, b, and c for the otherMTLC.

If any of the MTLCs are suspected ofbeing faulty, remove it and conductfurther bench testing. Replace theMTLC if it is faulty.

7.5 Operating Pressure Switch (OPS) AdjustmentThe OPS can be adjusted to open and stop

the burner at any desired maximum steam pressurewithin the operating range of the switch and inaccordance with Clayton prescribed switch setpointparameters. The switch has a fixed differential andwill close and restart the burner when steam pres-sure drops about 8 psi (0.55 bar) below the OPSsetpoint.

To adjust, turn the large slotted screw at thetop of the switch until the dial pointer on the switchis opposite the maximum desired operating pres-sure. The dial setting is approximate and finaladjustment should be made (if necessary) by reset-ting the switch to shut off the burner when desiredmaximum pressure is reached on the operating pres-sure gauge.

7.6 Limit Pressure Switch (LPS) AdjustmentThe LPS is part of the motor circuit. In the

event of excessive steam discharge pressure, thisswitch will actuate and shut down the machine(interrupting the holding circuit). A manual reset isrequired before the machine can be restarted.

7.6.1 Adjustment

To set the switch (using scale on switches)manually increase the OPS and LPS setpoints tosome value above the desired LPS setting (a pres-sure that is about halfway between the original OPSsetpoint and the opening pressure of the steamsafety relief valve(s)). Operate the machine and

slowly throttle the steam discharge valve to increasethe steam pressure to desired LPS setpoint. Set thelimit pressure switch (dial down) to open (shuttingmachine off). Reset the OPS to its original setting(See paragraph 7.5.).

7.7 Gas Pressure Switches

Damage to burner unit and steam generator willresult from improperly adjusted gas pressureswitches.

Maintenance and repair of thepackaged burner system and itsancillary devices should ONLY beperformed by Clayton Service or byClayton-authorized service technicians.

A set of gas pressure switches, two GPSLsand a GPSH, are part of the fuel system (See Fig.7-10.). These switches will initiate a safety shut-down when gas pressure falls out of range of theswitch’s setpoint.

The low gas pressure switch (GPSL) closeson an excessive drop in supply gas pressure; thehigh gas pressure switch (GPSH) opens on anexcessive rise in burner pressure. If supply gas orburner pressure exceeds the setpoint of the respec-tive switch, the burner circuit will open and cause acomplete shutdown of the machine. A manual resetis required if either switch is actuated.

A manual reset is required on the GPSLinstalled at the main gas supply inlet. A manualreset is required on the GPSH. The GPSH is foundinside the housing of the packaged burner unit.

Note: Manual reset can be accomplishedwithout removing the clear cover. To manuallyreset the pressure switch, press the spot on the coverimmediately above the red manual reset button(Fig. 7-10).

If needed, the GPSL/GPSH setpoint may beadjusted as follows:

Sect07_CSMG_b.fm 7-8 04/26/2019


a. Remove clear cover from the switch togain access to adjustable (yellow) dial(Fig. 7-10).

b. Turn dial until the desired pressure set-point is aligned with the white line on theyellow dial face.

c. Verify the switch operates as intended.

d. Replace cover.

Fig. 7-10. GPSL/GPSH adjustment dial and manual reset button. The GPSL installed at the main gas inlet requires a manual reset. The GPSH, located inside the packaged burner unit

housing, requires a manual reset.

04/26/2019 7-9 Sect07_CSMG_b.fm



Sect07_CSMG_b.fm 7-10 04/26/2019

A-1

Steam Generator List of Parts

Fig. 01A - Main Heating Section–SM15 ..........................................................A-2

Fig. 01B - Economizer Stack Outlet Kit–SM15 ................................................A-4

Fig. 01C - Main Heating Section–SM30 ..........................................................A-6

Fig. 01D - Economizer Coil–SM30 ..................................................................A-8

Fig. 01C - Main Heating Section–SM40 ........................................................A-10

Fig. 01D - Economizer Coil–SM40 (Sht 1 of 2) ............................................A-12

Fig. 02A - Steam Discharge and Separator Hookup—SM-15 .......................A-14

Fig. 02B - Steam Discharge and Separator Hookup—SM-30/40 ..................A-16

Fig. 02C - Steam Trap and Control Valve Hookup .........................................A-18

Fig. 02D - Safety Relief Valve Hookup ...........................................................A-19

Fig. 02E - Pressure Indicating System ...........................................................A-20

Fig. 04A - Feedwater Pump Hookup–C1 .......................................................A-22

Fig. 04B - Feedwater Pump Hookup–C2 .......................................................A-23

Fig. 05A - Pump Assy–C1 .............................................................................A-24

Fig. 05B - Pump Assy–C2 .............................................................................A-26

Fig. 06 - Check Valve .....................................................................................A-28

Fig. 07 - Relief Valve ......................................................................................A-28

Fig. 09 - Fuel Gas System .............................................................................A-29

Fig. 13 - Electrical Control Box .......................................................................A-30

Fig. 18 - Separator High Level Alarm Kit ........................................................A-31

Fig. 01A - Main Heating Section–SM15

HeatingSect_SM15_a.fm A-2 04/30/2019

FIG. 01A - Main Heating Section – SM15

04/30/2019 A-3 HeatingSect_SM15_a.fm

Fig. 01B - Economizer Stack Outlet Kit–SM15

HeatingSect_SM15_a.fm A-4 04/30/2019

FIG. 01B - Economizer Stack Outlet Kit – SM15

04/30/2019 A-5 HeatingSect_SM15_a.fm

Fig. 01C - Main Heating Section–SM30

HeatingSect_SM30_b.fm A-6 12/05/2018

FIG. 01C - Main Heating Section – SM30

12/05/2018 A-7 HeatingSect_SM30_b.fm

Fig. 01D - Economizer Coil–SM30


FIG. 01D - Economizer Coil – SM30


Fig. 01C - Main Heating Section–SM40


FIG. 01C - Main Heating Section – SM40


Fig. 01D - Economizer Coil–SM40 (Sht 1 of 2)


FIG. 01D - Economizer Coil –SM40


Fig. 02A - Steam Discharge and Separator Hookup—SM-15

Sep-Trap-PressMfld_SM153040_b.fm A-14 04/30/2019

FIG. 02A - Steam Discharge and Separator Hookup — SM-15

04/30/2019 A-15 Sep-Trap-PressMfld_SM153040_b.fm

Fig. 02B - Steam Discharge and Separator Hookup—SM-30/40


FIG. 02B - Steam Discharge and Separator Hookup — SM-30/40


Fig. 02C - Steam Trap and Control Valve Hookup

FIG. 02C - Steam Trap and Control Valve Hookup

Item Part No. Description Qty.

1 0016601 VALVE, Angle, 3/8 in., 6000# ................................... 2

2 0044836 VALVE, Check, in-line, 3/8 in. ......... ......................... 1

3 0019348 VALVE, Globe, 1 in., 800# ....................................... 3

0019929 VALVE, Globe, 3/4 in., 800# ..................................... 3

0020001 VALVE, Globe, 1/2 in., 800# ..................................... 3

4 0019929 VALVE, Globe, 3/4 in., 800# (feedwater) .................. 1

0020001 VALVE, Globe, 1/2 in., 800# (feedwater) .................. 1

5 0019348 VALVE, Globe, 1/2 in., 800# (steam discharge) ........ 1

0020191 VALVE, Globe, 1 1/2 in., 800# (steam discharge) ...... 1

6 0018525 TRAP, Steam, 213, 1 in. - 1/4 in. ........ ....................... 1

0033152 TRAP, Steam, 211, 1/2 in. - 1/8 in. ............................ 1

0033203 TRAP, Steam, 212, 1/2 in. - 1/8 in. ............................ 1

1

4

5

1

3

2

6


Fig. 02D - Safety Relief Valve Hookup

FIG. 02D - Safety Relief Valve Hookup


Fig. 02E - Pressure Indicating System


FIG. 02E - Pressure Indicating System


Fig. 04A - Feedwater Pump Hookup–C1

FIG. 04B - Feedwater Pump Hookup – C1


1 UH30824 VALVE, Relief, 1/2 in., 275 psi (See Fig. 07 for details.) ............ 1

2 UH23304 VALVE, Check, 1 1/4 in. (See Fig. 06 for details.) ..................... 1

3 UH27215 CHAMBER ASSY, Intake Surge ................................................ 1

4 UH24615 SNUBBER ASSY, Discharge, 300 psi .......... .............................. 1

5 UH40129 PUMP ASSY, Water, C1 (See Fig. 05A for details.) ................... 1

6 0030484 VALVE, Ball, lockable, 1 1/2 in., 1000 psi .... .............................. 1

7 0031462 BELT, V, 3VX500 ...... ............................................................... 1

8 0040868 MOTOR, 1 hp, 1200 rpm, TEFC, 145T ........ .............................. 1

1

24

3

7

8

5

6

PumpHkup-C1-C2_parts_a.fm A-22 03/05/2019

Fig. 04B - Feedwater Pump Hookup–C2

FIG. 04B - Feedwater Pump Hookup – C2


1 UH30824 VALVE, Relief, 1/2 in., 275 psi (See Fig. 07 for details.) ............ 1

2 UH23304 VALVE, Check, 1 1/4 in. (See Fig. 06 for details.) ..................... 1

3 UH27215 CHAMBER ASSY, Intake Surge ................................................ 1

4 UH24615 SNUBBER ASSY, Discharge, 300 psi ........................................ 1

5 UH39671 PUMP ASSY, Water, C2 (See Fig. 05B for details.) ................... 1

6 0030484 VALVE, Ball, lockable, 1 1/2 in., 1000 psi ........ ......................... 1

7 0031462 BELT, V, 3VX500 ... .................................................................. 1

8 0038193 MOTOR, 3/4 hp, 1200 rpm, TEFC ............................................. 1

0041360 MOTOR, 2 hp, 1800 rpm, TEFC ................................................ 1

1

2

3

4

5

7

8

6

03/05/2019 A-23 PumpHkup-C1-C2_parts_a.fm

Fig. 05A - Pump Assy–C1


FIG. 05A - Pump Assy – C1


Fig. 05B - Pump Assy–C2


FIG. 05B - Pump Assy – C2


CheckValve_ReliefValve_b.fm A-28 11/20/2018

Fig. 06 - Check Valve

FIG. 06 - Check Valve

Fig. 07 - Relief Valve

FIG. 07 - Relief Valve


UH21728 VALVE, Check, 1 1/2 in., 350# ................................ Ref.



1 UH12797 . CAP ........................................................................ 1

2 0016547 . GASKET, Copper, 2 in. id / 1 3/4 in. od ....................... 1

3 UH18285 . SPRING .................................................................. 1

4 UH25196 . DISC ....................................................................... 1

5 UH25189 . SEAT, Rulon (Used on UH21728 and UH23304.) ....... 1

UH62860 . SEAT, Stainless Steel (Used on UH30530.) ........ ....... 1

6 UH12722 . HOUSING (Used on UH21728 and UH30530.) ........... 1

UH15479 . HOUSING (Used on UH23304) ................................. 1


UH30824 VALVE ASSY, Relief, 1/2 in., 275 psi .......... ............ Ref.

1 0027740 . SCREW, 3/8-16 x 1 1/2 in. ...................................... 1

2 0012100 . NUT, 3/8-16 ........................................................... 1

3 UH13659 . BODY .................................................................... 1

4 UH13660 . SEAT, Stainless Steel ... .......................................... 1

5 UH13661 . DISC, Stainless Steel ............................................. 1

6 UH13662 . STEM .................................................................... 1

7 UH13663 . GUIDE .................................................................. 1

8 K006153 . WASHER, Spring ......... .......................................... 2

9 K006201 . SPRING ................................................................ 1

10 UH14290 . HOUSING .............................................................. 1

GasBurnerSys_SM15-30-40_a.fm A-29 04/30/2019

Fig. 09 - Fuel Gas System

FIG. 09 Fuel Gas System

3

6

7

5 2x

2x

9

Item Part No. Description Qty. Item Part No. Description Qty.

1 0044420 BURNER, Compact, Gas, WG40N/1-A ............. 1 6 0022088 VALVE, Ball, bronze, 1/4 in. ........ ....................2

0044627 BURNER, Compact, Gas, WG30N/1-C ............. 1 7 - - - SWITCH, Pressure, 0.4 in. – 4.0 in. w.c., ..........1

0044628 BURNER, Compact, Gas, WG20N/1-C ............. 1 GAO-A4-4-3, Dungs 266920

2 - - - VALVE, Ball, bronze, 3/4 in, DN20 ................... 2 8 - - - SWITCH, Pressure, 1.0 in. – 20.0 in. w.c., .........1

PN30W-MOP5 17/80 GML-A4-4-4, Dungs 266945

- - - VALVE, Ball, bronze, 1 in, DN25 CW510L ........ 2 - - - SWITCH, Pressure, 12.0 in. – 60.0 in. w.c., .......1

3 - - - ACTUATOR, Gas Valve, P.O.C., SKP25.011U1 . 1 GML-A4-4-6, Dungs 266947

(Clayton equivalent part no.: 0039296) 9 - - - VALVE, Solenoid, 3/4 in., 120v / 60Hz, Asco, .....1

4 - - - BODY, Gas Valve, 3/4 in., VGG10.204U ........... 1 8214G030

(Clayton equivalent part no.: 0036993) - - - VALVE, Solenoid, 1 in., 120v / 60 Hz, Asco, ......1

- - - BODY, Gas Valve, 1 in., VGG10.254U .... .......... 1 8214G251

(Clayton equivalent part no.: 0032792)

5 - - - GAUGE, Pressure, 2 1/2 in., in. w.c. / kPa, ....... 2

0 – 3 psi (0 – 20.5 kPa)

8

4

2

1

2

ControlBox_CSM_a.fm A-30 11/20/2018

Fig. 13 - Electrical Control Box

FIG. 13 Electrical Control Box

1

5

13

13

22 47 7

20 21

23 25 24

18

11

14

15

16

17

2x

10x

3x

50x

29

31

12

27

28

30

6

10

9 8

4x

26

SHLA_a.fm A-31 02/08/2019

Fig. 18 - Separator High Level Alarm Kit

FIG. 18 Separator High Level Alarm Kit


1 0038294 SENSOR, Conductance, water level .......................... 1

2 0038263 PROBE, Sensor, conductance .................................. 1

3 0039202 CONTROL, Liquid Level, octal .......... ........................ 1

3

1

2

INSIDE LEFT DOOR

OIU

E-STOPPUSHBUTTON

Blank_Left.fm A-32 08/16/2017


B-1

Feedwater Skid Option List of Parts

Fig. 01 - Vertical Hotwell ..................................................................................B-2

Fig. 02 - Water Softener Plumbing Hookup ......................................................B-2

Fig. 03 - Water Level Indication and Control ....................................................B-3

Fig. 04 - Water Temperature and Blowdown Tank Hookup ..............................B-3

Fig. 05 - Sparger Tubes–Water Heating ..........................................................B-4

Fig. 06 - TDS Control System—Equipment Option .........................................B-4

Fig. 07 - Circulation Pump Hookup - TDS System ...........................................B-5

Fig. 08 - Booster Pump Hookup .......................................................................B-5

Fig. 09 - Sample Cooler/Water Sampling ........................................................B-5

Fig. 10 - Optional Sparger Tube–Water Heating .............................................B-5

25–75 bhp Feedwater Skid Option

Fig. 01 - Vertical Hotwell

Fig. 02 - Water Softener Plumbing Hookup

Fig. 1 - Vertical Hotwell

Table 11 UH40252 Hotwell and Base-Vertical, 50 bhp

2 0030484 Valve, Ball, 1 1/2 in.

0030485 Valve, Ball, 2 in.

1

2

Fig. 2 - Water Softener Plumbing Hookup

Table 21 0040723 Water Softener, 30,000 grain, EFC-30-1-F

0040724 Water Softener, 60,000 grain, EFC-60-1-F

0040841 Water Softener, 90,000 grain, EFC-90-1-F

2 0040829 Valve, Solenoid, 2 way, 1/2 in. (Make-up Water Valve)

3 0029872 Valve, Ball, 1 in., 1000 psi

0033793 Valve, Ball, 3/4 in., 1000 psi

4 0037877 Valve, Ball, 1/4 in., 1000 psi

5 0029872 Valve, Ball, 1 in., 1000 psi

6 0016389 Gauge, Pressure, 2 in.

7 0003440 Valve, Ball, 1/4 in.

8 0033793 Valve, Ball, 3/4 in., 1000 psi

* 9 0038557 Meter, Flow, pulse, 0.44 – 52 gpm (optional equipment)

0043721 Meter, Flow, pulse, 0.22 – 22 gpm (optional equipment)

1

2

3

8

4

5

6

9 *

*Optional Equipment

7

FeedwtrSkid_VHtwl_25-75bhp_a.fm B-2 11/26/2018


Fig. 03 - Water Level Indication and Control

Fig. 04 - Water Temperature and Blowdown Tank Hookup

Fig. 3 - Water Level Indication and Control

0038263 - Probe,Conductance, 4 1/2 in.

0038294 - Sensor,Water Level

0036203 - Valve,Gauge Glass, Top

0037074 - Gauge,

0036204 - Valve,Gauge Glass,Bottom

Glass, Level

0037744 - Receptacle,3-prong, GFCI

0039202 -Control,

Liquid Level

0038581 - Box,Receptacle,

Rain-tight

0038581 - Box,Receptacle,Rain-tight

Fig. 4 - Water Temperature and Blowdown Tank Hookup

Table 31 0019567 Thermometer, 3 1/2 in., 300° F

2 0038293 Switch, Temperature, 100° – 300° F

3 0033793 Valve, Ball, 3/4 in., 1000 psi (Hotwell Drain Valve)

4 0017096 Valve, Regulator, Temperature, 3/4 in.

5 0033793 Valve, Ball, 3/4 in., 1000 psi

6 UH35841 Tank Assembly, Blowdown, 11 gal., 25 – 200 bhp

0037944 Tank Assembly, Blowdown, 3.5 ft3, CRN, Model GF-1830

3

12

6

5

4

11/26/2018 B-3 FeedwtrSkid_VHtwl_25-75bhp_a.fm


Fig. 05 - Sparger Tubes–Water Heating

Fig. 06 - TDS Control System—Equipment Option

Fig. 5 - Sparger Tubes–Water Heating

2

1

2

1

3 4 5

6

Table 41 UH32041 Tube Assembly, Sparger

2 0029882 Valve, Check, 1 in.

3 0020001 Valve, Globe, 1/2 in.

4 0043175 Valve, Check, 1/2 in.

5 0038297 Valve, Solenoid, 1/2 in.

* 6 0038194 Valve, Ball, 1/2 in. (Gravity Fill Hookup)

7 0019929 Valve, Globe, 3/4 in.

*

*Equipment Option

Fig. 6 - TDS Control System—Equipment Option

2

1

5

67

5

3

4

Table 51 0051007 Controller, TDS, WBLW100HN-A

2 0038172 Pump, Chemical, 14 gpd, EZB11D1-PEM

0038536 Pump, Chemical, 14 gpd, EWB11Y1-PCM

0038568 Pump, Chemical, 50 gpd, EWN-C21PEURM

3 0038194 Valve, Ball, 1/2 in.

4 0030227 Coupling, 1/2 in.

5 0025603 Valve, Globe, 3/4 in.

6 0038323 Valve, Solenoid, 3/4 in.

7 UH29616 Valve, Dump, Ball, TDS, 3/4 in.

8 0033793 Valve, Ball, 3/4 in., stainless steel

8

SENSOR PROBE-TDS CONTROLLER



Fig. 07 - Circulation Pump Hookup - TDS System Fig. 08 - Booster Pump Hookup

Fig. 09 - Sample Cooler/Water Sampling Fig. 10 - Optional Sparger Tube–Water Heating

Fig. 7 - TDS System Circulation Pump for Dual Unit, Single Booster Pump Installation

Table 61 0033793 Valve, Ball, 3/4 in., stainless steel

2 0037877 Valve, Ball, 1/4 in., stainless steel

3 0030485 Valve, Ball, 2 in., stainless steel

4 0043398 Valve, 3 way, 1/4 in., stainless steel

5 0044809 Pump, Water Circulation

5

3

2

SENSOR PROBE-TDS CONTROLLER

1

4

Fig. 8 - Booster Pump Hookup

6

7

89

9

3

41

2

3

5

Table 71 0037864 Gauge, Pressure, 2 1/2 in., 0 – 60 psi

2 0030491 Tube, Syphon, Loop, 1/4 in.

3 0003440 Valve, Ball, 1/4 in, FPT / MPT

4 0030484 Valve, Ball, 1 1/2 in., 1000 psi

0030486 Valve, Ball, 2 1/2 in, 1000 psi

5 0033095 Pump, Centrifugal, 1/2 hp, 230 / 460 v

0037910 Pump, Centrifugal, 1/2 hp, 575 v

0044875 Pump, Centrifugal, 3/4 hp, 575 v

6 0030485 Valve, Ball, 2 in., 1000 psi

7 0017144 Strainer, Y, 1 1/4 in.

8 0029885 Valve, Check, 1/4 in.

9 0037877 Valve, Ball, 1/4 in.

Fig. 9 - Sample Cooler/Water Sampling

0037877 - Valve,Ball, 1/4 in.

0037877 - Valve,Ball, 1/4 in.

0059349 -Sample Cooler

MUNICIPALWATERINLET

TOBLOWDOWN

TANK

Fig. 10 - Optional Sparger Tube–Water Heating

2

1

Table 81 UH32041 Tube Assembly, Sparger

2 0029882 Valve, Check, 2 in.


R027906A-2018.10.22

Refer to instruction manual for maintenance procedure details.It is owner's responsibility to ensure proper care and maintenance of their unit(s).

Service work and replaced parts may be noted on far left column and on the reverse side.Some of the items described may not apply to each model.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

1

2

3

4

5

Pump Relief Valve (Semi-annually)

MONTH / YEAR:

CHEMICAL PUMP RATE

(STROKE/SPEED)pH

(8.0 MINIMUM)CHEMICAL PUMP RATE

(STROKE/SPEED)

CONDENSATE

ANNUAL / SEMI-ANNUAL (INDICATE DATES)

OPERATING PRESSURE (PSI)

COIL FEED PRESSURE (PSI) HARDNESSDATE

STEAM TRAP PRESSURE (PSI)

STACK

TEMPERATURE (oF)

TDS(3,000 - 6,000)

PPM

FEEDWATER TREATMENT

SULFITE(50 - 100)

PPMpH

(10.5 - 12.5)

PERIODIC MAINTENANCE LOG

WALK-AROUND INSPECTION

MODEL:

SERIAL NUMBER:

TIME

CUMULATIVE OPERATING

HOURS

MONTHLY

WHILE UNIT IS SHUT DOWN

WHILE UNIT IS OPERATING

TEMPERATURE CONTROLLERS

WEEKLYCHECK BELT

TENSION

PARTIALLY DRAIN HOTWELL

TANKWATER METER

(GAL.)WEEKLY RUN

(HOURS) VOLUTE PRESSURE

(w.c.i.)

ATS SETTING

(oF)

MTLC1

(oF)

MTLC2

(oF)

INTAKE SURGE CHAMBER /DISCHARGE SNUBBER

DRAIN AND FLUSH Safety Relief Valve(s)

Packaged Burner Unit (-Weishaupt-)PUMP HEADS HOTWELL

REPLACED: Pump Check-valves Seats and Discs

Feedwater Discharge Check-Valve Seat and Disc

Pump Diaphragms and Washers

Pump Surge Chamber / Intake Snubber

TESTED:

R027906A-2018.10.22

Steam Generator Instruction Manual


17477 Hurley Street, City of Industry, California 91744-5106, USA

Email: [email protected]

Internet: www.claytonindustries.com

Phone: +1 (626) 435-1200 Fax: +1 (626) 435-0180

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