R024138b.C9035 E1004

Cover
Steam Generator
Instruction Manual
MODEL E-1004
PLC • Siemens LMV Burner Control
CLAYTON INDUSTRIES
City of Industry, California
Since 1930
R024138B.C9035
04-2016
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 SUMMARY
DANGEROUS VOLTAGES
Exercise caution when working inside electronics control box. Coming in contact with high
voltages can injure or result in death.
FIRE AND EXPLOSION DANGER

Keep ALL flammable rags, towels, paper, solvents, scrap wood, and other such debris 6
feet (1.5 meters) or more away from steam generator. When performing maintenance on
the steam generator’s fuel system, make sure main fuel supply valves are tightly closed.
Immediately, wipe up all fuel oil spills.
HIGH PRESSURE DANGER

psi Always verify all steam systems are relieved of pressure before performing plumbing
( kPa )
system, heating system, or pressure vessel system repair and maintenance.
oF oC
HIGH TEMPERATURES
Steam generator heating unit, steam separator vessel, and steam pipe surfaces are HOT.
Allow steam/boiler system to cool before performing repairs or maintenance.
Observe all Caution labels and Warning labels affixed to the steam generator unit and all its components.
Failure to observe these Caution and Warning labels may lead to serious personal injury and to damage of
the equipment.
Observe all Caution and Warning notes appearing throughout this Instruction Manual.
All operation and maintenance personnel are fully responsible for understanding and abiding by the
CAUTIONS and WARNINGS affixed on the equipment and listed throughout this Instruction Manual.
CAUTION
CAUTION safety labels provide instructions for proper handling of equipment to prevent damage or
destruction of the equipment or loss of operating effectiveness.
WARNING
WARNING safety labels provide information on potentially hazardous conditions that may cause bodily injury
if precautions are not taken while working on the equipment.
• Disconnect main power 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.
Personnel must become thoroughly familiar with all aspects of safety and proper operating and maintenance
procedures before attempting to operate or maintain this equipment.
i
IMPORTANT INFORMATION
PLEASE READ THIS PAGE CAREFULLY
1. READ THIS INSTRUCTION MANUAL AND THE INSTALLATION MANUAL CAREFULLY BEFORE
INSTALLING, 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 com-
bustible 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 Equipment,” 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.
ii
ASME Conformance Statement
A Clayton Steam Generator is manufactured in conformance with the ASME (American

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 manufacturing.
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 requirements
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 INDUSTRIES
17477 Hurley Street
City of Industry, CA 91744-5106
USA
Phone: +1 (626) 435-1200
Fax: +1 (626) 435-0180
Internet: www.claytonindustries.com
Email: sales@claytonindustries.com
© Copyright 2011, 2012, 2013 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 SERVICE

UNITED STATES OFFICES
ATLANTA • CHICAGO • CINCINNATI • CLEVELAND • DALLAS • DETROIT
KANSAS CITY • LOS ANGELES • NEW ENGLAND • NEW JERSEY
NORTHERN CALIFORNIA
LICENSEES, AFFILIATES, SALES and SERVICE DISTRIBUTORS WORLDWIDE

Table of Contents
Safety Summary ...................................................................................................................................................... i

Important Information ........................................................................................................................................... ii
ASME Conformance Statement ........................................................................................................................... iii
Section 1 Introduction ....................................................................................................................... 1-1

1.1 General ....................................................................................................................... 1-1
1.2 Feedwater Pump ......................................................................................................... 1-1
1.3 Installation Instructions ................................................................................................ 1-2
1.4 Feedwater Treatment .................................................................................................. 1-2
Section 2 Description ........................................................................................................................ 2-1

2.1 General ....................................................................................................................... 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 Hot-well Tank ...................................................................................................... 2-2
2.2.4 Heating Coil ........................................................................................................ 2-3
2.2.5 Steam Separator ................................................................................................. 2-4
2.2.6 Separator Level Control System .......................................................................... 2-4
2.3 Fuel System - Gas-fired Machines ............................................................................... 2-5
2.4 Fuel System - Oil-fired Machines ................................................................................. 2-6
2.5 Automatic Burner Modulation ....................................................................................... 2-7
2.6 Burner Manifold - Gas- or Oil-fired Machines ............................................................... 2-7
2.7 Description - Electrical Devices ................................................................................... 2-8
2.7.1 Audible Alarm (AA) ............................................................................................. 2-8
2.7.2 Atomizing Air Pressure Switch (AAPS) - oil operation only .................................. 2-8
2.7.3 Actuators ............................................................................................................ 2-8
2.7.4 Air Pressure Switch (APS) .................................................................................. 2-8
2.7.5 Air Relief Solenoid Valve (ARSV) ........................................................................ 2-9
2.7.6 Air Solenoid Valve (ASV) - oil operation only ....................................................... 2-9
2.7.7 Auxiliary Thermostat Switch (ATS) ...................................................................... 2-9
2.7.8 Auxiliary Relay (AR) - (optional equipment) ......................................................... 2-9
2.7.9 Bleed Valve (BV) ................................................................................................ 2-9
2.7.10 Cooling Water Solenoid Valve (Special Applications) ........................................... 2-9
2.7.11 Electrical Interlock Switch (EIS) .......................................................................... 2-9
2.7.12 Electronic Safety Control (ESC) ....................................................................... 2-10
2.7.13 Feedwater Pressure Switch (NPSH) (optional feedwater pump only) ................. 2-10
2.7.14 Fuel Pressure Switch (FPS) - oil operation only ................................................ 2-10
2.7.15 Galvanic Isolation Relay (GIR) .......................................................................... 2-10
v
2.7.16 Group Motor Protectors (GMP) ..........................................................................2-11
2.7.17 Gas Pressure Switch - High (GPSH) ..................................................................2-11
2.7.18 Gas Pressure Switch - Low (GPSL) ...................................................................2-11
2.7.19 Ignition Electrode (IE) ........................................................................................2-11
2.7.20 Ignition Transformer (IT) ....................................................................................2-11
2.7.21 Limit Pressure Switch (LPS) ..............................................................................2-11
2.7.22 Magnetic Controller (M1) ...................................................................................2-11
2.7.23 Magnetic Controller (M2) .................................................................................. 2-12
2.7.24 Main Gas Valve (MGV) ..................................................................................... 2-12
2.7.25 Main Temperature Limit Controllers (MTLC) ...................................................... 2-12
2.7.26 Motor - Blower System ....................................................................................... 2-12
2.7.27 Main Oil Valves (MOV) ...................................................................................... 2-12
2.7.28 Programmable Logic Controller (PLC) ............................................................... 2-12
2.7.29 Pilot Valve (PV) ................................................................................................ 2-13
2.7.30 Power Supply ................................................................................................... 2-13
2.7.31 Pushbuttons (STOP/START) ............................................................................. 2-13
2.7.32 Remote Stop Switch (RSS) (customer option) ................................................... 2-13
2.7.33 Safety Relays (SR1/SR2) .................................................................................. 2-13
2.7.34 Safety Shutoff Gas Valve (SSGV) - gas operation only ...................................... 2-13
2.7.35 Safety Shutoff Oil Valve (SSOV) - oil operation only .......................................... 2-13
2.7.36 Stepdown Transformer (115 VAC) ..................................................................... 2-13
2.7.37 IR (infrared) Flame Scanner .............................................................................. 2-14
2.7.38 Variable Speed Drive (VSD) .............................................................................. 2-14
Section 3 Initial Firing ....................................................................................................................... 3-1

3.1 Before Firing ............................................................................................................... 3-1
3.2 Conditioning Of New Installations ................................................................................ 3-2
3.2.1 Procedure ........................................................................................................... 3-2
Section 4 Operating Instructions ...................................................................................................... 4-1

4.1 Operating Sequence .................................................................................................... 4-1
4.2 Before Starting ............................................................................................................ 4-3
4.3 Filling Procedure ......................................................................................................... 4-4
4.4 Initial Starting .............................................................................................................. 4-4
4.5 Shutdown Procedures ................................................................................................. 4-7
4.5.1 Wet Shutdown–Overnight Only .......................................................................... 4-7
4.5.2 Wet Shutdown 1 ................................................................................................. 4-7
4.5.3 Wet Shutdown Procedure 1 ................................................................................. 4-7
4.5.4 Wet Shutdown Notes .......................................................................................... 4-9
4.5.5 Restart After Wet Shutdown ................................................................................ 4-9
4.5.6 Extended Shutdown (Dry Shutdown/Blowdown) .................................................. 4-9
4.6 Freezing Precautions and Extended Shutdown .......................................................... 4-10
4.7 Intermittent Fill Cycle ..................................................................................................4-11
Section 5 PLC / OIU Operating Instructions ....................................................................................... 5-1

5.1 Programmable Logic Controller (PLC) ......................................................................... 5-1
5.2 OIU (Operator Interface Unit) ...................................................................................... 5-2
5.2.1 Using The OIU .................................................................................................... 5-2
vi
Section 6 Periodic Maintenance ........................................................................................................ 6-1
6.1 General ....................................................................................................................... 6-1
6.2 Feedwater Treatment .................................................................................................. 6-1
6.3 Conditioning Of New Installations ................................................................................ 6-1
6.4 Daily Service ............................................................................................................... 6-1
6.4.1 Record Operating / Steam Pressure ..................................................................... 6-1
6.4.2 Test and Record Feedwater ................................................................................ 6-2
6.4.3 Manual Blowdown ............................................................................................... 6-2
6.4.4 Soot Blow - Oil-fired Machines Only .................................................................... 6-2
6.4.5 Record Pulsation Dampener Pressure ................................................................ 6-3
6.4.6 Walk Around Inspection ..................................................................................... 6-4
6.5 Weekly Service ........................................................................................................... 6-4
6.5.1 Fuel Filter Element ............................................................................................. 6-4
6.5.2 Hot-well Tank ...................................................................................................... 6-4
6.5.3 Blower Belts and Pulleys .................................................................................... 6-4
6.6 Monthly Service ........................................................................................................... 6-4
6.6.1 Check Coil Feed Pressure .................................................................................. 6-4
6.6.2 Check Volute Pressure ....................................................................................... 6-5
6.6.3 Flush Feedwater Pump ....................................................................................... 6-5
6.6.4 Check Dual Element Thermocouple Sensor ........................................................ 6-5
6.6.5 Check Main Temperature Limit Controllers (MTLC) ............................................. 6-6
6.6.6 Clean Strainers ................................................................................................... 6-8
6.6.7 Drain and Flush Hot-well Tank ............................................................................ 6-8
6.6.8 Clean and Adjust Burner ..................................................................................... 6-9
6.6.9 Lubricate Blower Wheel Bearings ....................................................................... 6-9
6.7 Annual Service .......................................................................................................... 6-10
6.7.1 Replace Oil Burner Nozzles .............................................................................. 6-10
6.7.2 Lubricate Bearings ............................................................................................ 6-10
6.7.3 Test Safety Relief Valves .................................................................................. 6-10
6.7.4 Gas Valve Leak Testing .................................................................................... 6-10
6.8 Lubrication .................................................................................................................6-11
6.8.1 Lubricate Electric Motor .....................................................................................6-11
Section 7 Component Maintenance ................................................................................................... 7-1

7.1 Feedwater Pump ......................................................................................................... 7-1
7.2 Heating Coil Scale Removal ........................................................................................ 7-1
7.2.1 Setting Up Machine Descaling ............................................................................ 7-1
7.2.2 Descaling The Machine ...................................................................................... 7-3
7.2.3 After Descaling Is Complete ................................................................................ 7-4
7.3 Heating Coil Replacement ........................................................................................... 7-5
7.3.1 Heating Coil Removal ......................................................................................... 7-5
7.3.2 Burner Base Insulation Replacement .................................................................. 7-6
7.3.3 Heating Coil Repair and Installation ...................................................................7-11
7.3.4 Coil Water Washing ...........................................................................................7-11
7.4 Net Positive Suction Head (NPSH) Switch ................................................................. 7-12
7.5 Check And Set ATS .................................................................................................. 7-12
7.5.1 Limit Stop Adjustment ....................................................................................... 7-12
vii
7.6 MTLC Check ............................................................................................................. 7-12
7.7 LPS Adjustment ........................................................................................................ 7-13
7.7.1 Adjustment ....................................................................................................... 7-13
7.8 APS Adjustment ........................................................................................................ 7-13
7.9 Air Damper Adjustment .............................................................................................. 7-13
7.10 Gas Pressure Regulator ............................................................................................ 7-14
7.10.1 Preliminary Adjustment ..................................................................................... 7-14
7.10.2 Final Adjustment ............................................................................................... 7-14
7.11 Gas Pressure Switches ............................................................................................. 7-14
7.12 Gas Pilot Pressure Regulator Adjustment .................................................................. 7-15
7.13 FPR (Fuel Pressure Regulator) Adjustment - Oil-fired Machines ................................ 7-15
7.14 FPS Adjustment - Oil-fired Machines ......................................................................... 7-16
7.15 Modulating Oil Control Valve Adjustment ................................................................... 7-16
7.16 Oil Burner Manifold ................................................................................................... 7-17
7.16.1 Cleaning and Adjustment .................................................................................. 7-17
7.16.2 Electrode Adjustment - Oil-fired Machines ......................................................... 7-17
7.17 AAPS Adjustment ...................................................................................................... 7-19
7.18 Gas Burner Manifold .................................................................................................. 7-19
7.18.1 Cleaning ........................................................................................................... 7-19
7.18.2 Electrode Adjustment ........................................................................................ 7-20
7.19 Blower Motor Belt Replacement ................................................................................. 7-21
7.19.1 Removal ........................................................................................................... 7-21
7.19.2 Assembly .......................................................................................................... 7-21
Section 8 Troubleshooting ................................................................................................................ 8-1

8.1 Annunciator System .................................................................................................... 8-1
8.2 Water System .............................................................................................................. 8-3
8.3 Fuel System - Gas-fired Machines ............................................................................... 8-3
8.4 Fuel System - Oil-fired ................................................................................................. 8-4
8.5 Electrical System ......................................................................................................... 8-6
8.6 Burner Safety Controls ................................................................................................ 8-8
Appendix A - Supplemental Instructions ......................................................................................... A-1

Auxiliary Pressure Control ................................................................................................... A-3
Heating Coil Water Washing ................................................................................................ A-7
Automatic Remote START/STOP ...................................................................................... A-11
Light Oil Pilot .................................................................................................................... A-15
Power Loss Timer ............................................................................................................. A-21
Stack Damper Control With PLC ........................................................................................ A-23
Feedwater Valve and Strainer Kit ....................................................................................... A-25
Appendix B - Reference Tables and Charts ..................................................................................... B-1

Specifications ...................................................................................................................... B-3
Reference Values ................................................................................................................ B-4
Main Temperature Limit Controllers (MTLC) ......................................................................... B-5
ABB ACS550-U1 ................................................................................................................. B-6
viii
Appendix C - Parts Catalog .............................................................................................................. C-1
Fig. 1A - Heating Unit Assembly .......................................................................................... C-4
Fig. 1B - Heating Unit Feedwater Piping Hookup ................................................................. C-7
Fig. 2A - Steam Separator and Level Control ....................................................................... C-8
Fig. 2B - Pressure Manifold and ATS ................................................................................. C-10
Fig. 3 - Feedwater Pump Hookup ...................................................................................... C-11
Fig. 8 - Gas System .......................................................................................................... C-12
Fig. 9 - Fuel Oil System ..................................................................................................... C-13
Fig. 10 - Pilot Gas Hookup ................................................................................................ C-15
Fig. 11A - Burner Manifold–Gas ......................................................................................... C-16
Fig. 11B - Burner Manifold–Oil & Oil-Gas ........................................................................... C-18
Fig. 12A - Air Blower Hookup ............................................................................................ C-20
Fig. 12B - Air Duct and Damper ......................................................................................... C-22
Fig. 13A - Electrical Control Box-Right Front Door ............................................................. C-24
Fig. 13B - Electrical Control Box-Left Compartment and Blower VSD ................................. C-25
Fig. 13C - Electrical Control Box-Right Compartment ......................................................... C-27
Fig. 14 - Gravity Fill–Elevated Receiver ............................................................................. C-29
Fig. 15 - Soot Blower Option ............................................................................................. C-30
Fig. 19 - Separator Discharge Valve Kit (Option) ................................................................ C-31
Fig. 21 - Valve Option Kit Hookup ...................................................................................... C-32
Appendix D - KSB Multitec Pump IOM ............................................................................................. D-1
Appendix E - Delta Electronics OIU ................................................................................................... E-1
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x
Section I INTRODUCTION
1.1 GENERAL
This manual contains instructions for operating and maintaining a Clayton Steam Generator. Recom-
mendations given herein result from many years of experience in the manufacture and service of this type of
equipment. The efficiency and service of your steam generator will depend upon strict adherence to these
instructions. It is important that the operator study all sections of this manual to gain a working knowledge of
the operation and maintenance requirements of the Clayton Steam Generator.
The information contained in this manual applies to gas-fired, oil-fired, and gas/oil-fired machines.
Section II of this manual acquaints you with the machine; this section provides an overview and descriptions
of a machine’s systems, such as the water supply and fuel system. The machine overview includes a discus-
sion on the theory of operation of a Clayton Steam Generator.
Before a new machine is placed into service, the residual mill scale and other contaminants developed
during manufacturing must be purged from inside the heating coil. This initial firing procedure and other pre-
startup requirements are discussed in Section III. If this is your first experience with a Clayton Steam Gener-
ator, then you should familiarize yourself with its controls by reviewing Section IV and Section V. This sec-
tion discusses machine startup, filling, wet shutdown, dry shutdown, and introduces the Operator Interface
Unit (OIU).
Section VI discusses the scheduled maintenance requirements that will help maintain the efficiency
and reliability, increase the operating life, and minimize the down-time of the machine. Section VII contain
basic procedures for maintaining, repairing, or replacing components and assemblies on the machine, such as
replacing the heating coil and maintaining the burner manifold. Section VIII provides troubleshooting proce-
dures for some of the more common problems that may occur during the machine’s operation.
The appendices at the end of this manual contain supplemental instructions, reference tables and
charts, and the parts catalog, which is used for ordering replacement parts. The parts catalog contains illustra-
tions of steam generator assemblies and their corresponding parts list.
1.2 FEEDWATER PUMP
CAUTION
DO NOT RUN PUMP DRY! Potential pump damage may occur if the pump is
allowed to operate without water.
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1-2 Steam Generator Instruction Manual
The Clayton E1004-series steam generator uses a multi-stage centrifugal pump to provide the
required feedwater capacity and input pressures for steam generation. Special start-up, operating, and mainte-
nance procedures, must be observed to ensure reliable, long-term operation of this feedwater pump. A manu-
facturer’s (OEM) operation and maintenance manual for this pump is provided in Appendix D of this
manual. ALL PERSONNEL RESPONSIBLE FOR OPERATING OR PERFORMING MAINTENANCE
ON THE STEAM GENERATOR SHOULD ALSO REVIEW THIS PUMP MANUAL PRIOR TO EQUIP-
MENT START-UP.
1.3 INSTALLATION INSTRUCTIONS

A separate installation manual (part number: R016600) is provided with every Clayton Steam Gener-
ator. This manual provides general machine dimensions, site preparation requirements, plan installation
drawings, electrical drawings, and other useful information for installing a Clayton Steam Generator. After
the machine installation has been completed, retain this manual for reference in the event any modifications
to the installation becomes necessary.
1.4 FEEDWATER TREATMENT

Proper and adequate feedwater treatment must be used from the time your Clayton steam generator is
commissioned. Suitable water treatment equipment should be installed before placing the steam generator
into service. Daily treatment and care of the feedwater supply is the sole responsibility of the user.
Continuous feedwater treatment is required at all times, even during the periods of wet lay-up shut-
downs. Water testing must be conducted daily, even during the periods of wet lay-up shutdowns.
A separate feedwater treatment manual (part number: R015216) is provided with every Clayton
Steam Generator. This manual covers the available water treatment packages from Clayton, general guide-
lines on scheduled feedwater maintenance, and the appropriate chemicals required for treatment to minimize
the down time of your machine.
Sect01_1004_b.fm 10/21/2013
Section II DESCRIPTION
2.1 GENERAL
The Clayton steam generator will deliver its rated output of 99 percent quality steam (containing less
than one percent moisture) per hour from 60° F (16° C) feedwater. It will develop its full rated steam pressure
within five minutes from a filled coil, cold start condition.
Standard equipment includes safety devices for protection against water failure, burner failure, exces-
sive pressure and electrical overload. Automatic controls regulate the flow of feedwater and modulate the
burner in accordance with steam demand.
2.2 WATER AND STEAM SYSTEM

(See Fig. 2-1.)
2.2.1 Flow
Makeup water, chemicals, and process condensate returns blend in the hot-well tank and then flow,
either by gravity or by booster pump, into the feedwater pump. The chemically treated feedwater is delivered
directly into the heating coil, flowing through the spiral single-passage section of the coil in a direction oppo-
site that of the combustion gases (counterflow principle). As the steam-water mixture leaves the generating
section, it passes through the helically wound lower water wall section, into the separating nozzle of the
steam separator. Steam is delivered from the discharge outlet of the steam separator. The surplus liquid is
returned to the hot-well tank through the automatic dump system on the separator.
2.2.2 Feedwater Pump

Feedwater is delivered to the heating unit by a high pressure, multi-stage, centrifugal pump. This
pump ensures a wet-tube heating coil by delivering the required volume of water to the heating coil under all
load conditions. The pump is protected against over-pressure by a pressure relief valve.
CAUTION
DO NOT RUN PUMP DRY! Pump can be damaged if it is allowed to operate without
water. Review pump start-up, operating, and maintenance instructions in Appendix D of
the manual.
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Fig. 2-1 Water and Steam System (typical)
2.2.3 Hot-well Tank

The primary purpose of the hot well tank is for expelling oxygen from the feedwater and blending
sufficient anti-scaling and anti-corrosion chemicals with the feedwater. Soft water enters the hot-well tank
where it mixes with the customer’s process condensate, if any, and return separator water. For optimum per-
formance, the hot-well tank temperature should be maintained between 190° –200° F (88° –93° C). This will
reduce the oxygen content to 1–2 ppm. Furthermore, the hot-well tank vent should always be vertical to
facilitate oxygen escape.
The softened make-up water is introduced through a level control valve, which controls the rate of
make-up in direct proportion to the system requirement. The make-up is introduced below the water surface
in a manner that minimizes the entrainment of air. The hot-well tank is heated by steam injection and is con-
trolled by a temperature control valve. The steam, process condensate, and return separator water are intro-
duced through a steam sparger inducer tube.
Sect02_1004_c.fm 03/31/2016
Section II - Description 2-3
There are primarily three hot-well tank systems offered with Clayton steam generators: open (hot-
well)/atmospheric, deaerator, and semi-closed.
2.2.4 Heating Coil

The heating coil consists of a series of
carbon steel spirally wound tube sections
(commonly referred to as pancakes or pancake
sections). The heating coil is constructed in a
single-pass, mono-tube design. A counterflow
method of fluid circulation, at controlled
velocities, is used to provide maximum heat
transfer. The combustion gases flow upward
around the tubes of the heating coil while the
fluid inside the tubes is circulating in a down-
ward direction. The heating coil is mounted to
allow free expansion.
2.2.4.1 Primary main temperature limit
Fig. 2-2 Thermocouple assembly
controller (MTLC2)
This over-temperature safety control-
ler uses one half of the dual element thermo-
couple sensor shown below in Fig. 2-2. The safety controller has a fixed trip-point1, which is set slightly
lower (usually 25° F {14° C}) than that of the secondary main temperature controller. It will interrupt the
motor and burner control circuits on a severe over-temperature condition. It must be manually reset before
normal operation can be resumed. A “STEAM COIL TEMP. -OVER LIMIT-” safety shutdown condition
will be indicated on the OIU, and an audible alarm will sound, in the event of an MTLC2 trip condition.
2.2.4.2 Secondary main temperature limit controller (MTLC1)
This redundant over-temperature safety controller uses the other half of the dual element thermocou-
ple sensor described above under primary main temperature controller (MTLC2). This controller has a fixed
trip-point1, which is slightly higher than that of the primary main temperature controller. It also will interrupt
the motor and burner control circuits on a severe over-temperature condition. As with MTLC2, it must also
be manually reset before normal operation can be resumed. A “STEAM COIL TEMP. -OVER LIMIT-”
safety shutdown condition will display on the OIU and an audible alarm will sound, in the event of an
MTLC1 trip condition.
2.2.4.3 Thermocouple sensor
MTLC2 and MTLC1 each use one-half of a dual-element thermocouple sensor. The sensor is inserted
in a sleeve and spring loaded to contact the base of the sleeve. The sleeve is inserted traversely into the hot-
test section of the heating coil. The sleeve end is flush against the inner wall of the coil. (See Fig. 2-2.)
1
See the Table of Reference Values in Appendix B for MTLC trip-point value.
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2.2.5 Steam Separator

The steam separator is designed to expel excess water from the steam-water mixture discharged from
the heating coil. The steam-water mixture enters the separator at a high velocity and passes through the noz-
zle vanes inside the separator, which causes the steam-water mixture to swirl. The centrifugal action of the
swirling forces the heavier water in the steam-water mixture to the separator wall, where the water then cas-
cades to the bottom of the separator. What results is “dry” steam being discharged from the steam separator
outlet (A, Fig. 2-1).
An Automatic Dump Valve (ADV) opens to drain excess water from the separator when the high
water level sensor on the separator is activated. The excess separator water is recirculated back to the hot well
tank.
A dial thermometer (optional) mounted on the steam separator indicates the steam temperature.
Under normal operating conditions the indicated temperature should be close to the saturation temperature
relative to the pressure in the separator (see Table 2-1, Pressure - Temperature Table). A substantial tempera-
ture rise above the saturation temperature for the corresponding operating pressure will actuate the ATS,
indicating a water shortage condition.
2.2.5.1 Auxiliary thermostat switch (ATS)
The Auxiliary Thermostat Switch (ATS) functions as an additional over-temperature control device.
It responds to an increase in steam temperature above the saturation temperature for the specific steam sep-
arator pressure. When actuated, the motor and burner control circuits are interrupted and requires a manual
reset. A “STEAM SEPARATOR TEMP -OVER LIMIT-” safety shut-down alarm is displayed on the OIU
and an audible alarm sounds (similar to the MTLC’s). The sensing bulb for the ATS is located in the upper
body of the steam separator.
IMPORTANT
The cause of any “thermostat low water” condition must be determined and effectively
corrected prior to re-initializing the burner control circuit. An adequate “cool down” pe-
riod must be allowed to prevent thermal stress of the heating coil.
2.2.6 Separator Level Control System

The separator level control system maintains proper water levels inside the steam separator and trig-
gers an alarm if the water levels exceed their safety limit. A level indicator provides a visual indication of the
water levels inside the separator. A level transmitter, attached to the float chamber, sends 4-20 mA signal to
the PLC for processing. The PLC will signal the automatic dump valve to open or close, accordingly, to
maintain water levels within the preset safety limits.
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Table 2-1: Pressure-Temperature

GAUGE GAUGE GAUGE GAUGE GAUGE GAUGE
PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE
PSIG TEMP F kPa TEMP C PSIG TEMP F kPa TEMP C PSIG TEMP F 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
2.3 FUEL SYSTEM - GAS-FIRED MACHINES

(See Fig. 2-3.)
Gas enters the fuel train through the gas pressure regulator (optional equipment). It then flows
through the safety shut-off gas valve (SSGV), main gas valve (MGV), main gas cock and modulating gas
control valve. It enters the combustion chamber through the gas burner ring. The gas pressure regulator con-
trol line is connected upstream of the safety shut-off gas valve. This arrangement allows the regulator to
maintain a stable gas pressure to the modulating gas control valve. A vent valve is located between the SSGV
and MGV.
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Fig. 2-3 Flow Diagram - Fuel System (gas-fired machines)
2.4 FUEL SYSTEM - OIL-FIRED MACHINES

(See Fig. 2-4.)
Fuel is delivered to the forced draft burner under pressure. Maximum fuel pressure is governed by an
adjustable fuel pressure regulator. With the fuel control valve closed, all fuel is by-passed back to the fuel
tank and there is no fuel pressure at the burner. After a manual start, burner operation is fully automatic and
all controls are arranged to “fail-safe.” Flame failure will cause automatic fuel shut-off within two seconds
after failure and, if flame is not established within ten seconds thereafter, the Electronic Safety Control (ESC)
will “lock-out” the burner, requiring a manual reset of the combustion control. Clean, dry compressed air is
used as the fuel oil atomizing medium.
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Fig. 2-4 Flow Diagram - Fuel System (Oil-fired machines)
2.5 AUTOMATIC BURNER MODULATION

Automatic burner modulation prevents frequent “on-off” cycling of the burner and provides stable
operation during periods of light loads. This is accomplished by the PLC’s modulating pressure setting. Its
selectable setpoint allows for convenient selection of pressure ranges between minimum and maximum out-
put. When the signal is given to modulate, an actuator motor operates the air damper and the fuel control
valve (gas or oil), restricting the burner combustion air and fuel supply, to maintain the proper air-fuel ratio.
The Variable Speed Drive (VSD) is linked with the PLC to maintain the proper water supply for the given
firing rate. It is this automatic water, fuel and air ratio control that enables completely automatic operation of
the machine.
2.6 BURNER MANIFOLD - GAS- OR OIL-FIRED MACHINES

Air entering the burner volute from the blower is centrifugally directed at high velocity to the burner
manifold. It blends with fuel from the burner and is ignited by a pilot flame. On gas-fired machines, a gas
burner ring surrounds the pilot tube and cone assembly for the best distribution of gas. On oil-fired machines,
an air atomizing nozzle is used to ensure the best burner operation over the entire modulating range. The ESC
must detect the presence of a pilot flame before the burner controls are energized. After the burner starts, the
main flame, either gas or oil, is monitored by the ESC. The ESC uses an IR (infrared) scanner for flame
detection.
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NOTE
On gas-oil combination machines, set the machine for gas operation through the ESC dis-
play and operating unit (on the electronics control box door). Close the main oil valve
and disengage the fuel oil pump drive coupling.
CAUTION
Severe damage to the fuel oil pump will result if it is allowed to operate without oil flow.
2.7 DESCRIPTION - ELECTRICAL DEVICES

2.7.1 Audible Alarm (AA)
The alarm horn is mounted to the electrical control box. The horn will sound whenever a safety shut-
down condition occurs. The horn is electrically powered by the PLC. The audible alarm can be reset by push-
ing the STOP button.
NOTE
The operator must note the alarm condition on the PLC display prior to resetting. Once
the alarm is cleared, the alarm condition is erased.
2.7.2 Atomizing Air Pressure Switch (AAPS) - oil operation only

This air-actuated switch is used on all oil-fired machines as a safety device to ensure that atomizing
air delivery from an external supply is adequate and available to the burner. The switch is interlocked in the
fuel oil circuit and will not allow the fuel oil solenoid valves to open unless there is sufficient atomizing air
pressure available. (See the Table of Reference Values in Appendix B for air pressure settings.)
2.7.3 Actuators
The air damper, gas valve damper, and oil control valve are operated by motor actuators. These actu-
ators are part of the ESC system. They provide automatic burner operation through automated control of the
fuel and air supply. The actuators receive control signals from the ESC; this initializes the actuator’s stepper
motor to drive the gas valve damper/oil control valve and air damper(s) to their designated positions. The
actuators receive their required 12 vac power either through the ESC or directly from an external power sup-
ply.
2.7.4 Air Pressure Switch (APS)

Actuated by blower air pressure, the Air Pressure Switch (APS) will open and interrupt the burner
controls if there is insufficient combustion air for operation. An insufficient combustion air condition will
prevent the ESC from activating the fuel control valves.
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2.7.5 Air Relief Solenoid Valve (ARSV)

The ARSV supports the ESC in the APS testing process. This 3-port solenoid valve is installed in-line
between the blower air duct and the APS. When energized, the ARSV relieves pressure to the APS to simu-
late a no-pressure condition. If the APS actuates, this indicates to the ESC that the switch is functioning prop-
erly. If the APS fails to actuate, then the ESC will initiate a burner shutdown. If the APS has failed to actuate,
determine and remedy the cause of the APS malfunction before restarting the machine.
2.7.6 Air Solenoid Valve (ASV) - oil operation only

The air solenoid valve (ASV) controls the flow of atomizing air to the air atomizing burner nozzle. It
is normally closed, electrically energized to open. It shuts off the atomizing air flow during burner off-cycles.
2.7.7 Auxiliary Thermostat Switch (ATS)

See paragraph 2.2.4.4.
2.7.8 Auxiliary Relay (AR) - (optional equipment)

This relay can be used to activate chemical pumps, booster pumps, or other equipment automatically
when the machine is in operation. The relay is mounted in the control box.
2.7.9 Bleed Valve (BV)

This valve functions as a vent valve to bleed the gas, trapped between the safety shutoff gas valve
(SSGV) and the main gas valve (MGV) during burner off-cycles, to atmosphere (plumbed outside building).
This solenoid valve is normally open, energized to close when the safety shutoff and main gas valves are
energized to open, and vice versa.
2.7.10 Cooling Water Solenoid Valve (Special Applications)

This valve controls the water flow through the pump head cooling water jackets. It is located inside
the electrical control box and opens whenever the control circuit is energized. The cooling water solenoid is
used on high feedwater temperature or high steam pressure applications.
2.7.11 Electrical Interlock Switch (EIS)

This door switch will de-energize all control circuit (115 VAC) electrical power in the control box
whenever the door is opened, completely securing the machine. The switch has an over-ride position (pulled
out) that enables troubleshooting or control adjustments while the door is open. The switch will reset itself
whenever the door is closed and the steam generator can be restarted with the START pushbutton.
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2.7.12 Electronic Safety Control (ESC)

The ESC is a microprocessor-based burner man-
agement system designed to control and supervise forced
draft burners. It provides a proven burner purge period
prior to each firing sequence. This control monitors both
pilot and main flames. It cycles automatically each time
the PLC’s operating pressure setpoint is achieved. In the
event of a flame failure during a firing cycle, all fuel
valves are de-energized. The ESC will then lock out and
total burner shutdown will be indicated on the display and
operating unit. Before the burner can be started again, a Esc Enter < Select >
manual reset of the ESC is required.
The ESC has a safety checking circuit that is oper-
ative on each start. If a flame is detected prior to a firing
sequence or during the purge period, the burner controls
will not energize. Total safety shutdown will occur requir-
ing a manual reset of the ESC.
Operating and programming of the ESC, diagnosis
of burner operations, and readouts of ESC settings and
operating states are executed from a display and operating Fig. 2-5 Display and Operating Unit used
unit (Fig. 2-5), which is mounted on the right-hand door to with ESC
the electronics control box. The display and operating unit
features a 4 x 16 character LCD display, 4 silicon user
buttons, and communication ports for external device
interfacing.
2.7.13 Feedwater Pressure Switch (NPSH) (optional feedwater pump only)

The feedwater pressure switch is used to shutdown the machine in case of inadequate NPSH to the
feedwater pump (See the Table of Reference Values in Appendix B.).
2.7.14 Fuel Pressure Switch (FPS) - oil operation only

The fuel pressure switch (FPS) closes, energizing the oil solenoid valves (OSV and SSOV) only when
the fuel pump is operating and sufficient fuel oil pressure is established for burner operation. If the switch
fails to close during the trial-for-ignition period, the ESC will lock out. Burner lock out will also occur if the
switch opens during normal burner operation.
2.7.15 Galvanic Isolation Relay (GIR)

This 110 vac relay isolates the 110 vac circuit from the 24 vdc circuit in the electronics control box.
The GIR is energized through the limit safety circuit to permit burner light off. In the event of a severe over-
temperature condition, the GIR is de-energized; this, in turn, de-energizes the safety relays (see paragraph
2.7.33), which initiates a safety shutdown of the burners.
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2.7.16 Group Motor Protectors (GMP)

The group motor protectors function as a 3-phase, manual, motor starter/protector for control and pro-
tection of their respective motor(s). These short circuit protection devices are equipped with adjustable,
phase loss sensitive, bimetallic overload trips and adjustable magnetic trips. If tripped, a manual reset is
required.
2.7.17 Gas Pressure Switch - High (GPSH)

This normally closed safety switch is connected in series with the combustion control circuit. It will
open, and interrupt burner operation, in the event of high burner gas pressure. This switch requires a manual
reset after each interruption. The switch is installed between the main gas cock and main gas valve (MGV).
The pressure switch has an adjustable range of 1/2–5 psi (0.03–0.34 bar). The GPSH is factory set approxi-
mately 50% above the normal burner operating pressure at the maximum firing rate.
2.7.18 Gas Pressure Switch - Low (GPSL)

This safety switch is also connected in series with the combustion control circuit and will open, pre-
venting burner operation, in the event of low supply gas pressure. This switch requires a manual reset when-
ever gas supply is interrupted to the machine and at the time of initial firing. This switch is installed
immediately upstream of the safety shutoff valve. The switch has an adjustable range of 1–10 psi (0.07–.67
bar). The GPSL is factory set approximately 50% below the actual gas supply pressure.
2.7.19 Ignition Electrode (IE)

The ignition electrode provides a high voltage arc used to ignite the pilot fuel for both gas- and oil-
fired operation. For gas pilot operation, the electrode is located within the pilot tube and the spark gap is
between the electrode and the ground electrode located in the pilot tube. For light oil pilot applications the
ignition and ground electrodes are located outside the pilot tube directly above the light oil pilot nozzle.
2.7.20 Ignition Transformer (IT)

This transformer supplies high voltage (10,000 volt) to the ignition electrode. The ignition trans-
former remains energized only during the pilot-trial-for-ignition period. The ESC will de-energize the trans-
former after the pilot is proven.
2.7.21 Limit Pressure Switch (LPS)

This safety limit switch is connected in series with the holding circuit. In the event of excessive steam
pressure, the LPS will open, removing control voltage from the holding circuit, shutting down the machine.
A manual reset is required before the machine can be restarted.
2.7.22 Magnetic Controller (M1)

The “M1” magnetic controller contains three main power contacts and an additional auxiliary control
contact. Momentarily pressing the START pushbutton energizes the magnetic controller circuit to start the
blower motor. Motor operation is continuous while in the automatic firing mode and secured during burner-
off cycles. The auxiliary contactor is wired in-series with the burner control circuit. It will de-energize the
burner controls in the event of a motor malfunction.
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In a blower system requiring a fifty horsepower, or greater, motor, a controller with a soft-start fea-
ture is required. The soft-start feature allows the motor to ramp up to speed slowly; thus, reducing the risk of
damage to the blower system.
2.7.23 Magnetic Controller (M2)

This controller is similar to the M1 controller described above, and is used to energize the cooling air
fan motor. It runs continuously once the START pushbutton is pressed.
2.7.24 Main Gas Valve (MGV)

This valve is an electrically operated, two-position (ON/OFF), hydrometer gas valve. It is piped in
series and wired in parallel with the safety shutoff gas valve (SSGV). It provides positive gas shutoff within
one second.
2.7.25 Main Temperature Limit Controllers (MTLC)

See paragraphs 2.2.4.1 and 2.2.4.2.
2.7.26 Motor-Blower System

The blower motor is a four-pole ODP type motor (TEFC and other types optionally available). It is
energized during firing cycles. The blower motor may continue to run for a short time during “off-cycles”
(when operating pressure is above OPS setpoint). It will be secured if the motor protection device (GMP1) is
activated or when the STOP button is pressed.
2.7.27 Main Oil Valves (MOV)

This normally closed solenoid valve is energized to allow fuel oil flow to the burner and is de-ener-
gized to stop fuel flow to the burner when steam pressure reaches the steam pressure setting cutout point.
2.7.28 Programmable Logic Controller (PLC)

The PLC manages the feedwater supply in the
steam generating system. It automatically controls
the feedwater rate required to maintain the steam
load. The percentage load is displayed while in the
firing (RUN) mode, and the pumping rate is dis-
played while in the filling (FILL) mode. The PLC
receives a 4-20 mA signal from the OPX (Operating
Pressure Transducer), and in turn provides a 4-20
mA reference current output signal to the VSD
(Variable Speed Drive) to achieve the desired feed-
water pump motor speed.
An OIU (Operator Interface Unit) (Fig. 2-6)
enables communications between the operator and
the PLC. It enables the operator to modify system
Fig. 2-6 Standard OIU
Sect02_1004_c.fm 03/31/2016
operating parameters, as needed. A a digital display on the OIU provides PLC operation messages. The dis-
play provides information on operating modes, operating conditions, safety alarms, and parameter setpoints.
2.7.29 Pilot Valve (PV)

The pilot valve is electrically actuated by the ESC. The valve provides pilot fuel to initiate the igni-
tion sequence.
2.7.30 Power Supply

The power supply provides a filtered 24 VDC power supply to the PLC.
2.7.31 Pushbuttons (STOP/START)

These momentary contact pushbuttons are used to start and stop the machine.
2.7.32 Remote Stop Switch (RSS) (customer option)

A remote stop switch (normally-closed contact) can be used to stop the machine from a remote loca-
tion. It can be wired into the control circuit by removing the jumper at terminal board TB1 and TB2.
2.7.33 Safety Relays (SR1/SR2)

The SR1 and SR2 relays make up the 24 vdc safety circuit. They initiate a safety shutdown of the
burners when the safety circuit is disrupted. SR1 and SR2 are energized on machine startup through the GIR
(see paragraph 2.7.15) contacts. When a severe over-temperature conditions occurs, the GIR contacts open to
disrupt the safety circuit. This, in turn, de-energizes the safety relays, which initiates a safety shutdown of the
burners.
2.7.34 Safety Shutoff Gas Valve (SSGV) - gas operation only

This valve is an electrically operated, two-position (ON/OFF), hydrometer gas valve. It is piped in
series and wired in parallel with the main gas valve, with both closing and opening at the same time. It pro-
vides positive gas shutoff within one second.
2.7.35 Safety Shutoff Oil Valve (SSOV) - oil operation only

This redundant oil shut-off valve is plumbed in series, and wired in parallel, with the oil solenoid
valve. It acts as a safety shutoff device in the event of a malfunction of the oil solenoid valve to ensure that no
oil is admitted to the burner during the off-cycle.
2.7.36 Stepdown Transformer (115 VAC)

ST1 is a 230–575/115 vac step-down transformer that supplies 115 vac to control circuit voltage.
(See Fig. 2-7 for connection points.)
ST2 is a 115/12 vac step-down transformer that provides 12 vac power through the ESC to external
ESC-powered devices. The 115 vac power to the primary side of ST2 is supplied by the ESC.
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2.7.37 IR (infrared) Flame Scanner

The IR flame scanner detects the infrared radiation emitted by the pilot and burner flames. An analog
signal voltage of 0–5 vdc generated by the scanner is sent to the ESC. The flame strength information is
accessed through the ESC display, which is mounted on the electronics control box door.
Fig. 2-7 Wiring Diagram - Power Supply Connections
2.7.38 Variable Speed Drive (VSD)

The VSD provides variable frequency input to the feedwater pump motor(s), dictating the rpm of the
feedwater pump(s). It is controlled by a 4-20 mA reference voltage signal from the PLC. Detailed informa-
tion on operation, programming, and troubleshooting is provided in VSD manufacturer’s operators manual
provided at time of initial startup.
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Section III INITIAL FIRING
3.1 BEFORE FIRING

Every steam generator is thoroughly tested from the factory and all necessary adjustments are
made under actual operating conditions prior to shipment. Rough shipping and handling may cause some
plumbing connections to loosen and cause some alterations in equipment adjustments. To ensure satisfac-
tory operation, the following procedures are recommended prior to starting the machine:
a. Visually inspect and tighten any loose plumbing and electrical connections. Verify that
the machine has been installed in accordance with the Clayton Installation Manual (p/n:
R016600) and the special installation instructions provided by Clayton Industries.
b. Check the alignment of the blower and motor pulleys with a straightedge and secure all
set screws in pulley and bushing hubs. Check the belt tension.
c. Check the blower motor rotation before placing the unit in service.
d. Check the operation of water softener. Suitable water treatment equipment and chemi-
cals should be installed and available. Proper feedwater treatment must be used from the
time the steam generator is first placed into service.
e. Check the pump motor wire connections at the electrical controls cabinet are correct.
Momentarily start and immediately stop the pump motor to verify its direction of rota-
tion matches the direction arrow label.
f. Prime feedwater pump with properly treated feedwater.
CAUTION
DO NOT RUN PUMP DRY! Potential pump damage may occur if the pump is
allowed to operate without fluid. (Refer to pump manufacturer’s operating and
installation manual for commissioning and start up procedures.)
g. Select fuel type for machine operation.

It is important that the temperature safety controls be tested after the steam generator has been ini-
tially started and brought up to operating pressure. The controls should be tested periodically to ensure
continuous protection (See Section VI, “Periodic Maintenance.”)
04/13/2015 Sect03_xx4_KSB_a.fm 3-1

3.2 CONDITIONING OF NEW INSTALLATIONS

To remove residual mill scale, oil, and contamination in the heating coil which developed during
manufacturing, the heating coil should be “boiled out” prior to initial starting of the machine.
3.2.1 Procedure
a. Using soft water, flush out the hotwell and steam generator system.
b. Refill with soft water and then add five gallons of Coil Guard 1 to the hotwell. The prod-
uct may be added through any opening in the hotwell or pumped in with a transfer pump
or the chemical feed pump. (Using the chemical feed pump may take 4–8 hours to add
the product)
c. Short fire the steam generator to raise the water temperature to about 180° F.
d. Recirculate the water for two hours. Keep main header closed but the atmospheric vent
open.
e. Shut down the machine and drain the hotwell and steam generator. Fill with soft water
and rinse again. Continue to rinse until the water is clear with no visible sediment.
f. With the machine filled, add Coil Guard 2 (1 gallon per 100 bhp). Recirculate and then
start the machine for normal operation.
g. Start the chemical treatment with the appropriate chemical treatment chemicals.
NOTE
Refer to Feedwater Treatment Manual for detailed instructions.
Sect03_xx4_KSB_a.fm 04/13/2015
Section IV OPERATING
INSTRUCTIONS
4.1 OPERATING SEQUENCE

The following subsections provide an overview of the SGU operating sequence. If necessary, review
Section 5, PLC/OIU Operating Instructions, for instructions on operating the PLC through the OIU.
Verify that all fuel, water supply, and drain valves are in their proper starting position and that proper
feedwater treatment chemical and equipment are available and operational. Review Section III for general
operating instructions.
Before starting the machine, all pressure and operating parameter setpoints should be programmed to
the desired setting and verified. The machine will always start in the AUTO-FILL mode at a 20 percent fill
rate. The OIU display (Fig. 4-1) will indicate the starting mode.
Initial filling may be accomplished in MANUAL

mode by selecting manual from the AUTO/MAN button
(Fig. 4-1) and entering the fill rate manually fill rate
field. If placed in the AUTO mode, the machine will
automatically modulate down to the 20 percent fill rate.
Fill rate cannot be increased when in the AUTO mode—
the fill rate field is deactivated.
When the heating coil is full (as verified by water

flow from the separator drain, blowdown tank outlet, or
coil gravity drain), press the designated FILL/RUN but-
ton on the OIU to initiate a firing sequence. Initial firing
should be accomplished while in MANUAL Mode. The
following OIU message will be displayed: Fig. 4-1 Fill rate screen on OIU
INITIATING PURGE
SEQUENCE
Upon selecting the RUN mode, the burner controller will initialize; which, it will energize and go into
the PURGE cycle. The following OIU message will be displayed:
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PURGE CYCLE
Now, the actuator motor will drive the damper to the purge position.
NOTE
Although the air damper is driven to the purge position during the PURGE cycle, the
water rate remains at the minimum fill rate position of 20 percent.
Once the limit switch is made, the burner controller begins the purge timing. When the PURGE cycle
ends, the actuator motor drives back down to the minimum fire position. The burner controller will energize
the pilot circuit opening the pilot fuel valve and energizing the ignition transformer. The following OIU mes-
sage will be displayed:
COMMENCING
BURNER IGNITION
The ignition transformer energizes the ignition electrode creating a spark in the pilot tube; the pilot fuel
is ignited. If the flame scanner detects a stable pilot flame, as indicated by the flame strength displayed on the
remote display module, the burner controller will energize the main fuel valves. After the short pilot trial for
ignition (PTFI) period, the pilot fuel valve, ignition transformer, and ignition electrode are de-energized and
after the main flame stabilization period, the fuel control system is released to operate, as commanded by the
PLC. The firing rate screen, shown in Fig. 4-2, displays on the OIU.
While in MANUAL Mode, close the separator
outlet valve to enable the machine to pressurize and
cycle off on the operating pressure setting. The fir-
ing rate may be manually adjusted. When the
machine completes another ignition sequence (main
fuel valves opened), the AUTO mode may be
selected. The AUTO indicator flag will indicate
“AUTO” (above the function key in the display
screen).
Gradually open the separator outlet valve.
Once the outlet valve is completely open, the
machine will be in a fully automatic operating
mode; the firing rate and water rate will automati-
cally adjust to maintain the desired operating
pressure.
Fig. 4-2 Firing rate screen on OIU
Sect04_1004_c.fm 03/31/2016
Operating Instructions 4-3
During normal operation, whenever the steam generator output exceeds system demand, the operating
pressure setting “open setpoint” will be reached and the machine will cycle off (burner off). The machine will
briefly go through a post-purge cycle, as indicated by the following OIU display:
POST - PURGE
CYCLE
Simultaneously, the post-fill function is activated, allowing the feedwater pumps to continue pumping
water into the coil. The following OIU message will be displayed once post-purge is complete:
POST - FILL
-STANDBY-
The post-fill function will continue until the coil temperature achieves the temperature of the fluid in
the hot well tank. The post-fill function will end when the desired preset coil temperature is achieved. The
following OIU message will be displayed at completion of the post-fill function:
-STANDBY- NO DEMAND
STEAM PRESS. ### PSI
In the standby state, the coil is full, the burner is off, and pump is off.
In the following sections, the letters contained in the parenthesis

correspond to the letter call-outs in Fig. 4-3 (page 4-6).
4.2 BEFORE STARTING

a. Verify that the water softener and feedwater chemical treatment systems are operating.
NOTE
Test the feedwater for proper chemical treatment levels prior to filling the heating coil.
b. CLOSE: Separator discharge valve (A), coil drain valves (F1 and F2), soot blow valve (if
equipped-not shown), and all drain cocks.
OPEN: Separator blowdown/drain valve (E), auto dump discharge valve (V), continuous blow-
down shutoff valve (L1)**, and partially open continuous blowdown needle valve (L2)**.
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NOTE
1. Installations with Clayton feedwater treatment skid: Follow instructions on the skid
panel prior to filling.
2. If the machine is in wet shutdown mode, the feedwater intake valve (C), the coil
feed valve (B), the auto dump discharge valve (V), and the gravity fill isolation valve
(K) would already be open.
4.3 FILLING PROCEDURE

a. Verify open the feedwater intake valve (C), coil feed valve (B), and gravity fill isolation valve
(K).
b. Pull out the STOP button.
c. Press the START pushbutton.
d. Select MANUAL using the AUTO/MANUAL function key.
e. Enter the desired fill rate from the OIU’s numeric keypad
f. Check the feedwater pump prime by throttling the coil feed valve (B) until feed pressure rises
to 100 psi (690 kPa).
g. Continue filling for at least 45 minutes (from a completely dry coil).
h. Slowly open the coil drain valve (F1) to check for water flow. If a steady water flow is evident,
then the coil is sufficiently filled.
4.4 INITIAL STARTING

a. Oil-fired operation: Verify that all compressed air and fuel oil supply system valves are open.
Open the main oil supply valve and the pilot gas cock (I), or light oil pilot valve (R). If applica-
ble, engage the fuel oil pump drive coupling.
NOTE: On gas-oil combination machines, set the machine for oil operation through the ESC
display (on the electronics control box door). Close the main gas cock (H1/H2).
Gas-fired operation: Verify that all compressed air and gas supply system valves are open.
Open the main gas cocks (H1/H2) and the pilot gas cock (I); and the pilot air cock (IA) for LNB
machines.
NOTE: On gas-oil combination machines, set the machine for gas operation through the ESC
display and operating unit (on the electronics control box door). Close the main oil supply valve
and, if applicable, disengage the fuel oil pump drive coupling.
CAUTION
Severe damage to the fuel oil pump will result if it is allowed to operate without oil
flow.
Sect04_1004_c.fm 03/31/2016
b. Select RUN using the FILL/RUN function key. The machine will cycle through its preset purge
period, return to the minimum fire light-off position, then energize the pilot circuit. If a stable
pilot flame is successfully established, the main burner control circuit will be activated.
A stable flame must be achieved within the pilot trial-for-ignition (PTFI) period and maintained
during the main flame trial-for-Ignition (MFTI) period; if not, the ESC will lock out, requiring
a manual reset.
NOTE
During the warm-up period, the separator blowdown/drain valve (E) may require par-
tial closing to achieve the operation pressure.
c. As pressure rises and approaches the OPS cutout setpoint, set the machine to automatic opera-
tion using the AUTO/MANUAL function key. Gradually open the separator discharge valve
(A). The machine will now operate between minimum and maximum firing rate depending
upon the steam demand.
NOTE
During this process, close the separator blowdown/drain valve (E) and observe the
trap pressure gauge for proper trap timing.
d. The machine is in a fully automatic operating mode when the separator discharge valve (A) is
completely open.
NOTE
If the machine is operated continuously, some method of automatic blowdown must
be used to control the Total Dissolved Solids (TDS). TDS control can be accom-
plished with a continuous blowdown valve arrangement or automatic TDS controller.
03/31/2016 Sect04_1004_c.fm
GLOBE VALVE PS PRESSURE SWITCH PRESSURE REGULATOR
S
SOLENOID VALVE (N.O.) BACK PRESSURE
MANUAL GAS VALVE/COCK
REGULATOR
M S
MOTOR ACTUATED SOLENOID VALVE (N.C.)
DAMPER
E
H ELECTRO-HYDRAULIC
PUMP (FEEDWATER)
VALVE (N.C.)
SUPER
ECONOMIZER K
A
Gravity Fill
B C
PUMP
SEPARATOR
Feedwater Supply
COMBUSTION
L2 CHAMBER
O1
L1 F1
S
O2 F2
FLAME
E SCANNER H1
V R M E
H
Main Gas
Fuel Return Supply
S
LIGHT OIL PILOT
I
S S S
Fuel Supply Pilot Gas
F
* A. Separator Discharge Valve ** L1. Continuous Blowdown Shutoff Valve

B. Coil Feed Valve(s) ** L2. Continuous Blowdown Needle Valve
C. Feedwater Inlet Valve * O1/O2. Coil Blowdown Valve
* E. Separator DrainValve ** R. Light Oil Pilot Valve
F1. Coil Drain Valve V. Auto Dump Discharge Valve
F2. Coil Drain Valve (upper water-wall)
H1. Main Gas Cock
I. Pilot Gas Cock ** optional equipment
K. Gravity Fill Isolation Valve * optionally available or else customer furnished
Fig. 4-3 Diagram of steam generator operating controls
Sect04_1004_c.fm 03/31/2016
4.5 SHUTDOWN PROCEDURES

(Refer to Fig. 4-3 for parenthetical call outs.)
4.5.1 Wet Shutdown–Overnight Only 1

Press the AUTO SHUTDOWN pushbutton. The make-up water valve (S, Fig. 4-4) and, if equipped, the
continuous blowdown solenoid valve (T, Fig. 4-4) will close. On elevated head tank systems, feedwater is
pumped through the head tank orifice, filling the head tank; feedwater flows from the tank through the grav-
ity-fill check-valves and into the heating coil. Excess water supply will return to the feedwater tank.
4.5.2 Wet Shutdown 1

Refer Clayton Feedwater Treatment Manual (R015426) for additional details.
Elevated Head Tank Water Supply Systems (14 days maximum)
An elevated head tank water supply system provides a positive coil feed pressure through a
feed line from the head tank to the heating coil gravity fill connection during wet shutdown. Suffi-
cient head pressure must be available during the entire shutdown period. Leaking plumbing and
components must be repaired or replaced immediately to prevent damage to the heating coil—refer
to installation manual for head height requirements.
NOTE
Verify gravity fill isolation valve (K) is open prior to the wet shutdown procedure.
Clayton Feedwater Skid Supply System (7 days maximum)

The Clayton feedwater supply skid provides a positive coil feed pressure through a feed line
from the hot well tank to the steam separator gravity fill connection during wet shutdown. Suffi-
cient head pressure must be available during the entire shutdown period. Leaking plumbing or com-
ponents, or both, must be repaired or replaced immediately to prevent damage to the heating coil—
refer to installation manual for head height requirements.
4.5.3 Wet Shutdown Procedure 1

a. Place the machine in FILL mode to shut off the burner.
b. Open the separator drain/blowdown/drain (E).
c. Close the separator discharge valve (A) and continuous blowdown shut-off valve (L1), if equipped.
d. Allow the feedwater pump to circulate treated feedwater until the coil temperature drops to the hot
well tank temperature; then, all the pumps will stop. The drop in pressure inside the coil allows sup-
ply water to flow through the gravity fill (check-valve) connection into the heating coil.
1 Freeze protection required. Where freezing temperatures are a factor, a backdraft damper must be installed in the exhaust stack to prevent coil freeze-
ups.
03/31/2016 Sect04_1004_c.fm
HEAD
TANK
HOT-WELL TANK
A
K
Gravity Fill Line1 S
Gravity Fill Line2

K
T
Make-up
Water
Line
Feedwater Line
Booster 3
L1 Pump
A. Separator Discharge Valve **L1. Continuous Blowdown Shutoff Valve

K. Gravity Fill Isolation Valve S. Make-up Water Line Solenoid Valve
**T. Continuous Blowdown Solenoid Valve
1
Gravity Fill hookup used with elevated Head Tank supply system.
2
Gravity Fill hookup used with Clayton Feedwater Supply Skid system.
3
Booster Pumps for positive coil feed pressure.
** Optional equipment
Fig. 4-4 Gravity fill hookup diagram for elevated head tank supply systems and Clayton feedwater
supply skid systems
Sect04_1004_c.fm 03/31/2016
e. Push in the STOP button, to secure the machine, and immediately close the separator blowdown
valve (E).
f. Open the feedwater intake valve. Verify auto dump discharge valve (V) is open.
g. Close all fuel valves.
Maintain a sufficient chemical level throughout the wet shutdown to produce a minimum residual
oxygen scavenger of 100 ppm and a minimum pH of 10.
It may be necessary, in some installations, to periodically run the chemical pump(s) and, if equipped,
the booster pump(s) to maintain these feedwater conditions throughout extended periods of wet shutdown.
4.5.4 Wet Shutdown Notes

[1]Power source to all systems must remain powered until the feedwater pump(s) automatically
stop.
[2]Periodically check the system for leaks throughout the wet shutdown period.
[3]It is important that the coil drain valves (F1/F2), coil blowdown valves (O1) (O2 and O3, if
applicable), separator discharge valve (A), and the separator blowdown/drain valve (E) remain
tightly closed during wet shutdown.
[4]Perform any scheduled blowdown operation at least one hour before starting the wet shutdown
procedure.
[5]On steam generators equipped with the Clayton intermittent fill feature, the STOP button must
be left in the pulled-out position during the wet shutdown period. The intermittent fill auto con-
trol will cycle the feedwater, chemical, and booster pumps periodically during the wet shutdown
period.
4.5.5 Restart After Wet Shutdown

a. The hot well tank may first be drained if an excessive amount of precipitated sludge is present.
b. Manual blowdown should be accomplished after start-up to control the dissolved solids in the
system.
4.5.6 Extended Shutdown (Dry Shutdown/Blowdown)
CAUTION
DO NOT RUN PUMP DRY! Potential pump damage may occur if the pump is al-
lowed to operate without water. See Appendix D for pump operating instructions.
The preferred method of shutdown for extended periods is a dry shutdown. A dry shutdown leaves the
heating coil completely dry and protected with a nitrogen purge, sealed at a pressure of 35 psi (240 kPa).
a. Close the gravity fill isolation valve (K).
03/31/2016 Sect04_1004_c.fm
b. Run the machine at the maximum firing rate for a minimum of 5 minutes. To achieve the max-
imum firing rate while maintaining operating pressure:
1. Fully open the separator discharge valve (A) and, if necessary, throttle (open) the atmospheric
test valve (not shown).
2. Select MANUAL mode; raise the firing rate to 100 percent (maximum).
3. Slowly, close the separator discharge valve (A) to maintain the pressure just below the operating
pressure cutout (OPS opens).
c. Open the separator blowdown/drain valve (E) and the coil blowdown valves (O1), (O2 and O3,
if applicable).
d. Close the feedwater intake valve (C).
e. Start a three-minute time check.
f. Continue to progressively close the separator discharge valve (A), or atmospheric test valve, or
both, to maintain the pressure just below the pressure cutout setpoint (OPS as noted in step b,
above).
g. Continue firing the machine at the maximum rate until the three-minute time check expires.
h. Immediately, push in the STOP button to secure the machine once the three-minute time check
has expired. In some cases, the high temperature alarm will shut down the machine before the
time check expires, which is acceptable.
i. Open all coil drain valves (F1/F2); close the auto dump discharge valve (V).
If the dry shutdown was properly executed, only a whisper of vapor or a very small amount of
water should be visible from the coil drain valve(s) (F1/F2) and the coil blowdown valves (O1),
(O2 and O3, if applicable), when opened. If any measurable amount of liquid is discharged from
the coil drain valve(s), then the dry shutdown was unsuccessful and must be repeated.
NOTE
Flow from the coil drain valve(s) must be visible at all times through an open drain
or sight glass.
j. Close the following valves after a 60-minute cool-down period:

• Separator blowdown/drain valve (E)
• Coil blowdown valves (O1), (O2 and O3, if applicable).
• Continuous blowdown shutoff valve (L1), if equipped
4.6 FREEZING PRECAUTIONS AND EXTENDED SHUTDOWN

(Refer to Fig. 4-3, page 4-6, for parenthetical call outs.)
a. Execute a dry shutdown, as described in paragraph 4.5.6. Close the pilot gas cock (I), main gas
cock (H1), atomizing air supply valve, and main oil supply valve.
Sect04_1004_c.fm 03/31/2016
b. Remove and drain all tubes in the system in which a low sump may contain water. Remove the
pipe plug from the feedwater strainer.
c. Be sure all water is drained from the heating coil and steam separator.
d. After making sure that all water has been drained from the machine, replace all tubes which
were removed and re-install the intake and discharge check-valves in the water pump check-
valve housings.
e. Close all drain cocks at the base of feedwater pump.
NOTE
Tightly close all valves to prevent air from entering the system while the machine is
cooling.
4.7 INTERMITTENT FILL CYCLE

(Optional auxiliary relay required on non-skid applications)
The intermittent fill cycle is designed to improve the reliability of a wet lay-up shutdown (refer to para-
graph 4.5.2, in Section IV, for wet lay-up shutdown).
The intermittent fill cycle provides intermittent feedwater circulation and filling of the heating coil. It is
used to maintain proper chemical mix and eliminate air pockets, which can cause corrosion during a wet lay-
up. The cycle is only active when the STOP button is disengaged (in the pulled-out position) while the
machine is off; pushing in the STOP button provides emergency shutdown of all motors and outputs and will
prevent the intermittent fill cycle from becoming activated. The intermittent fill feature is enabled when the
pump icon appears in the bottom-left corner of the OIU display, as shown below:
Two PLC timers are used to control on/off times of the cycle. Provisions are made during commission-
ing to activate the intermittent fill cycle feature if the machine will be shut down wet. All adjustments are
made at the time of start-up for the particular application. A typical cycle would energize the feedwater,
booster, and chemical pumps for five minutes every two hours during a wet lay-up. During the ON fill cycle,
a FILL CYCLE flag (at the bottom of the default OIU display) will flash indicating pump activation:
03/31/2016 Sect04_1004_c.fm
The cycle will reset and continue until the machine is started. The alarm monitor will be active to pro-
vide adequate protection of limit pressure, VSD faults, feedwater pump trouble, and motor overload during
the intermittent cycle. If an alarm occurs during the intermittent cycle, all machine functions will cease and
the alarm will sound.
Sect04_1004_c.fm 03/31/2016
Section V PLC/OIU
OPERATING
INSTRUCTIONS
5.1 PROGRAMMABLE LOGIC CONTROLLER (PLC)
The PLC (Programmable Logic Controller) is responsible for the monitoring and controlling all aspects
of a machine’s operation. These operations include water flow rate control, automatic burner control and air
damper adjustment, and alarm signaling. Communications with the PLC is performed through an OIU.
The PLC is available in three configurations, Level I, Level II, and Level III. A Level I configuration
provides all the basic functions needed to operate a steam generator. In addition to the Level I functions, a
Level II provides two additional pressure and three additional temperature monitoring functions. A Level III
provides fuel flow and fluid mixture flow in addition to the Level I and Level II monitoring functions.
There are six standard operating modes programmed into the PLC. Each mode is described below and
can be accessed by pressing the appropriate on the OIU touchscreen.
• Manual mode: allows local manual control of the filling and firing rates.
• Automatic mode: considered the normal mode of operation it enables fully automatic con-
trol of the combustion (air/fuel ratio) and feedwater delivery systems (pump rate).
• Fill mode: allows manual operation of the feedwater pump(s) during “burner off” periods
and is the normal operating mode when filling the heating coil.
• Run mode: activates the ignition sequence and is the normal operating mode during firing
periods.
• Test mode: initiates operation of the blower motor and water pump(s) without activating the
burner controls.
• Auxiliary mode: used only on Auxiliary Pressure Control (APC) applications, it allows a
second set of operating pressure and modulating pressure setpoints to be used when the
machine is performing in a standby mode. These setpoints must also selected while in the
CALIBRATION mode.
NOTE
PLC is used only to provide reliability and solid state accuracy to the steam gener-
ator operating system. It does not replace any safety or limit control devices.
04/20/2016 Sect05_1004_Delta_a.fm 5-1

5.2 OIU (Operator Interface Unit)

The OIU is installed on the right-hand door
of the electrical control box on the front of the
machine. It is a full TFT graphical display that
incorporates touchscreen technology. It is the
communications channel between the PLC and
the machine operator. Operating parameters,
such as temperature and pressure setpoints, are
input through a virtual keypad and transmitted to
the PLC for processing and execution. An opera-
tor can view the PLC output, such as current
machine operating status and alarm history, on
the OIU display screen.
Once main power is established, the OIU is
powered on and the default Clayton Industries
service screen displays (Fig. 5-1). This screen
also displays after an alarm reset. Fig. 5-1 Clayton Industries OIU service screen.
5.2.1 Using The OIU

This section provides a short tutorial on some basic operations that are performed through the OIU. The
user interface is interactive and intuitively designed. Navigating to the different OIU screens simply requires
pressing the desired buttons on the touchscreen. Where data needs to be entered, a pop-up numeric or alpha-
numeric keypad displays for data entry.
For example, pressing the fill rate field while in manual fill mode (Fig. 5-2, left) will generate a pop-up
keypad (Fig. 5-2, right). Enter the desired fill rate on the numeric keypad and then press the ENTER key. The
fill rate is updated causing the feedwater pump to increase its speed.
FILL RATE FIELD
Fig. 5-2 Manual fill rate screen (left) and pop-up numeric keypad (right)
Sect05_1004_Delta_a.fm 04/20/2016
Section V - PLC/OIU Operating Instructions 5-3
5.2.1.1 Access levels and passwords

The OIU establishes three levels of accessibility to the machine. Two of the three levels are password
protected. The access levels, menu screens, personnel, and passwords are as follows:
Access Level Menu Screen Personnel Password

1 Modify Setpoints Plant operator (not required)
2 Modify Setpoints Plant engineer Call Clayton Service
Tune PID for password.
CPU Status
3 Calibration and all other screens Clayton Technician proprietary
5.2.1.2 Selecting a menu item

a. Press the CAL MENU button on the OIU screen to navigate to the main menu screen (Fig. 5-3, left).
The CAL MENU button can be found on both the Clayton service screen (Fig.5-1) and the fill screen
(Fig. 5-2, left).
b. Press the button for the desired menu item and that menu will display. The menu items with the red
strike-through line (CALIBRATION and PID TUNING) are password protected screens. Pressing
one of these buttons will display the alpha-numeric password keypad (Fig. 5-3, right).
NOTE
A password protected screen will automatically logout after 10 minutes or inactivity.
The password must be reentered to access the screen.
Fig. 5-3 OIU menu item screen (left) and alpha-numeric password keypad (right).
04/20/2016 Sect05_1004_Delta_a.fm
c. Press the ESC button and the OIU screen jump back to the previous screen.
d. Press the ALARM HIST button to access the alarm history.
5.2.1.3 Modifying setpoint
a. If not on the main menu, press the CAL
MENU button to display the main menu
screen.
b. Press the CALIBRATION button on the
main menu. The pop-up, alpha-numeric
keypad displays.
c. Enter the proper password, then press the
ENTER button on the keypad. The modify
setpoint screen displays (Fig. 5-4).
d. Press the numeric field for the desired set-
point that will be changed. A pop-up
numeric keypad displays.
e. Enter the new setpoint, then press ENTER.
The new setpoint will appear in the Fig. 5-4 Modify setpoint screen
numeric field for that selected setpoint.
f. Repeat steps d and e to update the other
setpoints.
g. When complete, press the MAIN MENU or ESC button to exit the modify setpoint screen.
5.2.1.4 High/Low Setpoint Selection
A dual set of setpoints are programmed into high-low pressure capable steam generators. From the
main menu, press MODIFY SETPOINTS (Fig. 5-5, left) to display modify setpoint screen (Fig. 5-5, right).
Fig. 5-5 OIU main menu screen with high/low pressure setting (left) and high/low setpoint screen (right).
Sect05_1004_Delta_a.fm 04/20/2016
Section V - PLC/OIU Operating Instructions 5-5
Enter desired modulating, cut-out, and cut-in

setpoints under the high pressure setpoint column
and under the low pressure setpoint column. Press
EXIT CAL MODE button when done.
To toggle the controls between high pressure
and low pressure operation, press HIGH/LOW
PRESSURE button from the main menu screen.
The high/low operation pressure selection screen
will display (Fig. 5-6). Press HIGH/LOW button
to enter steam generator into high pressure mode
or low pressure mode. The status of the machine
displays above the high/low pressure button. Press
EXIT CAL MODE button to return the display to
the main menu screen.
Fig. 5-6 High/Low operation pressure selection
screen
04/20/2016 Sect05_1004_Delta_a.fm
Sect05_1004_Delta_a.fm 04/20/2016
Section VI PERIODIC
MAINTENANCE
6.1 GENERAL
The Clayton steam generator must receive periodic inspection and maintenance to maintain the level
of reliability and performance it is designed to provide. The following service recommendations require only
a few minutes each day and will help maintain the efficiency of the steam generator, as well as, minimize
unscheduled repairs. Monthly maintenance log sheets are included with each machine, as well as, in the back
of this manual. Use of these log sheets will provide an accurate record and serve as a daily reminder of the
routine maintenance requirements. Extra sheets (Part Number: R007517) are available direct from Clayton
Industries. Cumulative hours of operation are viewed from either the ESC display or the hour meter mounted
inside the control box.
NOTE
Review pump operation and maintenance manual in Appendix D for multi-stage
centrifugal pump preventive maintenance instructions.
6.2 FEEDWATER TREATMENT

Feedwater treatment is an essential part of any steam generator maintenance program. Incorporating
proper feedwater treatment will prevent costly repairs, due to internal corrosion or scale formation, and
extend the life of the heating coil. Clayton feedwater treatment requirements are discussed in detail in the
Feedwater Treatment Manual (Part Number: R015216).
6.3 CONDITIONING OF NEW INSTALLATIONS

New piping or oily substances entering the water system may cause contamination, which will be evi-
dent in the feedwater pump and in the standpipe discharge. All new steam generators should be boiled-out to
clean the system. Follow the procedure described in Section 3.2.
6.4 DAILY SERVICE

6.4.1 Record Operating/Steam Pressure
Record the operating pressure in the Periodic Maintenance Log (Part Number: R007517).
04/04/2016 Sect06_1004_d.fm 6-1

6.4.2 Test and Record Feedwater

Record tested feedwater characteristics indicated in Periodic Maintenance Log.
Refer to Clayton Feedwater Treatment Manual for details.
6.4.3 Manual Blowdown

Manual blowdown is used to control dissolved solids and to remove suspended solids and sludge.
Manual blowdown may be eliminated from daily operation as long as continuous or automatic blowdown
devices are used and the feedwater is tested daily for total dissolved solids (TDS) content. If chemical tests
are not performed daily (so that blowdown frequency can be determined more accurately), a manual blow-
down should be performed every 10–12 hours of machine operation.
If the dry shutdown method is being used, it can be considered as the manual blowdown. If a wet
shutdown is used (see paragraph 4.5.2 for wet shutdown procedures), the blowdown may be performed any
time during the day, but at least one hour before final shutdown. Manual blowdown can be performed while
the machine is operating by opening the separator drain valve for 20 seconds. Allow the machine to stabilize,
then take another TDS measurement. Continue this procedure until TDS limits are within the desired range.
6.4.4 Soot Blow - Oil-fired Machines Only

(See Fig. 6-1.)
A soot blow of the coil should be performed daily to maintain its efficiency. Soot blowing removes
soot buildup from the outside surface of the coil. This operation is recommended every 12 hours.
During normal operation, the soot-blow valves (A) and (C) are kept tightly closed while valve (B)
remains open to check for blow-by of valve (A).
NOTE
High-pressure units, above 500 psi (34 bar), use only a single piston-type valve (A).
Soot blowing a high pressure machine only requires opening and closing one valve.
Refer to steps e, f, and g for soot blowing operations on high pressure units.
Soot blowing is performed as follows:

a. Fire the machine at normal operating pressure.
b. Verify the soot-blow drain valve (B) is fully open.
c. Partially open soot-blow valve (A) to expel any condensation in the soot-blow line.
d. Close the soot-blow drain valve (B).
e. Slowly, open soot-blow valve (C) and soot blow the coil continuously for 30 seconds.
NOTE
The separator discharge valve should be throttled down to achieve the maximum
soot-blow steam flow. Do not close-off the separator discharge valve to the point of
cycling off on high operating pressure.
Sect06_1004_d.fm 04/04/2016
Periodic Maintenance 6-3
f. Close valve (C) after 30 seconds has elapsed and allow two minutes for the machine to recover
and stabilize.
g. Repeat steps e and f once more.
h. Close valves (A) and (C). Fully open valve (B), slowly.
Increase the frequency of soot blowing if the coils are extremely sooted. If soot blowing operations
fail to effectively clean the coil, then perform a coil wash. See the coil water washing. Supplemental Instruc-
tion in Appendix A.
A
C
Fig. 6-1. Typical soot-blow valve hookup; on high-pressure machines, a single piston valve, in the
position of valve A, replaces valves A, B, and C.
6.4.5 Record Pulsation Dampener Pressure

On some special applications, nitrogen-filled, bladder-type dampeners are used in place of, or in addi-
tion to, Clayton intake surge chamber and snubbers.
Check and record the nitrogen charge pressure. Recharge to proper pressure as specified by the man-
ufacturer.
NOTE
Contact Clayton Service for maintenance information on these pulsation dampeners, as
needed.
04/04/2016 Sect06_1004_d.fm
6.4.6 Walk Around Inspection

Perform a walk-around inspection. Check for leaks, unusual noise, stack smoke, oil level, etc. Hot
lines on the manual blowdown discharge is an indication of valve leakage.
6.5 WEEKLY SERVICE

6.5.1 Fuel Filter Element
Rotate the fuel filter (oil-fired only). Clean the element in the fuel filter (located on fuel oil inlet) by
turning the T-handle one complete in turn either direction. This rotates an internal cartridge and combs out
accumulated solids. If the handle turns hard, rotate the handle back and forth until it is free. Do not use a
wrench to force the handle. Clean more often if necessary. A sudden change of fuel pressure indicates dirt
has caused restriction of flow.
6.5.2 Hot-well Tank

Partially drain the drain hot-well tank. Fully open the drain valve for one minute (may be done while
in operation). Do not allow water to drop out of sight in the gauge glass. This flushes loose solids from the
tank bottom.
Check all feedwater strainers and clean as necessary.
6.5.3 Blower Belts and Pulleys

Check the alignment of the blower, and motor pulleys with a straightedge and secure all set screws in
pulley hubs.
6.6 MONTHLY SERVICE

6.6.1 Check Coil Feed Pressure
Check the coil feed pressure at the high-fire rate. Record and compare with the original reading for an
indication of internal scaling.
NOTE
The normal feed pressure may vary slightly with each installation; therefore, it is
advisable to record the feed pressure reading in the commissioning phase of each
newly-installed steam generator. This will provide an accurate standard for checking
coil restriction.
Always note the coil feed pressure only after the steam generator has operated for several hours and is
thoroughly heated, and always at the same operating pressure, feedwater temperature, and at full load. The
operating pressure must stay at a level, under steady load condition, that will prevent burner modulation.
To check the feed pressure, open the valve to the feed pressure gauge enough to allow a steady read-
ing on the gauge. Coil restriction may exist if the feed pressure is 30 psi (2 bar) or more above the normal
feed pressure (noted immediately after installation or when the coil was completely clean). For example, it is
Sect06_1004_d.fm 04/04/2016
noted that feed pressure was 300 psi (21 bar) at a given operating pressure when the machine was new. The
feed pressure now reads 330 psi (23 bar). This would indicate there is restriction in the coil. (See Section 7.2
for scale removal procedures.)
If rising feed pressure is noted within 10–30 days after initial installation, take steps immediately to
correct the cause and to prevent future trouble. Carefully consider the following measures:
• Carefully check to be sure the feedwater treatment is adequate and is being used properly and con-
sistently. See that the water softener is being regenerated at regular intervals. To be effective, feed-
water treatment must be consistent and continuous.
• Blowdown the machine more frequently. It is sometimes necessary to blowdown more often than
specified to remove solids that are precipitated in the form of sludge. The blowdown operation may
not remove scale completely, but it will remove enough to delay coil restriction.
NOTE
The Feedwater Treatment Manual contains detailed information explaining the
importance of feedwater treatment. It also provides the recommended procedures
and equipment necessary to prevent scale and corrosion within the steam generator.
6.6.2 Check Volute Pressure

A 1/4-inch diameter tube stub is located on the left-hand side of the burner volute. This 1/4-inch tube
stub is for a manometer hose connection that is used in periodic or continuous monitoring of the volute pres-
sure. A 10-inch range water column instrument can be used for this purpose. An economical model may be
constructed from plastic tubing. Compare readings to those documented at the time of initial commissioning.
Variations may be indicative of combustion problems or a dirty blower wheel.
6.6.3 Flush Feedwater Pump

Flush feedwater pump as recommended by pump manufacturer. Review maintenance requirements
outlined in operation and maintenance manual provided in Appendix D.
6.6.4 Check Dual Element Thermocouple Sensor

The integrity of the dual element thermocouple sensor must be checked monthly. The sensor is
installed in the front lower section of the heating coil, just below and left of the control box installation. A
temperature test meter/indicator is required. The thermocouple sensor check is conducted under two condi-
tions, when the machine is in operation under load at operating pressure and when the machine is in wet lay-
up for at least two hours following a cease firing of the burner.
6.6.4.1 Coil temperature reading with steam generator in operation
a. Connect the test meter to the primary element of the dual element thermocouple sensor.
b. Record the coil temperature. Remove the meter leads from the primary element when tempera-
ture is recorded.
c. Connect the test meter to the secondary element of the dual element thermocouple sensor.
d. Record the coil temperature. Remove the meter leads from the secondary element when done.
04/04/2016 Sect06_1004_d.fm
e. Record the steam temperature reading from the separator thermometer.

f. Compare the recorded temperatures with the reference temperatures in Table 2-1 (Pressure-
Temperature) in Section II. Make a note of the differences for evaluation in paragraph 6.6.4.3.
6.6.4.2 Coil temperature reading with steam generator in wet lay-up
Note: The machine should be in wet lay-up for at least two hours following cease firing of the
burner. The cool-down time may be reduced by increasing the FILL rate.
a. Connect the test meter to the primary element of the dual element thermocouple sensor.
b. Record the coil temperature. Remove the meter leads from the primary element when tempera-
ture is recorded.
c. Connect the test meter to the secondary element of the dual element thermocouple sensor.
d. Record the coil temperature. Remove the meter leads from the secondary element when done.
e. Record the feedwater temperature reading on the thermometer on or near the feedwater pump.
Alternatively, a feedwater temperature reading from the thermometer on the hot-well tank may
be used.
6.6.4.3 Evaluate recorded values
a. The results from steps 6.6.4.1b and 6.6.4.1d should fall within 40° F (22° C) of the recorded
steam temperature or the value obtained from Table 2-1 in Section 2, Pressure-Temperature
Table.
b. The results from steps 6.6.4.2b and 6.6.4.2c should fall within 10° F (5° C) of the recorded
incoming feedwater temperature taken in step 6.6.4.2e.
c. If one of the coil temperature readings, from either the primary element or the secondary ele-
ment, are outside the accepted specified temperature range, then the corresponding element
wiring or connections are faulty.
d. If both coil temperature readings, from either the primary element or the secondary element,
are outside the accepted specified temperature range, and they are equal in the error value, then
it is likely that the thermocouple elements are not making sufficient contact with the sleeve
which is inserted in the tube. (See Fig. 2-2 in Section II and Section 8.1.)
6.6.5 Check Main Temperature Limit Controllers (MTLC)

a. Remove on thermocouple lead wire from the MTLC.
b. Verify that a shutdown occurs and an alarm is initiated within one minute.
c. Replace the thermocouple lead wire.
d. Repeat steps a, b, and c for other MTLC.
NOTE
If any of the MTLCs are suspected of being faulty, remove it and conduct further
bench testing. Replace the MTLC if it is faulty.
Sect06_1004_d.fm 04/04/2016
GLOBE VALVE PS PRESSURE SWITCH PRESSURE REGULATOR
S
SOLENOID VALVE (N.O.) BACK PRESSURE
MANUAL GAS VALVE/COCK
REGULATOR
M S
MOTOR ACTUATED SOLENOID VALVE (N.C.)
DAMPER
E
H ELECTRO-HYDRAULIC
PUMP (FEEDWATER)
VALVE (N.C.)
SUPER
ECONOMIZER K
A
Gravity Fill
B C
PUMP
SEPARATOR
Feedwater Supply
COMBUSTION
L2 CHAMBER
O1
L1 F1
S
O2 F2
FLAME
E SCANNER H1
V R M E
H
Main Gas
Fuel Return Supply
S
LIGHT OIL PILOT
I
S S S
Fuel Supply Pilot Gas
F
* A. Separator Discharge Valve ** L1. Continuous Blowdown Shutoff Valve

B. Coil Feed Valve(s) ** L2. Continuous Blowdown Needle Valve
C. Feedwater Inlet Valve * O1/O2. Coil Blowdown Valve
* E. Separator DrainValve ** R. Light Oil Pilot Valve
F1. Coil Drain Valve V. Auto Dump Discharge Valve
F2. Coil Drain Valve (upper water-wall)
H1. Main Gas Cock
I. Pilot Gas Cock ** optional equipment
K. Gravity Fill Isolation Valve * optionally available or else customer furnished
Fig. 6-2. Diagram of steam generator operating controls
04/04/2016 Sect06_1004_d.fm
6.6.6 Clean Strainers

Secure the machine. Close the feedwater intake valve (C, Fig. 6-2). Remove the strainer screen and
clean thoroughly. Reassemble the screen and cap and reopen the feedwater intake valve.
6.6.7 Drain and Flush Hot-well Tank

The hot-well tank should be drained and flushed monthly, or as determined by the feedwater quality.
The following feedwater conditions should be maintained AT ALL TIMES:
• Hardness: 0 ppm (4 ppm maximum)
• pH 10.5–11.5 (normal range), maximum of 12.5
• Oxygen free with an excess sulfite residual of 50–100 ppm during operation (>100 ppm during wet
lay-up)
• Maximum TDS of 8,550 ppm (normal range 3,000–6,000 ppm)
• Maximum dissolved iron of 5 ppm
• Free of suspended solids
• Maximum silica of 120 ppm with the proper OH alkalinity
NOTE
Review the Clayton Industries Feedwater Treatment Reference Manual (R015216)
for additional feedwater quality requirements.
CAUTION
Secure the machine before performing this maintenance procedure.
a. Open the drain valve at the base of the hot-well tank and allow the water to completely 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 is clean and free
of sludge. Repeat the steps above until the rinse water runs clean.
e. Close the drain valve.
f. Fill the tank to the proper level with chemically treated water.
IMPORTANT
Make sure TDS is brought back to the proper levels, see above, and optimum feed-
water conditions are met before placing the machine back into operation.
Sect06_1004_d.fm 04/04/2016
6.6.8 Clean and Adjust Burner

(See Section 7.19 and 7.21.)
6.6.9 Lubricate Blower Wheel Bearings

The blower wheel bearings (Fig. 6-3) should be lubricated at least once a month—more frequently
under severe operating conditions. The recommended grease is an NLGI #2, high temperature, lithium
grease.
CAUTION
Make sure blower wheel is completely stopped before lubricating bearings.
Stop the blower wheel. Initially, add one-half of the amount of grease listed in Table 6-1 into the bear-
ing. Start and run the blower wheel for a few minutes to allow grease to be evenly distributed within the bear-
ing. Stop the blower wheel and add the remaining portion of the grease quantity. A temperature rise,
sometimes 30° F (17° C), after relubrication is normal.
BLOWER HOUSING–FRONT BLOWER HOUSING–REAR
Fig. 6-3. Blower wheel shaft bearings and grease nipples
Table 6-1: Grease quantities

Bore 1/2 - 1 1/2 in. 1 11/16 - 1 15/16 in. 2 - 2 7/16 in. 2 1/2 - 2 15/16 in. 3 - 3 7/16 in. 3 1/2 - 4 in. 4 3/16 - 4 15/16 in.
Quantity 0.1 oz. (2.9 ml) 0.2 oz. (5.9 ml) 0.3 oz. (8.9 ml) 0.5 oz. (14.8 ml) 1.0 oz. (29.6 ml) 1.7 oz. (50.3 ml) 3.0 oz. (88.7 ml)
04/04/2016 Sect06_1004_d.fm
6.7 ANNUAL SERVICE
NOTE
Perform this annual service semi-annually if the steam generator is in use 24 hours a
day, 7 days a week (or similarly continuous operation).
6.7.1 Replace Oil Burner Nozzles

(See Section 7.19.)
6.7.2 Lubricate Bearings

Review pump maintenance requirements outlined in the operation manual in Appendix D.
6.7.3 Test Safety Relief Valves

Set the LPS to exceed the safety relief valve’s pressure setting. Allow pressure to increase by throt-
tling the separator discharge valve (A) until the safety relief valves actuate.
WARNING
Wearing ear protection is recommended to protect against the high noise level gen-
erated from the safety valves actuating. If the valves do not actuate, after exceeding
the pressure setting, open the separator discharge valve (A, Fig. 6-2, page 6-7)
immediately.
After the test is accomplished, regulate the operating pressure to the desired working pressure. Reset
the LPS. (See paragraph 7.7 for LPS setting instructions.) Open the separator discharge valve (A) com-
pletely. Service or replace the safety relief valve(s), as necessary, if test fails.
6.7.4 Gas Valve Leak Testing

Test MGV and SSGV for proper seal at least annually.
Due to the combustible nature of gas, gas valve leak testing should only be performed by Clayton Ser-
vice, a Clayton-authorized service contractor, or other qualified service personnel.
WARNING
Open flames or sparks can cause explosion. Make sure all safety precautions are
used during gas valve leak testing.
Sect06_1004_d.fm 04/04/2016
6.8 LUBRICATION
6.8.1 Lubricate Electric Motor
Check the electric motor lubrication. If the motor is equipped with sealed bearings, the bearings are
prelubricated for the life of the motor. When greasing bearings, wipe the grease fittings clean and use clean
equipment. If the motor is equipped with pressure grease fittings, remove the plug below the motor shaft and
pump the grease in slowly until grease appears at the plug outlet. To prevent rupture of grease seals, run the
motor for 4–5 minutes before replacing the plug. Use a good quality rust inhibited polurea-based grease, such
as Chevron SR1.
04/04/2016 Sect06_1004_d.fm
Sect06_1004_d.fm 04/04/2016
Section VII COMPONENT
MAINTENANCE
7.1 FEEDWATER PUMP

See the OEM (Original Equipment Manufacturer) Pump Operation and Maintenance Manual for
pump maintenance procedures.
7.2 HEATING COIL SCALE REMOVAL

Improperly 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 a restricted
coil.
A “feed-and-bleed” process is used in the descaling process. A large, open-top container is required
in this procedure to facilitate the adding of the acid solution and the monitoring of the descaling progress.
NOTE
This heating coil maintenance procedure requires 10–12 hours to complete.
7.2.1 Setting Up Machine Descaling

(See Fig. 7-1.)
a. Start the machine in the FILL mode (without burner operation). Allow cold water to circulate
through the entire system until it is cooled. Stop the machine and close the feedwater intake valve.
b. Obtain two, or more, non-galvanized, acid-resistant, 55-gallon (200 liter) containers and place
them nearby the feedwater pump. Also, make sure the container can withstand fluid temperatures
above 150° F (66° C).
NOTE
Larger containers maybe required if severe scaling exists. Review this entire desca-
ling procedure to determine if larger containers are needed. Check the coil feed
pressure (paragraph 6.6.1 in Section 6) to determine if additional containers are
required. If additional containers are used, install them in-series to one another.
04/04/2016 Sect07_1004_c.fm 7-1

c. Manifold the two containers in series so the acid solution can be kept consistent throughout the
containers.
d. Elevate the container to provide a 12-inch (30 cm) gravity feed to the feedwater pump. If possible,
provide a pipe outlet 1–2 inches (25–50 mm) above the bottom of the container for acid suction.
e. Remove and replace the intake surge chamber with a suction hose. Make sure the hose is manu-
factured from acid-resistant materials.
f. Attach the opposite end of the suction hose to the outlet at the bottom of the 55-gallon (200 liter)
container. If there is no outlet at the bottom of the container, fasten a fine mesh screen over the
end of the hose and place that end of the hose inside the container. Secure the hose to the container
to prevent it from slipping out.
NOTE
A shutoff valve may be installed at the outlet of the container. This will aid in pre-
venting any acid spillage from the container when the suction hose is disconnected
from the container.
g. Fill the container with 4–5 inches (10–13 cm) of clean, potable water. Make sure the suction hose
or suction outlet is below the water level.
HEATING COIL
FEEDWATER
PUMP
SEPARATOR SUCTION HOSE

STANDPIPE
CONTAINERS
12 in. (30 cm)

COIL DRAIN
VALVE
DRAIN / RETURN HOSE

separator/standpipe
drain valve
Fig. 7-1. The completed hose hookup for descaling should create a closed loop containing the heating unit, water
pump, separator, and 55-gallon (200 liter) containers.
Sect07_1004_c.fm 04/04/2016
Component Maintenance 7-3
h. Remove the coil drain valve at the separator/standpipe.

i. Attach a second acid-resistant type hose to the coil drain outlet. A flange adapter may have to be
fabricated to attach the hose. This hose must be long enough to reach the containers.
j. Securely fasten the opposite end of the hose to the container so that it will not dislodge during the
descaling operation. Considerable pressure can develop in the hose, which can cause it dislodge.
k. Close the separator/standpipe blowdown valve and the trap discharge valve.
NOTE
The completed hose hookups should create a closed loop system consisting of the
heating unit, feedwater pump, and 55-gallon (200 liter) containers, as shown in
Fig. 7-1.
7.2.2 Descaling The Machine

a. Start the machine in the FILL mode (without burner operation).
b. Add or remove water from the container until a steady circulation can be maintained through the
system and back to the container, with about 4–5 inches (10–13 cm) of water remaining in the
container. Be sure the feedwater pump housings are primed.
WARNING
Wear protective clothing. If acid is used improperly, it may cause serious personnel
injury.
c. Mix 3 ounces (89 milliliters) of KleenKoil Inhibitor to one gallon (3.8 liters) of 30% hydrochloric
acid (HCl), or one can of KleenKoil Inhibitor to 5 gallons (19 liters) of 30% HCl.
d. SLOWLY add this acid solution to the container. Monitor the feedwater in the container for foam-
ing. Continue adding the acid solution until foaming stops.
CAUTION
Adding the acid too rapidly can cause bubbling in the feedwater pump check-valve
housing. This can lead to the loss of pump prime.
NOTE
Depending on the severity of the coil scaling, this procedure can require 50 to 100
gallons (190–380 liters) of the acid solution.
04/04/2016 Sect07_1004_c.fm
Initially add the acid solution slowly until the circulation can be maintained without excessive
bubbling from the discharge hose. For example, add about 1/2 cup (120 cc) and wait for the reac-
tion to subside, then add another 1/2 cup (120 cc), repeat. As the cleaning operation progresses,
acid can be added in gradually increasing amounts. In extreme cases, it is possible to completely
block the passage through the coil with loosened scale if acid is added too rapidly.
e. Continue the circulation for 4–6 hours. A longer circulation time is required if bubbling still
occurs in the discharge solution.
NOTE
During this period, frequently check to be sure that the feedwater pump is primed.
The only way to make sure that the pump is primed is to slowly throttle coil feed
valve until the pressure rises on the feed pressure gauge. 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 adding a pinch of sodium bicarbonate (baking soda) into the
container (If baking soda is unavailable, use litmus paper). If no foaming reaction takes place, the
acid has been neutralized (a pH reading of 6.5 to 6.8) and it will be necessary to increase the acid
concentration in the acid solution.
g. When the bubbling subsides, SLOWLY heat the solution by intermittently starting and stopping the
burner until the solution temperature rises to a maximum of 150° F (66° C). Continue circulation
for an additional two hours, cycling the burner whenever necessary to keep the solution hot.
WARNING
DO NOT allow the solution to boil, as injury to personnel and damage to equip-
ment may result.
h. Shut down the machine after the acid solution has circulated for the additional two hours.
7.2.3 After Descaling Is Complete
WARNING
Disconnect hoses carefully to avoid injury from spilling acid solution. If a shutoff
valve was installed at the container, close the valve before disconnecting suction
hose.
Sect07_1004_c.fm 04/04/2016
IMPORTANT
Discharging the acid solution into a local sewage system may be in violation of
municipal codes and regulations. Verify with local government regulatory agencies
for the proper method of disposal.
a. Carefully remove the drain/return hose from the container and direct it to a drain.
b. Carefully disconnect the suction hose from the feedwater pump and direct it to a drain.
c. Open the separator/standpipe drain valve. Allow as much of the solution to drain as possible.
d. Reinstall the feedwater pump intake surge chamber.
e. Close the separator blowdown/drain valve and open the feedwater intake valve.
f. With the discharge hose still directed to the drain, start the machine without burner operation and
allow the machine to run for at least 10 minutes to flush the system of the acid solution. Be sure
the feedwater pump remains primed. Flush the feedwater pump standpipes by opening the drain
cocks to allow water to run until clear.
g. Stop the machine and remove the discharge hose. Reinstall the coil drain valve and plumbing.
h. Open the separator/standpipe drain valve and the trap discharge valve.
IMPORTANT
Start the machine and blowdown the machine thoroughly four to five times (see
paragraph 4.5.5, Section IV) before resuming normal operation. This will dislodge
and remove much of the loosened scale.
7.3 HEATING COIL REPLACEMENT

7.3.1 Heating Coil Removal
The heating coil has been designed to enable its removal without disassembling the coil, inner shell,
and insulation assembly (See Fig. 7-2.)
a. Disconnect piping from the heating coil inlet and outlet connections and all interference.
b. Remove the sealing plate, the thermocouple assembly and piping to avoid interference with the
heating coil removal.
c. Disassemble the removable section of the exhaust stack above the outer heater cover (1). Remove
the upper and lower clamp bands (3) and remove the outer and inner heater cover (1 and 2).
Remove the sheetmetal screws from the outer shell (4) and remove outer shell sections.
d. Loosen castable insulation, it may be necessary to remove some, or all of the insulation. Soaking
the castable insulation in water (insulation is water soluble) overnight may be required prior to
lifting coil assembly.
e. Remove the four hold-down bolts, located at the bottom of the shell at the four anchor brackets.
04/04/2016 Sect07_1004_c.fm
f. Lift the heating coil and shell assembly complete from the burner base using the lifting lug (16).
The burner base and frame must be bolted down while lifting the coil assembly.
1. Outer Heater Cover

2. Inner Heater Cover
3. Clamp Band
4. Outer Shell
5. Burner Base
6. Burner Manifold
7. Burner Volute
8. Refractory Insulation
9. Cap Screws
10. Castable Insulation
11. Water Air Passage
12. Air Passage
13. Heating Coil
14. Coil Insulation
15. Cap Screws
16. Lifting Lug
Fig. 7-2. Heating Unit (typical)
7.3.2 Burner Base Insulation Replacement
IMPORTANT
Read through the instructions in this section thoroughly before starting. DO NOT
mix any of the refractories until it is needed.
NOTE
The refractory replacement process requires 3 days to complete
Sect07_1004_c.fm 04/04/2016
The Clayton recommended refractories are:

• Pyro Castable Insulation (Part #: 18506)
• Super Kast-Set Plus refractory cement (Part #: 11297)
NOTE
The mixing instructions in this section applies to the above mentioned refractories
only. These procedures do not apply for refractories from other suppliers
NOTE
Always store castable insulation and refractory cement in a clean dry place.
Remove the heating coil as instructed in paragraph 7.6.1. Repair any small breaks in the insulation
with a high temperature refractory cement and water.
Break up and remove the old refractory from the burner base. The castable insulation may be reused if
it is kept clean.
7.3.2.1 Mixing the refractories
The insulation and cement are designed to be mixed with water and cast into place. Water aids these
refractories in developing a hydraulic set. All porous (moisture absorbing) back-up materials or wooden
forms should be waterproofed.
Preparing the refractories
The following preparations apply to both the castable insulation and the refractory cement:
• Make sure all mixing vessels and tools used are clean of grease, oil, dirt, and rust. This is espe-
cially important for mixing the refractory cement. Any impurities from the tools or the mixing
vessels can compromise the strength of the cement.
• Use only clean potable water, such as, water suitable for drinking.
• Premix contents of the entire bag before adding water.
• Use a paddle-type mechanical mixer if available.
• Make sure the forms being used are sturdy and tight. Forms made from wood or other moisture
absorbing material should be greased or, otherwise, waterproofed.
Mixing the castable insulation
Pour the proper amount of dry castable insulation (see Table 1) into mixing vessel. Add 18 to 20
quarts (17 to 19 liters) of clean potable water to the insulation and thoroughly mix. Add water in small
increments while thoroughly mixing between pours. The objective is to use as little water as possible
to achieve the desired consistency (similar to a concrete mixture). Too much water can adversely
affect the strength of the insulation. The last portion of water should be added in small amounts
because the insulation consistency can changes rapidly with each additional amount of water.
04/04/2016 Sect07_1004_c.fm
CAUTION
Insufficient or excessive water content will adversely affect the strength of the
product.
Pour the mixture within 20 minutes from the time of mixing.
Table 7-1: Refractory Insulation Quantities
Castable Base Insulation Coil Setting Insulation Refractory Cement

MODEL
No. 18506 No. 18506 No. 11297 Item No. 3
E-1004 200 lb. (94 kg) 360 lb. (165 kg) 1540 lb. (700 kg)
Mixing the refractory cement

Pour the proper amount of dry refractory cement (see Table 1) into mixing vessel. Add 5 1/2
quarts (5.2 liters) of clean potable water to each 100 pounds (45.4 kg) of cement and thoroughly mix.
Add water in small increments while thoroughly mixing between pours. The objective is to use as lit-
tle water as possible to achieve the desired consistency (similar to a concrete mixture).
CAUTION
Insufficient or excessive water content will adversely affect the strength of the
product.
A simple test can be conducted with the cement to verify proper its consistency. Take a small
handful of the cement and attempt to form a ball by tossing it up and down—1 to 2 inches (25 to
50 mm)—10 to 12 times in the hand. If the cement is too dry, it will break into pieces. If it is too wet,
it will sag between the fingers.
Pour the mixture within 20 minutes from the time of mixing.
7.3.2.2 Pouring refractory cement and castable insulation
For best results, the temperature for the refractories should be between 50° F and 90° F (10° C and
32° C).
Burner base section surrounding the gas ring (Fig. 7-3)
1. Pour the castable insulation mixture (8) into the burner base bottom.
2. Tamp the burner base and mixture firmly to the approximate dimensions shown under col-
umns B and C in Table 2.
3. Allow insulation to set for 24 hours before preceding to the next step.
Sect07_1004_c.fm 04/04/2016
IMPORTANT
Do NOT disturb the insulation while it is setting. Keep its surface moist for the 24-
hour setting period.
NOTE
Before preceding with the next step, dampen all surfaces where the refractory
cement is being poured.
4. Pour the refractory cement mixture (3) over the castable insulation (8).
1. Fiberglass Insulation
2. Heating Coil
3. Refractory Cement
5. Burner Base
6. Coil Shell (Outer)
7. Vent Opening
9. Gas Burner Ring
10. Outer Refractory Band
11. Coil Shell (inner)
Fig. 7-3. Burner Base Insulation
Table 7-2: Refractory Pouring Dimensions
MODEL A B C D E
E-1004 / 1104 / 1204 2 in. (51 mm) 3/4 in. (19 mm) 4 in. (102 mm) 1 in. (25 mm) 6 in. (152 mm)
04/04/2016 Sect07_1004_c.fm
5. Carefully, trowel the cement, to the dimensions under columns A and D in Table 7-2. Slope
the surface from dimension D, above the inner refractory band, to the outside edge of the gas
burner ring (5).
6. Remove all air pockets using a concrete vibrator, spade, or trowel. Do NOT trowel cement
surface to a slick finish. Leave it rough.
7. Allow the cement time to set firmly.
8. Using a knife, or a piece of rigid sheetmetal, cut 6–8 equally spaced, 3/8-inch (10 mm)
expansion slots radially into the cement 3/8–1/2 inch (10–12 mm) deep (Fig. 7-4).
Fig. 7-4. Typical refractory expansion slots
9. Cover and seal the cement with plastic to prevent its surface from drying before the hydrau-
lic set. Allow 24 hours for the cement to set when the ambient temperature is above 60° F
(15° C). Cement setting time increases as the ambient temperature decreases below 60° F
(15° C).
NOTE
Protect the cement from freezing temperatures during its hydraulic setting period.
10.When the refractory cement has set, use a wire brush to remove any loose cement from the
surface.
Sect07_1004_c.fm 04/04/2016
Castable insulation moat surrounding inner burner base section

1. Coat all surfaces of the moat area (Fig. 7-4) that will be making contact with the insulation
with a form release agent.
2. Pour the castable insulation mixture into the insulation moat to the dimension specified in
column E of Table 3.
3. Lower the heating coil into the moat containing the insulation.
4. Make sure the moat is filled and no insulation has overflowed into the inner burner base
section.
5. Allow insulation to set for a minimum of 24 hours before preceding to the next step.
IMPORTANT
Do NOT disturb the Insulation while it is setting. Keep its surface moist for the 24-
hour setting period.
6. When the insulation has set properly, completely reassemble the machine.
7. Perform an initial firing. To prevent the insulation from cracking during the initial startup,
control the initial heat-up rate by firing at low fire for 10 to 20 seconds and then off for 5
minutes. Repeat this step several times until the insulation is cured.
7.3.3 Heating Coil Repair and Installation

(Refer to Fig. 7-2, page 7-6.)
Hydrostatically test the heating coil for leaks. If the code-proper weld repairs cannot be made in the
field, the coil must be sent to Clayton Industries factory repair facility or replaced. To replace the coil, pro-
ceed as follows:
a. Seal the vent opening around the top of the burner base and coil discharge outlet with masking
tape. This will prevent insulating material from entering the cooling air passage.
b. Fill the coil recess in the burner base with mixed castable insulation (only enough water to
dampen the mixture). Lift the coil and position it on the burner base, allowing the coil to settle into
the insulation. Secure the coil to the burner base with the four (4) hold-down bolts. Remove the
masking tape seal from the vent opening when the insulation dries sufficiently.
c. Replace the thermocouple assembly and plumbing. Re-install all outer shells (4), and Inner (2)
and outer heater covers (1). Replace the upper and lower clamp bands (3). Replace the removable
section of the exhaust stack.
d. Replace the cap screws which attach the separator to the bracket on the coil. Reconnect the heat-
ing coil inlet and outlet piping connections.
e. Verify all piping and electrical connections are attached correctly.
7.3.4 Coil Water Washing

See the Coil Water Washing (CW) Supplemental Instruction in Appendix A.
04/04/2016 Sect07_1004_c.fm
7.4 NET POSITIVE SUCTION HEAD (NPSH) SWITCH

The net positive suction head switch shuts down the machine when NPSH to the feedwater pump is
too low. A transducer installed at the feedwater inlet piping transmits a signal to the PLC. When low NPSH
(See Table of Reference Values in Appendix B) is detected, the PLC secures the machine.
7.5 CHECK AND SET ATS

(See Fig. 7-5.)
a. Operate the machine at the highest expected
pressure (20% rate).
b. Dial the ATS setpoint slowly down to the
point of interruption. Note the reading and
adjust the temperature to 25° F (14° C) above
this point.
c. Push the ATS reset lever.
d. If the dial reading at the shutoff point is
within 15° F (8° C) of the saturated tempera-
ture for the operating pressure at shutoff, the
ATS is operating properly; if it is not within Fig. 7-5. ATS Limit Stop Adjustment
15° F (8° C), replace the switch. (Refer to the
Pressure-Temperature Table in Section II.)
7.5.1 Limit Stop Adjustment

After setting the dial to the desired cut-off temperature (25° F above normal operating temperature),
remove the switch cover and slide the dial limit stop (left-hand side below dial) out against the step behind
the dial.
NOTE
This adjustment will limit the high-end temperature adjustment to within 5°–15° F
(3°–8° C) of the cut-off setting. This reduces the possibility of the switch being
accidentally set at a higher temperature after checking the switch.
7.6 MTLC CHECK

a. Remove one thermocouple lead wire from the MTLC.
b. Verify that a shutdown occurs and an alarm is initiated within one minute.
c. Replace the thermocouple lead wire.
d. Repeat steps a, b, and c for other MTLC.
Sect07_1004_c.fm 04/04/2016
NOTE
If any of the MTLCs are suspected of being faulty, remove it and conduct further
bench testing. Replace the MTLC if it is faulty.
7.7 LPS ADJUSTMENT

The LPS is connected in a series with the holding circuit and, in the event of excessive discharge pres-
sure, will actuate, completely stopping the machine. Once the pressure has been relieved, a manual reset is
required before the machine can be restarted.
7.7.1 Adjustment
The LPS should be set to open (shutting machine off) at a pressure midway between the OPS set point
and the opening pressure of the safety relief valves. To set the LPS, set the OPS to a pressure above the
desired LPS setting and slowly throttle the separator discharge valve to increase the pressure. Turn the LPS
adjusting dial to the desired set point, actuating (opening) the switch. It may take more than one attempt to
obtain an accurate setting. Reset the LPS and press the START pushbutton to restart the machine. Be sure to
reset the OPS to its original setting.
7.8 APS ADJUSTMENT
The APS will interrupt burner firing on low

blower air pressure. A shutdown of the burner
should occur within 75 percent below the low fir-
ing rate. If needed, the APS setpoint may be
adjusted as follows:
a. Place machine in RUN mode and decrease
the controls to minimum firing rate.
b. Remove cover from the APS to gain access
to adjustable (yellow) dial (Fig. 7-6).
c. Turn dial clockwise to increase pressure set-
ting until lockout occurs (ESC display reads
“lockout”).
d. Turn dial counterclockwise to 75 percent Fig. 7-6. APS adjustment
below the pressure setting in step c.
e. Replace cover.
7.9 AIR DAMPER ADJUSTMENT

The air damper may require adjustment when machine emissions fail to comply with local air quality
standards. In some cases, deteriorating emissions may also indicate the machine’s efficiency has deteriorated.
04/04/2016 Sect07_1004_c.fm
Adjusting the air damper affects the fuel-to-air ratio curve programmed into the LMV burner control-
ler. Modifications to this curve also requires proportional adjustment to the modulating gas control valve. In
addition, exhaust emission readings must be taken during the calibration procedure. Therefore, it is recom-
mended that air damper adjustment be performed by Clayton Service or Clayton authorized service personnel
only.
7.10 GAS PRESSURE REGULATOR

The gas pressure regulator maintains a constant gas pressure drop to provide a consistent flow rate in
response to the demand.
7.10.1 Preliminary Adjustment

Remove the cap and turn the spring adjusting nut down a distance of 2 1/4 inches (55 mm), measured
from the top edge of the housing to the top of the nut. This will give an approximate setting that will permit
the machine to be fired so that final adjustments can be made.
7.10.2 Final Adjustment

(Requires machine to be operable.) Check the gas supply pressure. (See the Specification Table in
Appendix B for gas supply requirements.)
a. Start the machine and operate it on low fire (minimum rate).
b. Check the damper position of the butterfly gas valve. Correct the setting if necessary. (See Table
of Reference Values in Appendix B for settings.)
NOTE
To obtain the most accurate setting, the use of a water column manometer is
required. Connect the manometer at the pressure sensing line pipe tee on the gas
pressure regulator.
c. Bring the machine to the maximum-fire position (100% rate) and adjust the gas pressure regulator
to hold the “gas burner pressure,” as recorded on the factory test sheet, by turning the spring
adjusting nut clockwise to increase pressure, and counterclockwise to reduce pressure. Replace
the cap after adjustment.
7.11 GAS PRESSURE SWITCHES

There are two gas pressure switches, GPSL and GPSH, installed in the fuel system of the steam gen-
erator. The low gas pressure switch (GPSL) closes on a loss in supply gas pressure; the high gas pressure
switch (GPSH) opens on rise of burner pressure. If supply gas or burner pressure exceeds the setpoint of the
respective switch, the burner circuit will open and cause a complete shutdown of the machine. A manual
reset is required if either switch is actuated. Note: Manual reset can be accomplished without removing the
clear cover. To manually reset the pressure switch, press the spot on the cover directly above the red manual
reset button (Fig. 7-7).
Sect07_1004_c.fm 04/04/2016
If needed, the GPSL/GPSH setpoint may

be adjusted as follows:
a. Remove clear cover from the switch to
gain access to adjustable (yellow) dial
(Fig. 7-7).
b. Turn dial until the desired pressure set-
point is aligned with the white line on the
yellow dial face. (See Table of Reference
Values in Appendix B for setpoint.)
c. Verify the switch operates as intended.
d. Replace cover.
7.12 GAS PILOT PRESSURE

REGULATOR ADJUSTMENT Fig. 7-7. GPSL/GPSH adjusting dial and manual reset
button.
The gas pilot pressure should be adjusted
to give the best flame strength signal as indicated
on the ESC display. Place the ESC RUN/CHECK dip switch in the CHECK position. This will prevent acu-
tation of the main burner controls during gas pilot adjustments. Adjust the pilot gas pressure up and down, as
necessary, to give the quickest or sharpest response (however, this might not necessarily give the highest
voltage reading).
This machine uses a flame sensor control with a 20 pull-in, and a 20–80 normal value. Properly
adjusted, the gas pilot pressure
7.13 FPR (FUEL PRESSURE REGULATOR) ADJUSTMENT -

OIL-FIRED MACHINES
Excessive fuel pressure will cause the burner to smoke and result in sooting of the heating coil. How-
ever, if the fuel pressure is too low, the machine will be slow in coming up to pressure and will not achieve
the designed output during periods of maximum demand. To adjust the regulator, adapt a test pressure gauge
(0–100 psi {0–690 kPa}) to the 1/8-inch tee connection at the bottom of the fuel pressure regulator. Loosen
the hex nut securing the adjusting screw. Turn the adjusting screw clockwise to raise the pressure; turn the
adjusting screw counterclockwise to lower the pressure. Avoid raising the pressure to a point which will
cause overfiring and thermostat interruption.
CAUTION
Do not exceed the maximum fuel input to the burner.
It is important to maintain a close balance between fuel input atomizing air and water rate. Therefore,
the adjusted values should not vary considerably from those shown in the performance chart, which is
included as part of each Factory Test Sheet. The burner oil pressure also depends on the atomizing air pres-
sure. Check it before making any fuel pressure adjustments.
04/04/2016 Sect07_1004_c.fm
7.14 FPS ADJUSTMENT - OIL-FIRED MACHINES

a. Install a test pressure gauge (0–100 psi {0–690 kPa}) in the fuel system (connection provided).
b. Start the machine.
c. Place the machine in FILL mode and close the manual fuel control valve.
d. Connect a VOM to the N.O. and COMM terminals of the fuel pressure switch and set the meter on
the resistance scale.
e. Adjust the fuel pressure regulator to raise and lower the fuel pressure to check the opening and
closing of the switch.
f. Turn the switch adjusting screw clockwise to raise the pressure setting, and counterclockwise to
lower the pressure setting.
NOTE
This setting will allow sufficient fuel pressure to induce proper atomization when
fuel is admitted to the burner. The differential (approximately 15 psi {105 kPa})
between opening and closing cannot be changed.
g. After the fuel pressure switch adjustment, return the fuel pressure regulator to its original setting
(see paragraph 7.16). If desired, the fuel pressure switch can be adjusted to close at the normal fuel
pressure regulator setting. Then turn the fuel pressure switch adjusting screw counterclockwise
one-half turn (one-half a turn is equal to approximately 15 psi {105 kPa}).
7.15 MODULATING OIL CONTROL VALVE ADJUSTMENT

(See Fig. 7-8.)
WARNING
Improper adjustment of this equipment and its
components can result in fire, explosion, or severe
personal injury.
Adjustment of this equipment should only be

performed by Clayton Service or other Clayton autho-
rized personnel. Call Clayton Service if the oil control
valve requires adjustment.
Fig. 7-8. Modulating fuel control valve
Sect07_1004_c.fm 04/04/2016
7.16 OIL BURNER MANIFOLD

7.16.1 Cleaning and Adjustment
(See Fig. 7-9.)
a. Disconnect fuel oil, atomizing air, and pilot lines (gas or oil), and flame scanner (13) from burner
manifold. Remove ignition cable from ignition electrode. Loosen the wing nuts holding the burner
manifold to burner base. Rotate the mounting plate (19) and remove the burner manifold assem-
bly. If necessary, scrape carbon deposits from manifold. Important: DO NOT SCRAPE TIP OF
THE NOZZLE.
b. Unscrew and remove the nozzle cap (6). Remove metering nozzle (4) and clean as required. Blow
parts out with compressed air, if available. Be sure all dirt and grit is removed. Clean the burner
manifold as needed.
CAUTION
Do not use a sharp instrument for cleaning because a sharp instrument can scratch
or disfigure the nozzle Tip. A slight scratch can seriously impair nozzle and burner
operation.
c. Reassemble metering nozzle (4) and nozzle cap (6) and screw onto nozzle body (7). Do not over-
tighten; hand tighten until nozzle is snug.
d. Inspect pilot tube (18). Make sure it is clean and free of debris.
e. Adjust nozzle height by loosening set screws (10) and raising or lowering pipe nipples (9) to meet
dimensions shown in Fig. 7-9. Set pilot tube deflector vane as shown.
7.16.2 Electrode Adjustment - Oil-fired Machines

a. Loosen the electrode lock nut (15) and adjust the ignition electrode (14) to meet specifications
indicated in Fig. 7-9.
CAUTION
Use care when adjusting electrode to avoid cracking the insulator. The insulator
may develop a short due to such a fracture, resulting in ignition failure.
b. Make sure ignition electrode is mounted properly, is clean, and in good condition.
c. If it is necessary to replace the ignition electrode (14), remove the lock nut (15). Remove the old
electrode and insert the new one. Rotate electrode so the end is perpendicular (90°) to, and 1/8
inch (3 mm) from, the pilot tube ground bar. Retighten lock nut. Make sure clearances conform to
dimensions given in Fig. 7-9.
04/04/2016 Sect07_1004_c.fm
(5 mm)
1/8” (3 mm)
1. Outer Cone Assembly 8. Pipe Bushing 15. Electrode Lock Nut

2. Inner Cone Assembly 9. Pipe Nipple 16. Electrode Base
3. Cap Screw 10. Set Screw 17. Set Screw
4. Metering Nozzle 11. Tube Connector, air 18. Pilot Tube
5. Swirl Chamber 12. Tube Connector, oil 19. Mounting Plate
6. Nozzle Cap 13. Flame Scanner 20. Air Deflector
7. Nozzle Body 14. Ignition Electrode
Fig. 7-9. Oil Burner Manifold
d. Ensure that the flame scanner (13) is clean and in good condition.
e. After starting the machine, check the flame detector voltage at the ESC display module. When a
flame is established, the display reading should be 4–5 vdc. It is normal for the meter to fluctuate
slightly. If the flame signal is inadequate, review Section V, Troubleshooting, for possible causes.
Sect07_1004_c.fm 04/04/2016
7.17 AAPS ADJUSTMENT

This switch is a safety device used to ensure proper air delivery from an external supply to obtain the
proper burner operation.
a. Install a test pressure gauge (0-100 psi {690 kPa}) in the air supply line.
b. Install a jumper between terminals one and the appropriate terminal inside the electrical control
box to open the Air Solenoid Valve (ASV).
c. Connect a VOM to the switch terminals, “N.O.” and ground it (conduit). Set the meter on 250 volt
scale. The voltage reading (110 volt) indicates the switch is closed.
d. Throttle the air supply shut-off valve (customer installed) to obtain the minimum supply pressure
setting on the gauge. The machine should not be running while performing adjustments. (See the
Reference Chart in Appendix B for proper values.)
e. Turn the large slotted pressure adjusting screw, located at the top right side of the switch, counter-
clockwise until the switch closes.
f. Continue to throttle the air supply shut-off valve until the pressure drops 10 psi (70 kPa) below the
above setting. Adjust the small slotted range adjusting screw, located at the top left side of switch,
until the switch opens (no voltage on VOM).
g. Remove the test gauge and jumpers.
7.18 GAS BURNER MANIFOLD

7.18.1 Cleaning
a. Remove the pilot gas line, ignition electrode cable, and flame scanner (4). (See Fig. 7-10.)
b. Unscrew and remove the nuts that attach the burner manifold to the volute and carefully lower the
manifold from the volute.
c. Clean the ignition electrode (5) and check for proper adjustment. (See Fig. 7-10 for dimensions.)
d. Make sure the pilot tube (9) is clean. Set the air deflector vane (11) as shown in Fig. 7-10.
CAUTION
Use care when bending or adjusting the electrode to avoid cracking the insulator.
The insulator may develop an invisible short due to such a fracture. This short will
result in an ignition failure.
04/04/2016 Sect07_1004_c.fm
1. Outer Cone Assembly 5. Ignition Electrode 9. Pilot Tube

2. Inner Cone Assembly 6. Electrode Lock Nut 10. Mounting Plate
3. Cap Screw 7. Electrode Base 11. Air Deflector
4. Flame Scanner 8. Set Screw
Fig. 7-10. Gas Burner Manifold
7.18.2 Electrode Adjustment

a. Loosen the electrode lock nut (6) and adjust the ignition electrode (5) to meet specifications indi-
cated in Fig. 7-10.
CAUTION
Use care when adjusting electrode to avoid cracking the insulator. The insulator
may develop a short due to such a fracture, resulting in ignition failure.
Sect07_1004_c.fm 04/04/2016
b. Make sure ignition electrode is mounted properly, is clean, and in good condition.
c. If it is necessary to replace the ignition electrode (5), remove the lock nut (6). Remove the old
electrode and insert the new one. Rotate electrode so the end is perpendicular (90°) to, and 1/8
inch (3 mm) from, the pilot tube ground bar. Retighten lock nut. Make sure clearances conform to
dimensions given in Fig. 7-10.
d. Ensure that the flame scanner (4) is clean and in good condition.
e. After starting the machine, the proper output of the flame detector can be checked by observing
the flame strength indicated on the ESC display. When the flame is established, the ESC display
value should be between 0% and 100%. If the flame signal is inadequate, review Section V, Trou-
bleshooting, for possible causes.
7.19 BLOWER MOTOR BELT REPLACEMENT

7.19.1 Removal
(See Fig. 7-11.)
a. Remove the blower motor belt guard.
b. Loosen the motor mounting hex nuts.
c. Turn the jack screws in an alternating sequence to
slide the motor inward so belt tension is removed.
d. Remove the belts from the pulleys.
7.19.2 Assembly
a. Install new belts over the pulleys.
b. Turn the jack screws in an alternating sequence to
pull the motor outwards. Continue jacking the
motor outwards until the belts are taut. Do not
overtighten.
c. Verify the blower and motor pulleys faces are
aligned when a straightedge is held up against
them (Fig. 7-12).
d. Tighten down the motor mounting hex nuts when
pulleys are properly aligned.
Fig. 7-11. Blower motor
e. Reinstall the belt guard.
04/04/2016 Sect07_1004_c.fm
Fig. 7-12. Verify the Blower and Motor Pulleys are aligned.
Sect07_1004_c.fm 04/04/2016
Section VIII TROUBLESHOOTING
8.1 ANNUNCIATOR SYSTEM

The following chart lists the primary safety shutdown conditions together with the cause and remedial
procedure to follow in the event a safety shutdown of the machine has occurred.
Trouble Possible Cause Remedy
Pump failing to maintain Low NPSH to water pump inlet causing Correct the cause for inadequate
proper feed volume to intermittent pump operation. water pump inlet pressure (NPSH).
heating coil, causing Vapor lock of pump due to inadequate head See manufacturer’s pump installation
thermostat interruption relative to temperature. manual.
Feedwater pump not primed. Prime feedwater pump.
Strainer partially plugged. Hot well tank drain Correct accordingly.
open. Float valve strainer plugged.
Blower motor overload Motor thermal overload has caused the ther-Check for and correct cause of over-
mal trip unit in the GMP to secure the blower
load in the motor circuit. The GMP
motor and burner controls. must be reset.
Thermostat Low water condition or improper ATS adjust-Correct cause of low water or water
ment stops motor and burner. failure condition.*Test Thermostat for
proper control (see paragraphs 6.6.6,
6.6.7, 7.5, 7.6).
*Possible causes:
1.Empty hot well tank.
2.Clogged inlet strainer.
3.Malfunctioning booster pump(s).
MTLCs fail to stop motor or MTLCs or thermocouple are malfunctioning. Check and replace faulty MTLC (see
burner paragraph 7.6.).
Check, adjust, or replace thermocou-
ple (see paragraph 6.6.4).
Blower motor overload Motor thermal overload has caused the ther- Check for and correct cause of over-
mal trip unit in the GMP to secure the motor load in the motor circuit. Allow the
and burner. GMP element to cool (2–3 minutes);
then, manually reset GMP.
04/13/2015 Sect08_1004_KSB_b.fm 8-1


Pump motor overload VSD over current (ground fault) or excessive Check for and correct cause of over-
current due to overload has caused the load in the VSD circuit. The GMP can
instantaneous or over current trip unit in the be reset and the annunciator lamp
GMP to secure the VSD and burner. will stop glowing after the overload
element cools (2–3 minutes) and is
manually reset.
VSD overload VSD over current (ground fault) or excessive Check for and correct causes of
current due to overload has caused the ther- overload in the VSD circuit. The
mal or over current trip unit, in the GMP, to GMP can be reset after the overload
secure the VSD and burner. condition is removed and the ele-
ment cools.
Burner The burner controls have been “locked out” Check causes and remedies of
by the ESC due to burner failure. burner failure, see Section 8.3 or 8.4.
The ESC must be manually reset
before an attempted burner restart
can be made.
Air pressure The APS has interrupted plant operation due Check blower belts and belt tension.
to blower failure or clogged air line. Check and clean air pickup tube
inside the air duct.
Limit pressure Excessive discharge pressure in the separa- Relieve the separator pressure. Ver-
tor caused LPS to actuate. ify LPS is functioning properly; verify
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.
Sect08_1004_KSB_b.fm 04/13/2015
Troubleshooting 8-3
8.2 WATER SYSTEM
Noisy Feedwater Pump operation See pump manufacturer’s operations manual in Appendix D.
Overheating Hot Well Tank Modulating system malfunction. Check and readjust modulating sys-
tem controls for proper water rate or
over firing.
Temperature regulator valve not Adjust temperature regulator for
working properly. proper temperature.
Weeping safety relief valve Contamination of the seating sur- Replace valve. The valve may be
faces of the seat or disc. resurfaced by an authorized repair
shop if the damage is not extensive.
NOTE: The pump relief valve is not to
be tampered with by an unauthorized
person.
8.3 FUEL SYSTEM - GAS-FIRED MACHINES
Pilot fails to ignite Gas shut off at supply. Open gas service cocks.
(Following purge period, pilot light will Pilot cock closed. Open pilot cock.
illuminate indicating gas pilot has Pilot solenoid valve failing to open. Check for burned-out solenoid coil.
been detected. If pilot flame is not
Faulty ignition. Check and adjust ignition electrode.
established within the trial for ignition
period after the purge period, the
ESC will lock out the burner controls) Test ignition transformer and ignition
cable.
Pilot ignites but safety shutdown Flame scanner lens dirty. Cleans lens.
occurs Scanner voltage too low. Test flame signal voltage.
Main gas cock closed. Open main gas cock.
Burner fails to ignite when main Pilot flame failure. Check causes and remedies under
gas cock is opened “Pilot Fails to Ignite”.
Main gas valve inoperative. Check circuit to main gas valve.
Delayed shutoff of burner during Main gas valve not seating properly. Check main gas valve.
automatic operation
04/13/2015 Sect08_1004_KSB_b.fm

Partial or improper burner Low gas service pressure caused by See Specifications (Appendix B) for
operation causing low system heavy gas demand or small service proper gas service installation.
pressure at normal load connection.
Burner equipment not suited to type Burner equipment must be altered if
of gas being used. gas service does not comply with gas
specification plate.
Improper air-fuel mixture. Adjust combustion air (see paragraph
7.9).
Measure exhaust stack draft. Check
exhaust stack for improper installa-
tion or restriction.
Insufficient air to boiler room. Install air duct from outside air to
blower. See R16600 Installation Man-
ual for air requirements.
8.4 FUEL SYSTEM - OIL-FIRED
Burner shuts off during normal MTLC1/2 or ATS interruption due to Correct cause of low water condition
operation or before maximum low water condition (alarm condition). immediately. Also check for improper
system pressure is reached Incorrect pressure setpoints. OPS or MPS setpoints. (see para-
graph 7.5 for ATS instructions.)
Low or no fuel pressure Fuel supply exhausted or supply lines Check fuel supply. Be sure all valves
(CAUTION: Stop machine restricted. in supply line are open.
immediately to avoid damage to Fuel Fuel not completely passing through Burner control valve must be fully
Pump.) burner control valve. open for maximum fuel pressure.
Fuel pressure not adjusted properly. Adjust fuel pressure (see paragraph
7.13).
Air leak in supply line causing loss of Suction line must be air tight and air
prime. pockets eliminated.
Fuel pump failure. Replace fuel pump.
Sect08_1004_KSB_b.fm 04/13/2015
Troubleshooting 8-5

Burner fails to ignite Faulty ignition. Check and adjust ignition electrode.
Check ignition transformer and igni-
tion cable.
Check for temporary or intermittent
low voltage condition which may
cause weak spark from transformer.
Install heavier feeder lines to
machine if necessary.
Fuel pressure switch failure. Check and adjust fuel pressure
switch or replace.
Burner nozzle not replaced in burner. Be sure to replace burner nozzle
after cleaning manifold.
Insufficient fuel pressure. Check causes and remedies under
“Low or No Fuel Pressure.”
Fuel solenoid valve failing to open. Check valve for burned out solenoid.
Partial or improper burner Fuel solenoid valve(s) failing to open. Check valve for burned out sole-
operation causing low system noid(s).
pressure at normal load Modulating system malfunction. Readjust modulating system controls.
Smoke from flue outlet Insufficient air supply to burner. Check air adjustment (see paragraph
(To prevent sooting of heating coil 7.9).
and burner, this condition must be Fuel pressure not adjusted properly. Adjust fuel pressure (see paragraph
corrected immediately.) 7.13).
Carboned, loose or worn burner noz- Clean and tighten burner nozzle.
zle. Replace if worn (see paragraph
7.16).
Heating coil sooted. Perform soot blow (see paragraph
6.4.4). If soot blowing is ineffective,
perform a coil wash (see Coil Wash
in Appendix A).
Dirt or sludge in fuel oil or wrong Be sure fuel is clean. (See Installa-
grade of fuel used. tion Manual for fuel specifications.)
Dead or fluttering burner shut off Oil valve(s) not seating properly. Check and clean oil solenoid
during automatic operation valve(s).
Oil drip from burner Oil valve(s) not seating properly. Check and clean oil solenoid
valve(s).
Loose burner nozzle. Tighten nozzle.
Carbon on burner nozzle causing Remove and clean Nozzle.
deflection of oil spray.
04/13/2015 Sect08_1004_KSB_b.fm

Dead or fluttering flame Restricted or sooted flue pipe caus- Remove soot or restriction. Be sure
ing back pressure in combustion exhaust stack is installed correctly
chamber. (see Installation Manual).
Heating coil sooted. Perform soot blow (see paragraph
6.4.4). If soot blowing is ineffective,
perform a coil wash (see Coil Wash
in Appendix A).
Insufficient air to boiler room. Install duct from outside air to blower.
Modulating air damper out of adjust- Adjust air damper (see paragraph
ment. 7.9).
Improper air adjustment to Burner.
Burner nozzle carboned over. Remove and clean nozzle (see para-
graph 7.16).
8.5 ELECTRICAL SYSTEM

WARNING
Observe all warning and caution labels to avoid electrical shock when working
with electrical components.

Burner purge cycle fails to occur GPSL actuated. Reset GPSL. Check supply gas pres-
sure. 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 Power failure or blown fuse. Check fuses in lines to machine.
operation Safety shutdown caused by thermal Wait for elements to cool; then manu-
trip unit in the GMP. ally 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.
Improper oil level in crankcase. Correct the oil level in the crankcase.
Check for low voltage. Correct cause.
Sect08_1004_KSB_b.fm 04/13/2015
Troubleshooting 8-7

Motor noisy or running hot Motor running single phase. Check for blown fuse in feeder lines.
Insufficient lubrication or bearing fail- Lubricate bearings. Check for worn
ure. bearings.
Excessive system pressure Modulating Pressure Setting Differen- Adjust based on existing steam load
variation tial out of adjustment. conditions.
Magnetic Controller fails to contact Operating coil failure. Also see trou- Replace coil. Be sure the coil is prop-
bles and remedies under “Motor Fails erly rated for the installation.
to Start.”
Contact failure caused by poor con- Replace contacts.
tact pressure, dirt, arcing, or low volt-
age.
Magnetic Controller fails to Welded contacts, due to arc, or Replace contacts. Correct cause of
disconnect mechanical binding. binding.
Magnetic Controller noisy Poor alignment, wrong coil, mechani- Check and clean magnetic controller.
cal binding, or gummy guide sur-
faces.
Burner purge cycle fails to occur Modulating motor, safety shut-off Modulating motor must be in low-fire
valve, ATS, or other upstream con- position.
tacts open. 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.
04/13/2015 Sect08_1004_KSB_b.fm
8.6 BURNER SAFETY CONTROLS

WARNING
Observe all warning and caution labels to avoid electrical shock when working
with electrical components.
Trouble Electrical Check Possible Cause Remedy

Gas pilot fails to ignite 120 vac to pilot valve, but Failed pilot solenoid valve Replace coil.
(Safety switch in ESC pilot valve fails to open. coil.
locks out. Also see ESC display shows no Pilot cock closed or fuel oil Open pilot cock. Remove
section 8.3.) scanner voltage. in pilot cock. pilot cock and clean.
Failed flame scanner. Replace flame scanner.
Pilot Cock partially opened. Clean Restrictor. Open Pilot
Partially clogged restrictor. Cock. Reset ESC.
Main burner fails to ignite 120 vac at actuator valve. No supply gas. Open supply gas valve.
(main gas cock open) 120 vac at actuator valve, Loose wire connection at Tighten terminals at ESC
but valve still fails to open. valve. Faulty valve actuator. and at gas valve actuator.
Gas pilot ignites but main 120 vac from ESC terminal Scanner or scanner leads Readjust/Clean scanner.
burner fails to ignite X9.01.03/04. Pilot lights, faulty. Replace scanner. Reset
(Safety switch in ESC but lockout occurring. ESC safety switch.
locks out.) Check ESC flame signal. If Scanner or scanner leads Readjust/Clean scanner.
OK, verify power to main faulty. Replace scanner. Reset
burner control circuit and ESC lockout (on ESC dis-
components. play).
Burner ignites but goes 120 VAC to oil fuel valves Scanner window dirty. Clean window.
out within 8–10 seconds (OSV/SSOV). Scanner circuit shorted or Check scanner circuit. Dis-
(Safety switch in ESC locks open. connect power and replace
out.) leads if damaged. Tighten
all connections and check
grounding on scanner
housing.
Check main burner control Loss of atomizing air. Check air supply AAPS and
circuit and components. ASV.
Loss of Fuel. Check FPS setting Check
OSV and SSOV.
Verify flame voltage at ESC Failed scanner. Replace if necessary.
display is between 80 and
100 percent.
Sect08_1004_KSB_b.fm 04/13/2015
Appendix A - Supplemental Instructions
APPENDIX A
SUPPLEMENTAL INSTRUCTIONS
OPTIONAL EQUIPMENT
for
AUXILIARY PRESSURE CONTROL
MODULATING STEAM GENERATORS
WITH PLC
DESCRIPTION
Auxiliary Pressure Control (APC) is designed for installations with two or more steam generating
units. Its operation requires at least one steam generator to always be on-line providing steam pressure.
APC allows the additional unit(s) to be in a standby mode and automatically come on-line should steam
demand exceed the capacity of the primary, or lead, unit. The standby steam generator(s) will stay on-line
until the steam requirement has been satisfied. When the steam demand has been met, the standby gener-
ator will shut down its burner and go back into standby mode. Its feedwater pump(s) will continue run-
ning for the duration of the post-run period.
When using APC, it is important that the system be at normal operating pressure during the unat-
tended start of the standby unit(s), allowing the water control system and steam trap to function at near
capacity within a few seconds after start. The PLC delayed firing rate timing (DFRT) function of the
standby unit(s) will keep the unit(s) at a reduced firing rate (typically 20–30%) for a programmed period
(typically 5–10 minutes). Delaying the high-fire operation, in conjunction with an Automatic Dump
Valve (ADV), allows time for the unit(s) to rid the steam separator of excess fluid without carryover. The
PLC post run period function keeps the feedwater pump motor(s) energized for a programmed period
(typically 15–20 minutes) after burner operation has been interrupted (steam demand has been satisfied).
Actual delayed firing rate settings will be selected and programmed based on trap timing and sep-
arator flooding observations made at the time of initial firing. The post-run period is determined by the
fluid temperature in the steam system or by timer.
INITIALIZATION
Setup the auxiliary unit(s) for APC.
1. Press the ESC/AUX key on the OIU keypad. The text “AUX” will display in the OIU screen
above the ESC/AUX key. This indicates that the machine is in auxiliary mode.
2. Pull out the STOP button.
3. Press the START pushbutton. The feedwater pump will activate and start pumping to fill the
heating coil.
The unit enters standby mode and remains there until steam demand requires it to come on-line. The
OIU screen will display “-STANDBY- NO DEMAND” and display the current steam pressure from the
steam header. When steam pressure falls below the cut-in setpoint, the auxiliary unit will start automati-
cally, go through purge, and light-off. The unit will run until steam demand is met. Once demand is met,
the burner is shut off. The unit will go through the Post Run Standby; then, it will shut off. The OIU
screen will read “-STANDBY- NO DEMAND” after completion of Post Run.
04/13/2015 A-3 APCsgR15276i.fm

NOTE
The unit(s) must be in automatic mode during auxiliary operation.
To return the unit(s) to standard operation, press the ESC/AUX Key on the OIU keypad. The text
“AUX,” above the ESC/AUX Key in the OIU screen, turns off indicating the unit is in standard mode.
SETTINGS
Figure 1, below, depicts the typical steam pressure setpoints for an APC installation consisting of
two steam generators. OPS1 represents the standard pressure setpoint for the primary unit. OPS2 rep-
resents the pressure setpoint for the auxiliary unit. Both units are set to modulate at 80 psi.
PRIMARY AUX
100
STD AUX p
r
95 open
modulation (psi) 80 80 s e 90 close
t s OPS1
open (psi) 95 82 e s 85
a open
u 80 modulation
close (psi) 90 75 m
r OPS2
e 75 close
70
Figure 1. Typical pressure settings for a two-unit APC system
The steam pressure setpoints may be modified in the MODIFY SETPOINTS menu. This menu is
password protected1. Once in the MODIFY SETPOINTS menu (Figure 2), the pressure settings for the
primary unit and the auxiliary unit(s) may be changed.
STANDARD AUXILIARY
SETPOINTS SETPOINTS
080 PSI MOD 080 PSI
095 PSI CUT-OUT 082 PSI
090 PSI CUT-IN 075 PSI
Figure 2. Modify Setpoints menu screen
1 See “OIU Basics” in Section III of the Instructions Manual for passwords, password entry procedure, and other OIU operations.
APCsgR15276i.fm A-4 04/13/2015

OPERATION
The auxiliary steam generator unit is automatically brought on-line when steam pressure in the
header reaches the OPS2 close setpoint (see Figure 1). A second operating pressure transducer (one for
each unit), mounted in the steam header, is used for this function.
The auxiliary unit will come on-line and will initially operate in a delayed firing rate mode. Once
the DFRT period expires, the unit will begin operating normally, automatically adjusting the firing rate to
match steam load. The primary and auxiliary units will modulate together toward their minimum firing
rate position as steam pressure rises. If the header pressure continues to rise to the auxiliary unit’s OPS2
open setpoint, the auxiliary unit will shut down (burner off) and go into the post-run period. The auxiliary
unit will refill with chemically treated water and return to an idle standby condition once the post-run
period has expired. The primary unit will once again carry the load until its capacity has been exceeded,
then the auxiliary unit will be called back into service.
Selection of either the primary (STD) or auxiliary (AUX) operating mode is accomplished by fol-
lowing the instructions provided on the Operator Interface Unit (OIU) display.
NOTE
Alternating the units on regular intervals will provide equal usage and
running hours.
INSTALLATION
The pressure transducers used for the Auxiliary Steam Pressure (OPS2) function must be located in
the steam header downstream of the steam discharge valves and any stop-check or back pressure regulat-
ing valves.
The Delayed Firing Rate, Post-Run Time Delay, steam pressure (OPS1 and OPS2) functions are
controlled by the PLC mounted inside the electrical control box.
Field retrofits will require electrical wiring modifications, specific to each machine. Modified elec-
trical drawings can be provided by the Clayton Engineering Department.
Due to a greater amount of fluid in the heating coil during automatic start, an Automatic Dump
Valve (ADV) is used to help the steam trap remove excess fluid from the steam separator. The ADV is a
normally closed, electrically actuated solenoid valve, energized to open during the delay firing rate
period, by the PLC DFRT function. The ADV returns to a closed position when the DFRT period expires.
IMPORTANT
Auxiliary Pressure Control (APC) is not practical for every applications.
Consult a Clayton Representative to determine if APC is recommended
for your application.
04/13/2015 A-5 APCsgR15276i.fm

Figure 3. APC Kit, mechanical hookup and parts list
APCsgR15276i.fm A-6 04/13/2015

HEATING COIL WATER WASHING
DESCRIPTION
Periodic water washing of the heating coil is required on oil-fired machines; it removes soot and dirt
accumulation not removed by soot blower operation (refer to Periodic Maintenance in the Instruction
Manual for soot blowing instructions). Regular soot blowing should maintain stack temperature within
20° F (11° C) of normal (compared to stack temperatures documented at time of initial firing), however
not all soot will be completely removed from the heating coil. Over a period of weeks or months, soot
will accumulate on the external tube surfaces of the heating coil. Excessive soot accumulation will be evi-
dent with a gradual rise in stack temperature. Frequency of water washing should be determined by daily
monitoring of the stack temperature. Water washing should be performed when the stack temperature
cannot be maintained within approximately 50° F (28° C) of normal by soot blowing alone.
NOTE
A 24W x 36H inch (60W x 90H cm) inspection door is required to facili-
tate coil water washing and should be installed in the lower portion of the
exhaust stack, immediately above the outer heater cover during.
PREPARATION
(See Fig. 1.)
Preparation for water washing of the Clayton heating coil should be performed as follows:
a. The facility water source must be capable of supplying water at a minimum of five gallons (20
liters) per minute.
b. If a floor drain is not available beneath the burner opening, obtain a ten to twenty gallon con-
tainer equipped with a large drain hose. The container may be made from a cut down 55-gal-
lon (200 liter) drum. Water may be drained or pumped from the pan or a water ejector could
be used.
c. Close all fuel system valves.
d. Remove the burner manifold.
08/22/2013 A-7 CoilWash_E404-604_R10168b.fm

WATER WASHING
Water wash the heating coil in accordance with the following instructions:
a. If the machine has been in operation prior to washing, operate the blower (burner off) for
approximately 15 minutes to cool the machine before washing.
b. Insert a garden hose (largest size possible) into the 24W x 36H inch (60W x 90H cm) inspec-
tion door. Turn on the water and manually distribute the water over the entire top of the heat-
ing coil. Continue this action until the drain water runs clear. It is important to have a high
water-flow rate to ensure proper coil cleansing.
c. Before placing online, perform the following:
1. Allow the water to drain from the heating coil.
2. Operate the blower for a few minutes to remove any water from the air
duct.
3. Replace the inspection door in the exhaust stack.
4. Re-install the burner manifold.
d. Open the fuel system valves and start the machine. Operate the machine at low fire for 15
minutes.
e. Resume normal operation of the machine
NOTE
A substantial quantity of contaminated fluid will be produced during the
water washing procedure. Proper environmentally accepted drainage and
disposal practices must be followed.
08/22/2013 A-8 CoilWash_E404-604_R10168b.fm

Fig. 1 Set up heating coil unit for water washing
08/22/2013 A-9 CoilWash_E404-604_R10168b.fm

CoilWash_E404-604_R10168b.fm A-10 08/22/2013

for
AUTOMATIC REMOTE START/STOP
Description
The Automatic/Remote Start/Stop (ARSS) system is designed to enable a steam generator to be
started up or shut down automatically or manually from a remote location. With an ARSS system, the
steam generator can be interfaced with a variety of devices, such as a time clock relay, a remote push-
button station, or computer system, to provide an actuating start/stop signal.
The ARSS system is designed for automatic or remote startup and shutdown of the steam gener-
ator and does not replace the prescribed maintenance requirements, as outlined in the instruction manual.
This system requires special considerations and equipment to be effective and to prevent damage to the
heating coil. A back pressure regulator is an essential and required component for all Auto Start/Stop
Systems.
System Components
Automatic Dump Valve (ADV) This valve is installed between the steam separator and steam
trap piping system. This valve is a normally closed, electrically actuated, solenoid valve. It is controlled
by the Delay Firing Rate Timer (DFRT). It is energized open during the delayed firing rate period to expel
excess fluid from the steam separator, preventing moisture carry-over into the steam system.
Auxiliary Relays (AR1/AR2) These two relays are provided to continue booster (if equipped)
and chemical pump operation during the Post Run Time Delay period. The time clock (if equipped) can
be programmed to energize AR1, and activate the booster (if equipped) and chemical pump(s), periodi-
cally during the wet lay-up period to ensure that a wet tube, properly treated, heating coil condition is
maintained. AR2 maintains power to the booster and chemical pumps while in the “standard” operating
mode
Continuous Blowdown Solenoid Valve (CBSV) This valve is installed only on units equipped
with the optional continuous blowdown valve. The CBSV is installed downstream of the blowdown
valve, in the blowdown line, to prevent flow to the blowdown line during periods of wet lay-up. This
normally closed valve is energized open upon automatic starting of the Unit and when in “standard” oper-
ating mode.
Steam Transfer Pressure Switch (STPS) This switch senses pressure in the steam separator. It
overrides the delayed firing rate circuit when sufficient steam pressure has built-up in the steam separator.
Without this pressure switch, the machine would go through a delayed firing rate sequence every time a
burner firing sequence is initiated. This switch should be set at an effective value below the Operating
Pressure Switch (OPS) setting.
03/2001 A-11 AutoRSS_R14585c.fm

Trap Bypass Solenoid Valve (TBSV) This valve is installed in the steam trap discharge line, in
parallel with the trap bypass check valve. It allows water from the condensate receiver to flow around the
steam trap discharge check valve, through the steam trap, and into the steam separator to help ensure a
wet tube heating coil condition during periods of wet lay-up. This normally open valve is energized to
close upon automatic starting of the machine, or when in “standard” operating mode.
IMPORTANT
When performing a dry shutdown, while in “standard” operating mode, the
trap discharge valve must be closed to prevent fluid from entering the
steam separator.
Delay Firing Rate Timer (DFRT) This timer prevents the machine from ramping up to the
maximum firing rate position during automatic starts. On initial start, there will be no steam pressure in
the system. Ordinarily, the pressure controls would sense the lack of steam pressure and signal the modu-
lating controls to increase the firing rate in an effort to satisfy the steam demand. Delaying the firing rate
allows a gradual and steady increase in steam header pressure while expelling excess fluid from the steam
separator through the automatic dump valve.
Post Run Time Delay (PRTD) Timer This timer allows the feedwater pump(s) to continue
running for some period of time after an automatic shutdown. This ensures a full heating coil condition
for the next automatic start.
NOTE
The DFRT setting determines the duration of the delayed firing rate period.
The DFRP setting determines the firing rate that will be achieved during
the delayed firing rate period. The PRTD setting determines the duration of
post-run pumping. DFRT, DFRP, and PRTD settings will be determined by
Clayton service personnel at the time of initial firing based on heating coil
and steam separator flooding conditions and system pressure stabilization
observations.
Modes of Operation
The steam generator has two modes of operation—standard mode and auxiliary mode. Mode
selection is made by a toggle-type Control Selector Switch (CSS)—installed inside the electrical control
box.
Standard mode The steam generator will require manual startup and shutdown, including opening
and closing of the appropriate valves, when the control selector switch is placed in the STANDARD
OPERATION position.
Auxiliary mode The steam generator is started and stopped automatically by the programmable
time clock, or other external signal, when the control selector switch is placed in the AUXILIARY
OPERATION position. THE STEAM GENERATOR MUST BE MANUALLY STARTED
INITIALLY TO ENERGIZE THE HOLDING CIRCUIT. After the initial start, the machine will
operate in a completely automatic mode.
AutoRSS_R14585c.fm A-12 03/2001

Theory of Operation
Automatic/Remote startup When a start command is initiated, either by a timing device or a
remote start/stop device, the ARSS relay circuit closes. This energizes the time clock relay (TCR), or,
with a remote start/stop device, the remote start/stop relay (RSR) energizes. The energized relay starts the
blower motor and feedwater pump. The continuous bleed valve (CBV) solenoid is also energized and
opens to allow normal blowdown flow to the blowdown tank.
In addition, the TBSV and CBSV (if equipped) are energized. The TBSV closes to prevent fluid
from bypassing the trap discharge check valve. The CBSV opens to allow normal operation of the contin-
uous blowdown system. The normally open circuit of the TCR closes energizing the Electronic Safety
Control (ESC). The burner circuit is energized and a normal ignition sequence is initiated.
With sufficient steam demand, the steam generator burner control will start a normal light-off
sequence. Once a stable flame has been established, the DFRT is energized along with the main fuel
valves. A delayed firing rate period will commence for the delayed firing period established by the DFRT
setting. The delayed firing rate period holds the burner at low fire; therefore, the potential carry-over and
thermal stress from a cold startup is minimized.
When the delayed firing rate period commences, the DFRT circuit also signals the ADV to open.
The ADV will remain open for the duration of the delayed firing rate period—expelling excess liquid
from the steam separator. At the end of the delayed firing rate period (DFRT “times out”), the machine
switches to normal operating mode—automatically modulating in response to steam demand. The ADV
returns to its normally closed position.
During normal operation, there may be periods of minimal steam demand (steam load is less than
minimum output of the machine) resulting in on-off cycling of the burner. To prevent recurring delayed
firing rate periods on subsequent ignition sequences, the STPS will bypass the delayed firing rate circuit
if there is sufficient pressure in the steam separator (above STPS set point). With a back pressure regu-
lator (BPR) installed, initial starting should be the only time the steam separator pressure is below the
STPS set point.
Automatic/Remote stopping When a stop command is initiated, either by a timing device or a
remote start/stop device, the ARSS relay circuit opens. This de-energizes the TCR, or, with a remote
start/stop switch, the RSR de-energizes. Power is also removed from the ESC when the TCR is de-
energized.
In the shutdown process, the burner turns off, the blower shuts down, the TBSV opens, the CBSV
(if so equipped) closes, and the CBV closes. The feedwater pump(s), booster pump (if so equipped), and
chemical pump(s) will continue operating for the duration of the PRTD timer setting. The PRTD function
ensures a filled heating coil (wet lay-up) for the next auto-start sequence.
During the wet lay-up period, when the machine is idle, an auxiliary recirculation pump will
continue running. If the machine is equipped with a chemical pump timer, the timer will control the
recycle operation of the chemical pump(s) to aid in proper chemical treatment during wet lay-up.
03/2001 A-13 AutoRSS_R14585c.fm

Automatic/Remote Start/Stop setup
NOTE
The heating coil must be properly filled with treated feedwater, as
prescribed in the Clayton Feedwater Treatment Manual (R015216), before
placing the steam generator in automatic/remote start/stop mode.
After the heating coil is filled, position the CSS, the Run/Fill Switch (RFS), the Auto/Manual
Switch (AMS), and the booster/recirculation pump inlet and outlet manual isolation valves as indicated
below.
1. CSS is placed in the REMOTE position.
2. RFS is placed in the RUN position.
3. AMS is placed in the AUTO position.
4. The booster/recirculation pump inlet and outlet manual isolation valves should be fully open.
Once the devices listed above are setup, the automatic/remote start/stop function is ready to use. If
standard control operation is desired, then place the CSS toggle switch in the STANDARD OPERATION
position and the ARSS system will no longer be active.
AutoRSS_R14585c.fm A-14 03/2001

for
LIGHT OIL PILOT
MODULATING STEAM GENERATORS
Models E-1004
Introduction
This supplement contains descriptive information and instructions pertaining to the Light Oil
Pilot (LOP) system for Clayton Model E1004. The light oil pilot can be applied to light oil (EO) or heavy
oil (EHO) fired applications. Fig. 3 and 4 contain illustrations and a detailed parts breakdown of the light
oil pilot system and LOP burner manifold. Each will serve as valuable references for maintenance and
repair.
Component Descriptions
Other than component differences, fuel type, and method of delivery, using light oil as the pilot
fuel presents no significant changes to the design, operation, or performance of the equipment. The light
oil pilot system is depicted in Fig. 1. The major components of the light oil pilot system are discussed
below. The primary fuel oil system components are the same as those used for a standard oil system with
gas pilot. Refer to the appropriate sections in the main body of this manual for information.
In addition to the components mentioned below, a manual shutoff valve and pressure gauge are
provided in the light oil pilot line.
Oil Pilot Valve (PV)
This normally-closed solenoid valve controls the flow of light oil to the burner pilot noz-
zle. It is energized to open during the 5-second pilot trial-for-ignition (PTFI) period, and is indi-
cated by PTFI being displayed on the ESC display.
Pilot Pressure Switch (PPS)
The pilot pressure switch verifies that an adequate oil pilot pressure is available prior to
allowing the pilot valve to open. This switch is set to close at 100 psi.
Back Pressure Regulator (BPR)
The pilot oil delivery pressure is controlled by the pilot back pressure regulator. It is
adjusted to maintain pilot oil pressure at 100 psi.
General
Pilot Oil Supply Requirements
Diesel Oil: Commercial Standard No. 2 or Pacific Standard No. 200
Pressure: 100 psi (regulated)
Flow Rate: 6.5 gph (interrupted).
04/05/2016 A-15 LOP_1004_b.fm

Fig. 1 Light Oil Pilot System
LOP_1004_b.fm A-16 04/05/2016

Description Of Operation
The machine is filled and started as described in the instruction manual. The fuel oil pump cou-
pling is engaged enabling the pump to be driven by the blower shaft. The fuel oil supply pressure is set to
100 psi using the pilot back pressure regulator. During the PTFI firing sequence, a 20–80 reading on the
ESC display indicates a strong pilot flame. Once the pilot flame has been established, the burner control
releases the burner enabling normal operation. The main fuel oil pressure reducing valve and fuel control
valve are used to adjust the fuel oil pressure to the burner. The Fuel Pressure Switch (FPS) is used to
ensure that an adequate fuel oil supply pressure is available prior to allowing the main fuel valves to
open.
Periodic Maintenance
Service Monthly
Burner manifold (Fig. 3) In addition to the maintenance described in the Instruction
Manual (Section VII), the following maintenance to the light oil pilot burner manifold is neces-
sary.
CAUTION
Do not use a sharp instrument for cleaning
which can scratch or disfigure the tip orifice or
slots in the distributor. A slight scratch on these
parts may seriously impair nozzle operation.
Pilot nozzle and strainer (see Fig. 2,

above) Unscrew the pilot nozzle from the pilot
stem. Unscrew strainer from nozzle and remove
screw. Clean parts with petroleum solvent. Con-
tamination may seriously impair nozzle operation.
Blowout parts with compressed air jet if available.
Be sure all dirt and grit is removed. Replace noz- Fig. 2 Light Oil Pilot Nozzle
zle if necessary. (Do not disassemble pilot nozzle
unless smoke persists.)
Electrode gap (Fig. 3) Adjust the ignition electrode (17) by loosening the lock nut (24).
Electrode may thus be adjusted to dimension shown. Tighten lock nut.
04/05/2016 A-17 LOP_1004_b.fm

Fig. 3 Light Oil Pilot Burner Manifold
LOP_1004_b.fm A-18 04/05/2016

Units
Figure & Part Per
Index No. Number 1 2 3 4 5 6 7 Description Assy
3 - LIGHT OIL PILOT BURNER MANIFOLD
3 UH-27066 MANIFOLD ASSY .........................................................................................Ref

-1 UH-27092 . CONE ASSY ................................................................................................. 1
-2 33548 . NOZZLE, Oil, pilot, 45° spray, 10.5 gph (39.75 l/hr) ..................................... 1
-3 UH-61481 . ELECTRODE, Ignition .................................................................................. 1
-4 UH-60619 . ADAPTER, Nipple, nozzle ............................................................................ 1
-5 26486 . NIPPLE, Pipe, 1/8 x 12 in., blk ..................................................................... 1
-6 11219 . SCREW, Set, 10-32 x 3/16 in. ...................................................................... 1
-7 24038 . CONNECTOR, Tube, 1/4T x 1/8P ................................................................ 1
-8 UH-60620 . SLEEVE, Nipple, pilot ................................................................................... 1
-9 UH-60396 . BASE, Nozzle ............................................................................................... 1
-10 16700 . SCREW, Set, 1/4-20 x 3/8 in. ....................................................................... 1
-11 UH-30316 . NIPPLE ASSY, Scanner ............................................................................... 1
-12 UH-61906 . PLATE, Mounting .......................................................................................... 1
-13 3286 . BUSHING, Pipe, 3/8 x 1/4 in. ........................................................................ 1
-14 --- . NOZZLE ASSY, Oil (See Fig. 4 for details.) ...............................................Ref
-15 UH-12867 . RING, Window, Inspection ............................................................................ 1
-16 UH-8889 . GASKET, Lens .............................................................................................. 2
-17 UH-8888 . LENS ............................................................................................................ 1
Not Shown 37985 SCANNER, Flame (IR) ..................................................................................... 1
04/05/2016 A-19 LOP_1004_b.fm

1
Fig. 4 Burner manifold nozzle assembly
Units
Figure & Part Per
4 - NOZZLE ASSEMBLY
4 -1 26116 CAP, Burner Nozzle, Delavan 33516-1 ............................................................. 1

-2 UH-61467 SET, Metering, 90° spray, 2.5 gpm (9.46 l/min.) ............................................... 1
-3 26114 CHAMBER, Swirl, 6-hole, 2.5 gpm (9.46 l/min.), Delavan 36123 ..................... 1
-4 26113 BODY, Nozzle, Delavan 33517 ......................................................................... 1
LOP_1004_b.fm A-20 04/05/2016

for
POWER LOSS TIMER
WITH PLC
Introduction
The Power Loss Timer (PLT) Kit is designed for modulating fluid heaters/steam generators with PLC.
The kit may be pre-installed on new machines or retrofitted into machines in the field. In the latter, new
electrical drawings, a new EEPROM, and additional installation hardware are required.
NOTE
The PLT kit may be used for both fixed and modular I/O PLC systems.
Details Of Operation
The PLT Kit, when installed with the additional PLC hardware (if required), allows the machine to
return to operating state it was in prior to the power interruption, under the following conditions.
1. The machine must have been in RUN mode prior to the power loss.
NOTE
If the machine was left in the FILL mode, TEST mode, CALIBRATE
mode, or the STOP button was pushed in, the machine will remain off-line
once power returns.
2. The PLT can allows up to 30 seconds of power interruption before timing out. Once timed out
(30 seconds or longer), the generator will stay off-line to prevent possible damage to the heating
coil.
Power Loss Timer - checkout procedure

Verify correct operation of the power loss circuit by first placing the machine on-line and firing it with
the EIS (electrical interrupt switch)1 pulled out. Simulate a power loss condition by partially pushing in
the EIS from one to twenty seconds, then pull it back out. The machine should restart in the FILL mode
and remain in pre-fill for a short time. After pre-fill has expired, the machine should return to the RUN
mode and continue its normal operation as before the interruption.
1
The EIS disables electrical power to the electrical control box if the control box door is opened while the machine is operating; thus, the
machine is shut down.
08/22/2013 A-21 PLT_PLC_R16114.fm

NOTE
If the generator was left in AUTO, then it will return to the AUTO mode. If
left in MANUAL, then the machine will return to MANUAL with a 20%
firing rate (burner on).
PLT_PLC_R16114.fm A-22 08/22/2013

STACK DAMPER CONTROL WITH PLC
Introduction
The Stack Damper Control (SDC) option provides interlocking control of the exhaust stack damper.
The SDC option kit provides a set of dry relay contacts inside the electronic controls cabinet of the Clay-
ton steam generator and a PLC program upgrade. The customer provides the hard wiring from the stack
damper actuator to terminal block TB1 inside the electronic controls cabinet.
The SDC option kit is either factory installed on new machines or it is retrofitted into existing
machines in the field. In the latter, new electrical drawings, a PLC program upgrade, and installation
hardware are required.
Details Of Operation
The SDC Kit, with PLC, provides interlocking control of the exhaust stack damper without affect-
ing optimum timing characteristics or jeopardizing the safety of burner firing cycles. In principle, the
machine is started in FILL mode. During the FILL mode, the damper remains shut. Once the machine is
placed in RUN mode, a signal is sent from the PLC to energize the Stack Damper Relay (SDR), which
actuates the damper motor to open the damper. The machine waits for the damper to make the fully
proven damper open switch—Stack Damper Limit Switch (SDLS). During the damper motor travel time,
the OIU display will read “POST-FILL - STANDBY” or “RUN MODE - STANDBY.” Once the SDLS
switch is made, the machine will commence a burner firing cycle. Immediately following a burner shut-
off cycle, a PLC controlled Stack Damper Control Timer (SDCT) will start timing (usually 15 minutes);
once timed out, the damper will close unless another firing sequence commences. The timer serves two
purposes:
1. It delays the damper closure to prevent the damper motor travel time from affecting the rapid
cycling and extended purge time of the firing sequence.
2. It allows the heating coil to partially cool down before closing the stack damper.
NOTE
Stopping the machine at with the STOP button will close the damper
immediately for safety reasons.
If the damper does not fully open (SDLS has not been actuated) at any time during purge or burner
firing sequence, the machine will commence burner shutdown and go into standby mode. An alarm will
be generated.
04/13/2015 A-23 SDC_PLC_R16115_b.fm

IMPORTANT
It is the customer’s responsibility to make sure the stack damper’s mechan-
ical linkage and limit switches are always properly adjusted.
If a problem develops on the machine where an alarm is generated, the PLC will activate the SDCT
to close the damper after time-out. It is recommended that the damper be prevented from closing immedi-
ately upon an over-temperature condition of the heating coil. Such a condition would only result if the
operator engages the STOP button to clear the over-temperature alarm but fails to disengage it. Pull out
the STOP button after clearing the alarm so the damper will reopen to allow the machine to cool down.
SDC_PLC_R16115_b.fm A-24 04/13/2015

for
Feedwater Valve and Strainer Kit
The feedwater valve and strainer kits are

available for the Clayton steam generator models
indicated in the chart below.
The illustrations to the right show the recom-
mended plumbing arrangement using the support
bracket (supplied with kit). The parts shown are
included in the applicable kits listed below. The
plumbing can be modified, if necessary; but, the sup-
port bracket must be used to eliminate any possible
damage to the feedwater pump due to distortion
caused by the weight of the intake plumbing.
NOTE
Enlarge the feedwater line between the hotwell
and generator one pipe size if the pipe run is lon-
ger than 50 feet (including 10 feet for each pipe
elbow or fitting). This will be necessary to elimi-
nate possible vapor-lock in the steam generator
feedwater pump due to excessive feedwater
temperatures.
FEEDWATER
CONNECTION KIT
MODELS SIZE (inches) NUMBER FIGURE
E-804 4 UH-35523 A
E-1004 6 (150# flng) UH-35375 A
Clayton Industries, City of Industry, CA

04/13/2015 A-25 Valve & StrainerKit_R006195g_xxx4.fm
Clayton Industries, City of Industry, CA

04/13/2015 A-26 Valve & StrainerKit_R006195g_xxx4.fm
Appendix B - Reference Tables and Charts
APPENDIX B
REFERENCE TABLES & CHARTS

Specifications
TABLE OF SPECIFICATIONS
OPEN SYSTEM
MODEL E-1004
See ENGLISH UNITS METRIC UNITS

Note standard. w/ SE standard w/ SE
OUTPUT:
Boiler Horsepower 1 1,000 1,000 bhp
Net Heat Output at 33,475 Btu/hr-bhp 1 33,475,000 33,475,000 Btu/hr 9,808 9,808 kw
Output, net at 100 psig from 60 o F (15.6 o C) & 100% makeup 1 28,825 28,825 lb/hr 13,072 13,072 kg/hr
Equivalent output, from and at 212 o F (100 o C) feedwater 1 34,500 34,500 lb/hr 15,649 15,649 kg/hr
OPERATION:
Modulation Range (on-off cycling below 20%) 20–100 20–100 % 20–100 20–100 %
Design Pressure (safety valve setting) 2 65–500 65–500 psig 4.6–35 4.6–35 kg/cm 2
Operating Pressure (depending upon design pressure) 3 60–450 60–450 psig 4.2–32 4.2–32 kg/cm 2
Condensate Receiver Temperature Recommended 1 180–200 180–200 oF 82–93 82–93 oC
THERMAL EFFICIENCY @ maximum firing rate (100%):

Gas Fired 82 85 % 82 85 %
Oil Fired 84 87 % 84 87 %
FUEL INPUT REQUIREMENTS @ maximum firing rate:
Gas-Fired Heat Input 1 40,822,763 39,383,338 Btu/hr 11,961.0 11,539.2 kw
Natural Gas Consumption (based on 1000 Btu/cu ft gas) 1 40,823 39,383 scfh 1,155 1,115 m 3/hr
Propane Gas Consumption (based on 2500 Btu/cu ft gas) 1 16,329 15,753 scfh 462.1 445.8 m 3/hr
Oil-Fired Heat Input 1 39,851,988 38,476,165 Btu/hr 11,676.5 11,273.4 kw
Oil Consumption (based on 140,600 Btu/gal #2 fuel oil) 1 283.4 273.7 gph 1,072.7 1,035.6 l /hr
SERVICE REQUIREMENTS @ maximum firing rate:
Gas Supply Pressure (standard gas train) 5–10 5–10 psig 0.35–0.70 0.35–0.70 kg/cm 2
Oil Supply Pressure 0–25 0–25 psig 0–1.8 0–1.8 kg/cm 2
Pilot Gas Pressure (regulated at 6 in. w.c.) 5–10 5–10 psig 0.35–0.70 0.35–0.70 kg/cm 2
Atomizing Air Consumption (oil-fired only) 30 30 scfm 0.85 0.85 m 3/min
Atomizing Air Pressure (oil-fired only) 70–100 70–100 psig 4.9–7.0 4.9–7.0 kg/cm 2
Water Supply 5,940 5,940 gph 22,485 22,485 l /hr
Compressed Air Supply Pressure 3–150 3–150 psi .21–10.55 .21–10.55 kg/cm 2
NPSHR for Standard Feedwater Pump 25 25 psi 7.6 7.6 m
Electric Service (460 vac / 60 Hz / 3 ph):
Full Load Amps (FLA) up to 300 psi design pressure 4 368 368 amps
Full Load Amps (FLA) up to 500 psi design pressure 4 423 423 amps
General:
Heating Surfaces (SEs: 6 pancake / 10 pancake) 2,807 3,546 / 4,113 ft 2 260.8 329.4 / 382.2 m 2
Combustion Volume (SEs: 6 pancake / 10 pancake) 5 392.3 462.5 / 492.0 ft 3 11.1 13.1 / 13.9 m 3
Electric Motors (blower, feedwater pump), up to 300 psi design pressure 125, 125 125,125 hp 93.2, 93.2 93.2, 93.2 kw
, 301 to 500 psi design pressure 125, 150 125,150 hp 93.2, 111.9 93.2, 111.9 kw
CUSTOMER CONNECTIONS:
(Refer to Plan Installation Dimensional {P&ID} Drawing for connection requirements.)
APPROXIMATE OVERALL DIMENSIONS:

(Refer to Plan Installation Dimensional Drawing for dimensions.)
NOTES:
1. SCR & DA condensate receiver applications, value dependent upon operating conditions.
2. Standard design pressures (safety valve settings): 150, 200, 300, 350 & 500 psig.
3. Operating pressures between 10 and 65 psi are typically obtained through use of a steam pressure reducing valve. Units designed to operate within 10 to 65 psig are
available upon special request.
4. For 575V, multiply by 0.8; for 380V, multiply by 1.1; for 230V, multiply by 2.0; for 208V, multiply by 2.2
5. Volume base on UL795 and CSA-CAN 1-3.1. Standards that define this as combustion chamber and flue gas passage volume up to the stack collar.
08/22/2013 B-3 Specs_1004_a.fm

Reference Values
TABLE OF REFERENCE VALUES

-Standard Design Pressure Units-
Typical Settings
See
Device Note E-1004
Limit Pressure Switch (LPS) Midway between OPS open and safety valve setting (requires manual reset)
Operating Pressure Switch (OPS) open, application specific 3 12–653 psi (.8–46 kg/cm 2 ), modulates from 20% to burner off (maximum operating pressure)
Operating Pressure Switch (OPS) close 3 10 psi (.7 kg/cm 2 ) below SPS open, modulates from burner off to 20%
Modulating Pressure Setting (MPS) 3 5 psi (.4 kg/cm 2 ) below OPS close, modulates between 20% and 100% (normal operating pressure)
Steam Generator Design Pressures, psig (kg/cm 2 ) 100 (7) 200 (14) 300 (21) 350 (25) 500 (35)
Primary Main Temperature Limit Controller (MTLC2), F (C) 475 o (246 o ) 500 o (260 o ) 525 o (274 o ) 550 o (288 o ) 575 o (302 o )
Secondary Main Temperature Limit Controller (MTLC1), F (C) 500 o (260 o ) 525 o (274 o ) 550 o (288 o ) 575 o (302 o ) 600 o (316 o )
Auxiliary Thermostat Switch (ATS) 50 o F (28 o C) above maximum operating saturation temperature in separator
Air Pressure Switch (APS) 6–9 wci (.015–.022 bar)

Atomizing Air Pressure Switch (AAPS) (psi) 1 close at 60 psi (4.2 kg/cm 2 ), open at 45 psi (3.2 kg/cm 2 )
Atomizing Air Pressure Regulator (psi) 1 45 psi (3.2 kg/cm 2 )
Pilot Pressure Switch (PPS) (psi) 1 close at 100 psi (7 kg/cm 2 ), open at 90 psi (6.3 kg/cm 2 )
Pilot Gas Pressure Regulator (adjust for best flame signal) (wci) 3–9 wci (.007–.022 bar) (adjust for best flame signal)
Light Oil Pilot Regulator 1 100 psi (7 kg/cm 2 )
Fuel Pressure Regulator (psi) 1 80–90 psi (5.6–6.3 kg/cm 2 )

Fuel Pressure Switch (FPS) (@ 15 psi differential) 1 close at 70 psi (4.9 kg/cm 2 ), open at 55 psi (3.9 kg/cm 2 ) (at 15 psi [1.1 kg/cm 2 ] differential)
Gas Pressure Switch High (GPSH) 50% above max burner pressure
Gas Pressure Switch Low (GPSL) 50% below normal gas supply pressure
Feedwater Pump Relief Valve, (psi) (preset) 750 psi (52.7 kg/cm 2 ) (preset)
Performance Chart (Typical Only)

E-1004
Device Output
Rate 20% 100%
Air Damper Angle (deg) 0–2 28–32
Gas Valve Angle (deg) 5–7 24–27
Gas Pressure - Burner (see Note 2) (wci) 0–1 18–21
Oil Pressure - Burner (see Note 2) (psi) 10–15 50–55
Upper Volute Pressure (wci) 0–1 10–14
Lower Volute Pressure (wci) 12–15 14–17
NOTES:
1. Oil firing only.
2. Burner Pressures on Semi-Closed Receiver (SCR) systems will be reduced by approximately 20%.
3. Setpoints programmed in PLC.
INDICATED VALUES ARE FOR REFERENCE ONLY.

Refer to Factory Test Sheet for “as-tested” combustion data and device set points.
Specs_1004_a.fm B-4 08/22/2013

Main Temperature Limit Controllers (MTLC)
Instructions:
1. Determine the design pressure of the machine. (-1=150 psig, -2=200 psig, -3=300 psig,
-3.5=350 psig, -5=500 psig, -6=600 psig, -7=700 psig, -8=800 psig, -10=1,000 psig,
-11=1,100 psig, -12=1,200 psig)
2. Select the corresponding Kit number from the Table below.
3. Select the MTLC part number from the first column as indicated by the “x” in the corresponding
“Design pressure & Kit no.” column.
Design pressures
& Kit no. -1 -2 -3 -3.5 -5/-6 -7 -8 -10/-11/-12
MTLC
part no. UH-31573 UH-31574 UH-31575 UH-31576 UH-31577 UH-33493 UH-33494 UH-32475
38277 (475 oF) X
38278 (500 oF) X X
38279 (525 oF) X X
38280 (550 oF) X X
38281 (575 oF) X X
38282 (600 oF) X X
40714 (625 oF) X X
38664 (650 oF) X X
38665 (675 oF) X
06/05/2013 B-5 MTLC_chart_G_one-pg.fm

ABB ACS550-U1
The table below lists the factory parameters used and the settings for each Clayton
Steam Generator, or Fluid Heater.
ACS550-U1 VSD Parameter Settings

PARA-
CODE METER FUNCTION
9901 0 LANGUAGE: 0 = English, 4 = Español
9902 1 APPLIC MACRO (Application Macro): 1 = ABB Standard
9905 460 MOTOR NOM VOLT (Nominal Motor Voltage): From motor nameplate (V)
9906 110 MOTOR NOM CURR (Nominal Motor Current): From motor nameplate (A)
9907 60 MOTOR NOM FREQ (Nominal Motor Frequency): From motor nameplate (Hz)
9908 3565 MOTOR NOM SPEED (Nominal Motor Speed): From motor nameplate (rpm)
9909 100 MOTOR NOM POWER (Nominal Motor Power): From motor nameplate (hp)
1003 1 DIRECTION: 1 = Forward, 2 = Reverse, 3 = Request
1104 34 REF1 MIN (Sets minimum for external reference 1.): Hz
1105 65 REF1 MAX (Sets maximum for external reference 1.): Hz
1301 20 MINIMUM AI1 (The minimum value of the analog input.): % (mA)
1302 100 MAXIMUM AI1 (The maximum value of the analog input.): % (mA)
2001 0 MINIMUM SPEED (The minimum speed allowed.): rpm
2002 3565 MAXIMUM SPEED (The maximum speed allowed.): rpm
2003 110 MAX CURRENT (The maximum output current supplied by the drive to the motor): A (amperage)
2007 33 MINIMUM FREQ (The minimum limit for the drive output frequency.): Hz
2008 65 MAXIMUM FREQ (The maximum limit for the drive output frequency.): Hz
2102 2 STOP FUNCTION (Selects motor stop method.): 1 = Coast, 2 = Ramp
2202 16 ACCELER TIME 1 (The acceleration time for zero to max. freq. for ramp pair 1.): s (seconds)
2003 30 DECELER TIME 1 (The deceleration time for max. freq. to zero for ramp pair 1.): s (seconds)
VSD_ABB-ACS550_params_a.fm B-6 04/13/2015

Appendix C - Parts Catalog
APPENDIX C
PARTS CATALOG
Table of Contents
Fig. 1A - Heating Unit Assembly .......................................................................................... C-4

Fig. 1B - Heating Unit Feedwater Piping Hookup ................................................................. C-7
Fig. 2A - Steam Separator and Level Control ....................................................................... C-8
Fig. 2B - Pressure Manifold and ATS ................................................................................. C-10
Fig. 3 - Feedwater Pump Hookup ...................................................................................... C-11
Fig. 8 - Gas System .......................................................................................................... C-12
Fig. 9 - Fuel Oil System ..................................................................................................... C-13
Fig. 10 - Pilot Gas Hookup ................................................................................................ C-15
Fig. 11A - Burner Manifold–Gas ......................................................................................... C-16
Fig. 11B - Burner Manifold–Oil & Oil-Gas ........................................................................... C-18
Fig. 12A - Air Blower Hookup ............................................................................................ C-20
Fig. 12B - Air Duct and Damper ......................................................................................... C-22
Fig. 13A - Electrical Control Box-Right Front Door ............................................................. C-24
Fig. 13B - Electrical Control Box-Left Compartment and Blower VSD ................................. C-25
Fig. 13C - Electrical Control Box-Right Compartment ......................................................... C-27
Fig. 14 - Gravity Fill–Elevated Receiver ............................................................................. C-29
Fig. 15 - Soot Blower Option ............................................................................................. C-30
Fig. 19 - Separator Discharge Valve Kit (Option) ................................................................ C-31
Fig. 21 - Valve Option Kit Hookup ...................................................................................... C-32
3
Parts Catalog
Fig. 1A - Heating Unit Assembly
Fig. 1A-1 Heating Unit Assembly (1 of 3)
HeatingSect_E1004_C8661_a.fm C-4 04/20/2016

Appendix C
04/20/2016 C-5 HeatingSect_E1004_C8661_a.fm

Parts Catalog
HeatingSect_E1004_C8661_a.fm C-6 04/20/2016

Appendix C
Fig. 1B - Heating Unit Feedwater Piping Hookup
Fig. 1-4 Heating Unit Feedwater Piping Hookup
04/20/2016 C-7 HeatingSect_E1004_C8661_a.fm

Fig. 2A - Steam Separator and Level Control
16 REF
8x 2
1 8x
8
15
6
18
16
19
5 8x 9
5 8x
9
2x 7
8x 2
20
13
17
14
11
10 8x
3 4 8 8 12 8x 8
Fig. 2a. Steam Separator Assembly and Level Control
Sep-LvlCtrl-PressMfld_E1004_a.fm C-8 04/06/2016

Units
Figure & Part Per
Index No. Number 1234567 Description Assy
2a 1 9052 STUD, 3/4-10 x 4 in. (includes two hex nuts each) ................................................................................. 8
2 9101 STUD, 5/8-11 x 3 1/2 in. (includes two hex nuts each) .......................................................................... 16
3 20636 TEE, Pipe, 2 in., 2000# .......................................................................................................................... 1
4 26768 NIPPLE, Pipe, 2 x 6 in., extra-heavy tube ............................................................................................... 1
5 27092 STUD, 3/4-10 x 4 1/4 in. (includes two hex nuts each) .......................................................................... 16
6 28594 GASKET, Metal, spiral wound, 2 1/2 in., 300# / 600# ................................................................................ 1
7 28846 GASKET, Metal, spiral wound, 1 in., 300# / 600# ...................................................................................... 2
10 29664 STUD, 5/8-11 x 4 in. (includes two hex nuts each) .................................................................................. 8
11 32284 FLANGE, Screwed, 2 in., 600# ............................................................................................................... 1
12 37818 STUD, 5/8-11 x 6 1/2 in. (includes two hex nuts each) ............................................................................ 8
13 43574 INDICATOR, Level, 60 in., 2x SPDT magnetic switches, 4-20 mA transmitter ........................................... 1
14 40990 VALVE, Control, stainless steel body, pneumatic actuator, digital positioner, 4-20 mA input ...................... 1
15 41404 VALVE, Relief, safety, 2 x 3 in. flanged, 150 x 150 psi ............................................................................. 1
31512 VALVE, Relief, safety, 2 x 2 1/2 in. flanged, 250 psi ................................................................................. 1
16 41413 VALVE, Relief, safety, 2 1/2 x 4 in. flanged, 300 x 150 psi ....................................................................... 1
31512 VALVE, Relief, safety, 2 x 2 1/2 in. flanged, 250 psi ................................................................................. 1
17 UH-34805 PIPE ASSY, Welded, separator drain / level control, 2 in. globe valve - 800# (CPN: 28920) ....................... 1
18 UH-35464 SPOOL ASSY, Safety Valve / Separator Discharge, flanged, 3 x 2 in. ........................................................ 1
19 UH-35477 SPOOL ASSY, Safety Valve / Separator Discharge, flanged, 3 x 2 1/2 in. .................................................. 1
20 --- KIT, Separator-Insulation-Jacket Replacement 1 ...................................................................................... 1
1 Call Clayton Service for replacement part number. Have machine model number and machine serial number available before calling.
04/06/2016 C-9 Sep-LvlCtrl-PressMfld_E1004_a.fm

Fig. 2B - Pressure Manifold and ATS
5 6 7
8 9 10
1 2 3
Fig. 2b. Pressure Manifold and ATS
Parts List: Steam Pressure Manifold
Item Part Number Description Qty.
1 33833 TRANSDUCER, Pressure, 4-20 ma, 300 psi (OPX) .......................................1

2 39278 SWITCH, Pressure, 58–300 psi, manual reset (LPS) .....................................6
3 18014 THERMOSTAT, 200°–500° F, manual reset (ATS) .........................................1
4 16601 VALVE, Angle, steel, 3/8 in., 6000# ..................................................................1
5 41123 GAUGE, Pressure, 1000 psi, 6 in. (feedwater pressure) .................................1
6 41124 GAUGE, Pressure, 500 psi, 6 in. (discharge pressure) ...................................1
7 41125 GAUGE, Pressure, 300 psi, 6 in. (trap pressure) ............................................1
8 UH-29443-031 LABEL, Feed Pressure .....................................................................................1
9 UH-29443-030 LABEL, Discharge Pressure .............................................................................1
10 UH-29443-032 LABEL, Trap Pressure ......................................................................................1
Sep-LvlCtrl-PressMfld_E1004_a.fm C-10 04/06/2016

Fig. 3 - Feedwater Pump Hookup
14
1
7
12 14
13 2 4x
3
15 6 2x
19 8
4 4x
5 8x
2x 10
20 6
11 6 2x
9 4x
16 5 8x
18
17
Fig. 3. Feedwater Pump Hookup
Units
Part Per
Index No. Number Description Assy
3 - FEEDWATER PUMP HOOKUP

1 40986 VALVE, Relief, pressure, 1 1/2 in., 1000# .............................................................................................. 1
2 9052 STUD, 3/4-10 x 4 in. (includes two hex nuts each) ................................................................................ 4
3 28593 GASKET, Metal, spiral wound, 1 1/2 in., 300 / 600# ................................................................................. 1
4 41573 STUD, 5/8-11 x 5 in. (includes two hex nuts each) ................................................................................ 8
5 37818 STUD, 5/8-11 x 6 1/6 in. (includes two hex nuts each) ......................................................................... 16
6 28965 GASKET, Metal, spiral wound, 2 in., 300 / 600# ...................................................................................... 5
7 40984 VALVE, Control, electro-pneumatic, wafer-style, 4–20 mA output, 2 in. .................................................... 1
8 40978 VALVE, Check, wafer-style, flangeless, 2 in., 600# ................................................................................. 1
9 34209 STUD, 1 1/8-7 x 7 1/2 in. (includes two hex nuts each) .......................................................................... 4
10 31627 GASKET, Metal, spiral wound, 1 1/2 in., 2500# ...................................................................................... 2
11 UH-70218 PLATE, Orifice, 1 1/2 in., 0.938 dia., flanged, 2500# .............................................................................. 1
12 25674 GAUGE, Pressure, 2 1/2 in., 1500# ....................................................................................................... 1
13 41230 TRANSDUCER, Pressure, 4–20 mA output, 1500 psig ............................................................................ 1
14 16601 VALVE, Angle, 3/8 in., 6000# ................................................................................................................ 2
15 UH-35493 PIPING ASSY, Welded, flanged, pump discharge – safety relief valve ....................................................... 1
16 UH-35492 PIPING ASSY, Welded, flanged, pump discharge, 90° elbow ................................................................... 1
17 41448 MOTOR, High Efficiency, 125 hp, 460 vac, TEFC, Class F, F-1 ................................................................ 1
18 41391 PUMP ASSY, Feedwater, 11 stage, KSB Multitec, A50 / 11-3.1 22.62 ........................................................ 1
19 39206 SWITCH, Pressure, Danfoss, 15 – 150 psi .............................................................................................. 1
20 30491 SYPHON, Loop, 1/4 in. NPT, 180 deg. ................................................................................................... 1
non-illus UH-34821 FLANGE ASSY, Welded, electro-pneumatic valve – check-valve ............................................................... 1
08/22/2013 C-11 WtrPmpHkup_KSB_C8661_a.fm

Parts Catalog
Fig. 8 - Gas System
1 2 6 4 10
6
11
3
13 2x
12
9
8
9
6
7 5
Fig. 8 Gas Supply System
Parts List: Gas Supply System
1 39296 ACTUATOR, Regulating, gas valve, P.O.C. (SSOV) ....................................................1

2 39295 ACTUATOR, Gas Valve, ON-OFF, P.O.C. (MOV) ........................................................1
3 35503 SWITCH, Pressure, gas, 40–200 in. w.c., manual reset (GPSL) ................................1
4 35504 SWITCH, Pressure, gas, 40–200 in. w.c., manual reset (GPSH) ................................1
5 41116 SWITCH, Pressure, gas, 40–200 in. w.c., auto reset (GPSH) .....................................1
6 3440 BALL, Valve, 1/4 in. .......................................................................................................4
7 38085 BODY, Gas Valve, double, 4 in., 150# ...........................................................................1
8 40956 COCK, Gas, flanged, 4 in. .............................................................................................1
9 34138 GASKET, Flange, full face, 4 in., Cranite ......................................................................4
10 37989 MOTOR, Servo, 20 Nm .................................................................................................1
11 39538 COUPLING, Disc, 1/2 in. x 14 mm ................................................................................1
12 40958 VALVE, Gas, butterfly, wafer, 4 in. .................................................................................1
13 28563 GASKET, Metal, spiral wound, 4 in., 150# ....................................................................2
GasTrainHkup_E1004_C8552_a.fm C-12 08/22/2013

Appendix C
Fig. 9 - Fuel Oil System
2 8 9
4
3 3
6
7
10
16 11
12
15
14
13
Fig. 9A Fuel Oil Supply System
Parts List: Fuel Oil Supply System
1 16516 VALVE, Globe, 1/2 in. FPT, 300# ........................................................ 1

2 41174 VALVE, Oil, safety shut off, 3/4 in., POC (MOV, SSOV) ..................... 2
3 20631 GAUGE, Pressure, 2 1/2 in., 0–100 psi .............................................. 2
4 37988 MOTOR, Servo, LMV5 ........................................................................ 1
5 38366 COUPLING, Flex, 3/4 in. x 10 mm ......................................................1
6 40950 VALVE, Oil, control, 1/2 in. NPT .......................................................... 1
7 3440 VALVE, Ball, 1/4 in. ............................................................................. 1
8 38162 SWITCH, Pressure, oil, 200 psi, NEMA 4X enclosure ........................ 1
9 40946 VALVE, Back Pressure Regulator, 40–125 psi ................................... 1
10 41236 PUMP, Fuel, 1/2 in. NPT ..................................................................... 1
11 41661 KIT, Adapter, fuel oil pump .................................................................. 1
12 41660 MOTOR, 1 1/2 hp ................................................................................ 1
13 37987 COUPLING, Scanner .......................................................................... 1
14 37985 SCANNER, Flame, IR, integrated amp. .............................................. 1
15 37986 HOLDER, Insulated, flame scanner .................................................... 1
16 UH-34700 MANIFOLD ASSY, Burner, oil/gas (See Fig. 11B for details.) ............ 1
04/20/2016 C-13 FuelOilSys_E1004_C8552_a.fm

Parts Catalog
3 4 3
2
REF 3 5
14
12
1
7
7
REF 11
10
9
6
11 15 5 13
8
Fig. 3-2 Fuel System Pilot and Atomizing Air
Parts List: Fuel System Pilot and Atomizing Air
1 38467 VALVE, Ball, 1/2 in., 250# ...................................................................1

2 22926 VALVE, Regulator, gas, 1/2 in., 125# ..................................................1
3 27618 VALVE, Solenoid, 2 way, 1/4 in., normally closed ...............................2
4 31701 VALVE, Solenoid, 2 way, 1/4 in., normally open ..................................1
5 3440 VALVE, Ball, 1/4 in. .............................................................................3
6 17094 STRAINER, Y, 1/2 in., 250 psi, 0.02 mesh screen ..............................1
7 13829 SWTICH, Pressure, 0–150 psi, SPST ................................................2
8 23866 REGULATOR, Air, filter, 0–160 psi gauge ..........................................1
9 25958 VALVE, Globe, 3/8 in., 200# ................................................................2
10 22928 VALVE, Pressure Reducing, 1/2 in. NPT, 0–60 psi .............................1
11 23509 VALVE, Solenoid, 2 way, 1/2 in., normally closed ...............................1
12 20631 GAUGE, Pressure, 2 1/2 in., 0–100 psi ..............................................1
13 25048 VALVE, Check, swing, 3/8 in. a ............................................................2
14 UH-30343 RESTRICTOR ASSY, Gas Pilot, 0.106 ...............................................1
15 UH-28257 RESTRICTOR ASSY, Atomizing Air, 0.177 .........................................1
a
Check-valves are used on gas-oil combination machines only.
FuelOilSys_E1004_C8552_a.fm C-14 04/20/2016

Fig. 10 - Pilot Gas Hookup
6 4 3 2
7 4 5 1
Fig. 10 Pilot gas hookup
Units
Figure & Part Per
10 - PILOT GAS HOOKUP
1 38467 VALVE, Ball, 1/2 in., bronze body, 250# ................................................................................. 1

2 22926 VALVE, Regulator, gas, 1/2 in. NPT, 125 psi, 6 – 14 in. w.c. outlet press. ................................. 1
3 33796 GAUGE, Pressure, 2 1/2 in. dia., 0 – 30 in. w.c. ...................................................................... 1
4 3440 COCK, Gas, male/female, 1/4 in. .......................................................................................... 3
5 27618 VALVE, Solenoid, 2 way, 1/4 in., 120 vac/60 Hz ..................................................................... 2
6 31701 VALVE, Solenoid, 2 way, 1/4 in., 120 vac/60 Hz, TFT8262G ................................................... 1
7 UH-30343 RESTRICTOR ASSY, Gas Pilot, 0.106 ................................................................................... 1
08/22/2013 C-15 PilotGasHookup_NFPA_E1004_a.fm

Fig. 11A - Burner Manifold–Gas
Fig. 11a Burner manifold – gas
BurnerMnfld_gas_UH34240_E1004_a.fm C-16 06/27/2011

PARTS LIST: Fig. 11A - Burner Manifold – gas
06/27/2011 C-17 BurnerMnfld_gas_UH34240_E1004_a.fm

Fig. 11B - Burner Manifold–Oil & Oil-Gas
Fig. 11b Burner manifold – oil & oil-gas combination
BurnerMnfld_O-G_UH34700e_E1004_c.fm C-18 08/22/2013

PARTS LIST: Fig. 11B - Burner Manifold – oil & oil-gas combination
08/22/2013 C-19 BurnerMnfld_O-G_UH34700e_E1004_c.fm

Fig. 12A - Air Blower Hookup
11 10
12
2
9 6
5
5
8
* 4
13
3
* Optional Equipment
Fig. 12A Air Blower Hookup
BlowerSys_E1004_c.fm C-20 04/13/2016

Units
Figure & Part Per
12A - AIR BLOWER HOOKUP
1 UH-34184 HOUSING ASSY, Blower ..................................................................................................................... 1

2 UH-34190 PLATE ASSY, Cover, blower, rear ........................................................................................................ 1
3 41634 BELT, V, 5-BP90 (5 belt set) ................................................................................................................ 1
4 41416 MOTOR, TEFC, 125 hp, 460 vac / 60 Hz / 3 ph, Class F, F-2 1 ................................................................ 1
42291 MOTOR, ODP, 75 hp, 380 vac / 50 Hz / 3 ph, Class F, F-3 2 .................................................................... 1
44166 MOTOR, TEFC, 125 hp, 460 vac / 60 / 3 ph, Class F, F-2 3 ..................................................................... 1
5 UH-34191 FLANGE ASSY, Inlet Air ...................................................................................................................... 2
6 40636 BEARING, Flanged, 2 7/16 in. (61.9 mm) bore ..................................................................................... 2
7 UH-34004 SHAFT ASSY WITH WHEELS, Balanced, fuel pump spindle ................................................................. 1
UH-35829 SHAFT ASSY WITH WHEELS, Balanced .............................................................................................. 1
8 UH-34189 PLATE ASSY, Cover, blower, front ....................................................................................................... 1
9 UH-34187 VOLUTE AND AIR DUCT ASSY ........................................................................................................... 1
10 UH-68822 GASKET, Rubber, volute-burner base, semi-circle ................................................................................ 1
11 UH-68823 GASKET, Rubber, volute-burner base .................................................................................................. 1
12 UH-68660 GASKET, Rubber, blower housing-air duct flange .................................................................................1
13 UH-33075 DISK ASSY, Speed Sensor, blower 4 .................................................................................................... 1
1 Machine Serial: 25004

2 Machine Serial: 25227, 25228
3 Machine Serial: 25611
4 Optional equipment. Used with blower VSD option.
04/13/2016 C-21 BlowerSys_E1004_c.fm

Fig. 12B - Air Duct and Damper
3 2
23
22
26
24
13
27 30
25
14
28
29
16
19
17
15
13
11 11
14
14
13 18
9
6 19
12
7 13 20
10 21
8 5 14
Fig. 12b Air Duct & Damper
BlowerSys_E1004_c.fm C-22 04/13/2016

Units
Figure & Part Per
12B - AIR DUCT & DAMPER–UNIVERSAL CONTROL
1 40027 BEARING, Flange-mounted, 7/8 in. bore (22.2 mm) .............................................................................. 4

2 4462 SCREW, Cap, 5/16-18 x 5/8 in., hex head ............................................................................................ 8
3 10017 WASHER, Lock, 5/16 in., medium ........................................................................................................ 8
4 UH-68949 WASHER, Spacer, damper link .......................................................................................................... 16
5 39326 MOTOR, Servo, air damper, flush panel mount (SQM48.697A9) ............................................................ 1
6 2749 SCREW, Machine, #10-32 x 3/4 in., round head ................................................................................... 4
7 2606 WASHER, Lock, #10 ........................................................................................................................... 4
8 33469 WASHER, Flat, #10, steel ................................................................................................................... 4
9 39538 COUPLING, Disc, 12 in. x 14 mm bore, 350 in./lb .................................................................................1
10 UH-68330 ROD, Linkage, damper-actuator adjustment ......................................................................................... 1
11 22963 ARM, Crank ....................................................................................................................................... 2
12 32620 SWIVEL, Linkage Rod, damper-actuator adjustment, 1/4-28 ................................................................. 2
13 2616 SCREW, Cap, 1/4-20 x 3/4 in., hex head .............................................................................................. 4
14 2608 WASHER, Lock, 1/4 in., medium .......................................................................................................... 4
15 UH-34192 POINTER, Damper Angle, lower .......................................................................................................... 1
16 UH-34193 POINTER, Damper Angle, upper ......................................................................................................... 1
17 UH-36596 PLATE, Support, damper blade, upper ................................................................................................. 1
18 UH-34202 PLATE, Support, damper blade, lower ................................................................................................. 1
19 UH-68775 GASKET, Support Plate, damper blade ................................................................................................ 2
20 UH-34194 BLADE ASSY, Damper, air .................................................................................................................. 2
21 UH-64714 PLATE, Name, damper blade angle ..................................................................................................... 1
22 2643 SCEW, Cap, 3/8-16 x 1 in., hex head ................................................................................................... 4
23 2610 WASHER, Lock, 3/8 in., medium .......................................................................................................... 4
24 UH-68962 PLATE, Cover, volute, outer ................................................................................................................ 1
25 UH-68706 GASKET, Cover Plate, outer ................................................................................................................ 1
26 UH-68961 PLATE, Cover, volute, inner ................................................................................................................ 1
27 38561 SWITCH, Pressure, 5–30 in. w.c., SPDT, auto reset (APS) .................................................................... 1
28 3440 VALVE, Ball, 1/4 in. ............................................................................................................................ 1
29 33809 VALVE, Test, 3 way, 1/4 in. NPT, push to test 1 ..................................................................................... 1
30 33796 GAUGE, Pressure, 0 – 30 in. w.c., 2 1/2 in. dia. .................................................................................... 1
1 Used on machine serial #25004 only.
04/13/2016 C-23 BlowerSys_E1004_c.fm

Parts Catalog
Fig. 13A - Electrical Control Box-Right Front Door
2
4
9 8 7
Fig. 13A Electrical Control Box-Right Hand Door (Inside)
Parts List - 13A: Electrical Control Box-Right Hand Door
1 UH-39240 OIU ASSY (EPROM Program: P-_____________ ...............1

2 36247 CABLE, Communication, OIU-to-PLC .....................................1
3 37984 MODULE, Display, 4 x 16 characters (ESC) ..........................1
4 37990 CABLE, Communication, ESC module ...................................1
5 UH-32282 PUSHBUTTON ASSY, Start, green, N.O. contact ...................1
6 UH-32281 PUSHBUTTON ASSY, Stop, red, N.C. contact .......................1
7 42513 PUSHBUTTON, Black, flush (auto shutdown) ........................1
8 41424 LIGHT, Pilot, white (control power) .........................................1
9 41423 LIGHT, Pilot, amber (alarm) ...................................................1
ElecCtrlBox_E1004_C9035_a.fm C-24 04/19/2016

Appendix C
Fig. 13B - Electrical Control Box-High Voltage Equipment
1 1
4 2x
3
2
7
6
7
6
Fig. 13B Electrical Control Box-High Voltage Equipment
04/19/2016 C-25 ElecCtrlBox_E1004_C9035_a.fm

Parts Catalog
Parts List - 13B: Electrical Control Box-High Voltage Equipment
1 40971 CONTROLLER, Drive, adjustable, 157 A, ABB ......................1

2 37166 TRANSFORMER, Step-down .................................................1
3 29980 FUSE, 5 A, 600 V ....................................................................1
4 33601 FUSE, 2 A, 600 V, time delay ..................................................2
5 41106 BLOCK, Power Distribution, 3 pole .........................................1
6 42661 PROTECTOR, Motor, 250 A (GMP1/3) .................................2
7 43132 CONTACT, Auxiliary Adder, N.O. (GMP1/3) ..........................2
8 44194 REACTOR, Line, 3 ph, 125 hp ................................................1
9 37257 RAIL, Grounding, 20 point .......................................................1

Appendix C
Fig. 13C - Electrical Control Box-Right Compartment
2 1 25
24 3 4 4 4 5
21 23 9 9 11
12
6 7 20 22 8 8 10
15 2x
16
17 5x
18 23x
13 14
15 2x
16
17 2x
18 59x
26
Fig. 13C Electrical Control Box-Right Compartment
04/19/2016 C-27 ElecCtrlBox_E1004_C9035_a.fm

Parts Catalog
Parts List - 13C: Electrical Control Box-Right Compartment
1 38661 CHASSIS, Combustion Control, LMV (ESC) .........................1

2 37992 TRANSFORMER, LMV, 120-12 vac .......................................1
3 41040 PROCESSOR, PLC, 120/240 vac, 32 I/O (A0) .....................1
4 37172 MODULE, Analog, I/O, voltage/current (A1/2) ......................3
5 37900 MODULE, Thermocouple Input, 4 channel (A3/4) .................2
6 38279 CONTROL, Temperature Limit, 525o F (MTLC2) ...................1
7 38280 CONTROL, Temperature Limit, 550o F (MTLC1) ...................1
8 33169 RELAY, Control, IDEC, SPDT, 10 amp (AR, GIR) ..................2
9 36609 SOCKET, IDEC, 5 pin .............................................................2
10 38106 RELAY, Control, IDEC, 3PDT, 10 amp (SR1, SR2) ................2
11 37164 SOCKET, IDEC, 11 pin ............................................................2
12 41412 SUPPLY, Power, linear, +24 vdc output, 2.1 A ........................1
13 33176 CAPACITOR, 1000 mfd, 35 vdc ..............................................1
14 23669 DIODE, Silicon ........................................................................1
15 38802 BLOCK, Terminal, end anchor ................................................4
16 38803 BLOCK, Terminal, end barrier .................................................2
17 38804 BLOCK, Terminal, partition plate .............................................6
18 38801 BLOCK, Terminal, 600 vac/vdc, 35 amp .................................73
20 34233 TIMER, Solid State, off-delay, 8 pin, 1–30 sec. (PLT) ............1
21 41722 SOCKET, Octal, 8 pin ..............................................................1
22 33169 RELAY, Control, IDEC, SPDT, 10 amp (PLR) ........................1
23 36609 SOCKET, IDEC, 8 pin .............................................................1
24 23769 SWITCH, Pushbutton, 2 pole ..................................................1
25 42199 FAN, Cooling, 169 cfm, 115 v ..................................................1
26 37257 RAIL, Grounding, 20 point .......................................................1

Fig. 14 - Gravity Fill–Elevated Receiver
1 2
Fig. 14. Gravity Fill Option - Elevated Receiver
Units
Figure & Part Per
14 - GRAVITY FILL OPTION - ELEVATED RECEIVER
1 38149 VALVE, Check, swing, 1 in., 800# . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2 40801 VALVE, Ball, two piece, 1 in., 250#, stainless steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
04/13/2016 C-29 GravityFill_E1xx4_b.fm

Steam Generator Instruction Manual
Fig. 15 - Soot Blower Option
4
3 12x
2x 5
16x 6
7
5 2x
6 16x
5
6 8x
Fig. 15. Soot Blower Option
Units
Figure & Part Per
15 - SOOT BLOWER OPTION
1 UH-36618 SPOOL ASSY, Soot Blower . . . . . . . . . . . . . . . . . . . . . ... ... ... . . . . . . . . . . . . . . . . . . . . . . .1

2 38401 GASKET, Metal, spiral wound, 8 in., 300# . . . . . . . . . . ... ... ... . . . . . . . . . . . . . . . . . . . . . . .1
3 31066 STUD, 7/8-9 x 5 3/4 in. (includes two hex nuts each) . ... ... ... . . . . . . . . . . . . . . . . . . . . . . 12
4 31157 VALVE, Globe, 3 in., 600# . . . . . . . . . . . . . . . . . . . . . . . ... ... ... . . . . . . . . . . . . . . . . . . . . . . .2
5 29134 GASKET, Metal, spiral wound, 3 in., 300 / 600# . . . . . . . ... ... ... . . . . . . . . . . . . . . . . . . . . . . .5
6 31064 STUD, 3/4-10 x 5 1/4 in. (includes two hex nuts each) ... ... ... . . . . . . . . . . . . . . . . . . . . . . 40
7 19348 VALVE, Globe, 1 in., 800# . . . . . . . . . . . . . . . . . . . . . . . ... ... ... . . . . . . . . . . . . . . . . . . . . . . .1
Sootblow_R23345b_a.fm C-30 11/04/2013

Fig. 19 - Separator Discharge Valve Kit (Option)
12x 3
SEPARATOR (REF)
Fig. 19. Separator Discharge Valve Kit (Option)
Units
Figure & Part Per
19 - SEPARATOR DISCHARGE VALVE KIT (OPTION)
UH-35259 KIT, Steam Discharge Valve, 8 in., 300# . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ref

1 41290 . VALVE, Globe, 8 in., flanged, 300#, chain operator . . . . . . . . . . . . . . . . . . . . . . . . .1
2 38401 . GASKET, Metal, spiral wound, 8 in., 300# . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3 31066 . STUD, 7/8-9 x 5 3/4 in. (includes 2 hex nuts each) . . . . . . . . . . . . . . . . . . . . . . . . 12
11/04/2013 C-31 SepDischgValvKit-flange_xxx4_a.fm

Fig. 21 - Valve Option Kit Hookup
Fig. 21 Valve Option Kit hookup
Units
Figure & Part Per
21 - VALVE OPTION KIT HOOKUP
1 7928 NIPPLE, Pipe, 2 x 4 in., x-hvy, sched 80 ................................................................................1

2 9101 STUD, 5/8-11 x 3 1/2 in. (includes two hex nuts each) .......................................................... 24
3 26109 VALVE, Globe, 2 in., 800# .....................................................................................................1
4 28965 GASKET, Metal, spiral wound, 2 in., 300/800# .......................................................................3
5 31066 STUD, 7/8-9 x 5 3/4 in. (includes two hex nuts each) ..............................................................8
6 31192 GASKET, Metal, spiral wound, 4 in., 600# ..............................................................................1
7 31211 VALVE, Globe, flanged, 2 in., 600# ........................................................................................3
8 UH-34822 SPOOL ASSY, Welded, 4 x 2 in., 600# ...................................................................................1
ValveOptionHkup_R21546a_a.fm C-32 11/04/2013

11/04/2013 C-33 ValveOptionHkup_R21546a_a.fm

Appendix D - KSB Multitec Pump IOM
APPENDIX D
Installation, Operation, and Maintenance
KSB Multitec® Pump

Supplementary Operating Instructions
1777.801/2-10 G3
Supplement to the Multitec Operating Instructions 1777.8/.-10
Starting up/commissioning pumps with graphite gland

packings
Non-compliance with these instructions could result in 2. In order to shorten the running-in process, rotate the shaft
hazards to persons and/or damage to the pump. The approx. 30 times by hand until the packing’s friction
personnel performing the work described must be fully qualified resistance is noticeably reduced.
for this type of work and must have read and understood these 3. Start the pump up 4 to 5 times for approx. 5 seconds
instructions. each and check the leakage.
4. Start the pump up again and check for sufficient leakage
General during operation.
Should the leakage stop, switch off the pump immediately
These supplementary operating instructions apply to gland
and repeat the start-up process.
packings made of pure graphite (99.9 % carbon).
5. During standstill, the clearance between shaft protecting
In order to ensure a long service life and maximum protection sleeve and gland packing increases as the pump cools
of the shaft protecting sleeve surface, paired with minimum down. This results in increased leakage, which must not
maintenance requirements, observe the following rules for be reduced.
installation and start-up/commissioning:
Maintenance
Installation
If the gland packing leaks excessively after prolonged
1. Remove the old packing rings and thoroughly clean the operation, stop the pump and re-tighten the packing gland’s
gland packing chamber and shaft protecting sleeve. hexagon nuts evenly by 1/6 turn each. Check the leakage
Replace any damaged components. again. If the leakage stops, switch off the pump immediately,
2. Displace each cut edge by 90 _ in relation to the previous remove the gland completely and repeat the start-up
one. procedure.
3. Press the packing rings onto each other by hand.
4. Mount the gland centred and at a right angle to the shaft.
Gently tighten the hexagon nuts at the gland by hand. The use of a gland packing is only recommended under the
following conditions:
-- constant inlet pressure (+/-- 2.5 bar permissible)
Commissioning/start-up -- constant temperature (+/-- 10 qC permissible)
General -- constant speed (+/-- 4 % permissible)
-- continuous operation (no intermittent operation)
Take the pump out of service for any adjustment and
maintenance work. -- clean liquid
-- operation with sufficient leakage
Always centre the gland and position it at a right angle to the
shaft. If you are planning to operate the pump at variable speed
and/or variable inlet pressure, ensure sufficient leakage at
Start-up procedure the packing in all operating conditions, especially at minimum
speed and/or minimum inlet pressure.
It must be ensured that leakage is predominantly
discharged between the shaft sleeve and the packing
rings and not between the packing rings and the stuffing box
housing. The amount of leakage should be at least 1 litre per
minute.
1. Prime the pump and check for leakage. There should
already be some leakage during standstill.
Subject to technical modification without prior notice.
29.04.2009
1777.801/2-10
KSB Aktiengesellschaft
P.O. Box 1361 x 91253 Pegnitz x Bahnhofplatz 1 x 91257 Pegnitz (Germany)
Tel. +49 9241 71-0 x Fax +49 9241 71-1793
www.ksb.com

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Pump with long-term preservation: Harmful preservatives in drinking water systems
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Installation on mounting surface which is unsecured and cannot support the load
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Warped baseplate or pump
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Channel section baseplates less than 400 mm wide are torsion-resistant and need not be
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For low-noise operation contact KSB to check whether the pump set can be installed on
anti-vibration mounts.
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Expansion joints can be fitted between pump and suction/discharge line.
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Impermissible loads acting on the pump nozzles
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Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
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It is recommended to install check and shut-off elements in the system, depending on the
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hinder disassembly of the pump.
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Welding beads, scale and other impurities in the piping
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Use a filter with laid-in wire mesh of 0.5 mm x 0.25 mm (mesh size x wire diameter)
made of corrosion-resistant material.
Use a filter with a filter area three times the cross-section of the piping.
Conical filters have proved suitable.
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Aggressive flushing and pickling agents
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Where fluid has to be pumped out of a vessel under vacuum, it is recommended to install
a vacuum balance line.
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An additional line (from the pump discharge nozzle to the balance line) fitted with a shut-
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Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing liquid,
etc.)
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Impermissible temperatures at the coupling or bearings caused by misalignment of the
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Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
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Increase in length and height at fluid temperatures > 100 °C
Warping and deformation of the pump (set)!
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CAUTION
Excessive forces and moments acting on the pump nozzles due to thermal expansion of
piping and pump
Warping and malfunction of pump!
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Work on the pump set by unqualified personnel
Danger of death from electric shock!
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Incorrect connection to the mains
Damage to the mains network, short circuit!
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It is recommended to fit a motor protection device.
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Switchover between star and delta on three-phase motors with star-delta starting takes
too long.
Damage to the pump (set)!
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Electrostatic charging
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Fire hazard!
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In compliance with DIN VDE 0530 - Part 8, three-phase motors are always wired for
clockwise rotation (looking at the motor shaft stub).
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Temperature increase resulting from contact between rotating and stationary
components
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Hands or objects inside the pump casing
Risk of injuries, damage to the pump!
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Drive and pump running in the wrong direction of rotation
Damage to the pump!
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CAUTION
Poor boiler feed water and condensate quality
Loss in component strength due to localised corrosion (graphitisation)!
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NOTE
If no constant-level oiler is provided on the bearing bracket, the oil level can be read in
the middle of the oil level sight glass arranged at the side of the bearing bracket.
CAUTION
Insufficient lubricating oil in the reservoir of the constant-level oiler
Damage to the bearings!
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An excessively high oil level can lead to a temperature rise and to leakage of the fluid
handled or oil.
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Risk of potentially explosive atmosphere inside the pump
Explosion hazard!
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Increased wear due to dry running
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For design-inherent reasons some unfilled volume in the hydraulic system cannot be
excluded after the pump has been primed for commissioning/start-up. However, once the
motor is started up the pumping effect will immediately fill this volume with the fluid
handled.
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Venting the seal chamber in hot condition
Danger of scalding by hot steam escaping!
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The permissible pressure and temperature limits will be exceeded if the pump is
operated with the suction and discharge lines closed.
Explosion hazard!
Leakage of hot or toxic fluids!
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Excessive temperatures due to dry running or excessive gas content in the fluid handled
Explosion hazard!
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The suction casing, discharge casing, stage casing, seal housing and seal cover take on
the same temperature as the fluid handled.
Risk of burns!
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The temperature at the bearing bracket can exceed 60 °C during operation.
Risk of burns!
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Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
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Start-up against open discharge line
Motor overload!
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On variable-speed pumps, the necessary gland packing leakage must be set for the
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conditions.
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Unprotected rotating parts
Risk of personal injury!
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Heat build-up inside the pump
Damage to the shaft seal!
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If the discharge line is equipped with a non-return or check valve, the shut-off element
may remain open.
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CAUTION
Risk of freezing during prolonged pump shutdown periods
Damage to the pump!
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Non-compliance with operating limits for pressure, temperature, fluid handled and speed
Explosion hazard!
Hot or toxic fluid could escape!
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Excessive surface temperature of the motor
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Re-starting while motor is still running down
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For pumps with shafts equipped with two keys at the coupling, the maximum number of
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Impermissibly high density of the fluid handled
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Prolonged shutdown periods should be avoided in the case of pumps in material variants
10, 13, 17, 20, 21 and 27 (cast-iron hydraulics), particularly if the pumps are handling
aggressive water qualities (high oxygen content). In such cases, the pump should remain
filled, and the operation check run should be performed at least every other day.
NOTE
The stage casings of horizontal pumps can only be drained completely through the drain
plugs provided on the stage casings (optional). If this is not possible we recommend to
proceed as described in the following section.
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Glycol-base preservatives (e.g. KLÜBERTOP K 01-601)
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Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts or escaping fluid!
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Risk of personal injury!
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Insufficient stability
Risk of crushing hands and feet!
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All maintenance, service and installation work can be carried out by KSB Service. Find
your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/
contact".
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Risk of potentially explosive atmosphere inside the pump
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Incorrectly serviced shaft seal
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Fire hazard!
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Excessive temperatures as a result of bearings running hot or defective bearing seals
Explosion hazard!
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Increased wear due to dry running
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Operation outside the permissible bearing temperature
Damage to the pump!
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After commissioning, increased temperatures may occur at grease-lubricated rolling
element bearings due to the running-in process. The final bearing temperature is only
reached after a certain period of operation (up to 48 hours depending on the conditions).
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If the clearances given are exceeded, replace the affected components or restore the
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Insufficient inlet pressure due to clogged filter in the suction line
Damage to the pump!
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Lubricants posing a health hazard and/or hot lubricants
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On some pump designs the rolling element bearings are lubricated for life. These pumps
are not provided with a lubricating nipple on the bearing bracket.
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If re-lubrication intervals are short, we recommend to completely replace the grease once
a year.
Otherwise, the grease fill must be replaced completely every two years. To do so,
remove the rolling element bearings, clean and pack with new grease.
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Appendix E - Delta Electronics OIU
APPENDIX E
Operating Instructions
Delta Electronics OIU

Page 1 of 6 DELTA AUTOMATION OIU OPERATION 1 April 2013
The start screen is displayed after power-up, or after alarm reset.

The CAL MENU button will cause the MAIN MENU to be displayed.
The red lines through the CALIBRATION and PID TUNING menu buttons indicate that a password must
be entered in order to access these menus. PID TUNING requires the Engineer password.
From the MAIN MENU, the Modulation Setpoint screen can be displayed.
To change a setpoint, press the numeric entry button. A numeric entry pop-up will be displayed.
Enter a value using the on-screen keypad and press Enter when done.
Press the MAIN MENU exit. Pressing the ESC key releases the CAL MODE.
Press the CALIBRATION menu button to access the service screens.
To enter the CAL MODE, you must be logged in using the Service password.
The CALIBRATION MENU button will have a red line through it if the password has not been entered.
A password entry pop-up will be displayed if the password has not been entered.
After entering the correct password, the calibration menu will appear.
Press PREV / NEXT to navigate to other calibration menus. Press the ESC key to exit the CAL mode.
The ALARM History allows the display of all alarms since the OIU was powered or until the alarms are
cleared. The O at the beginning of the line indicates an active alarm. The X at the beginning of the line
indicates an alarm that has been reset in the PLC. Press the CLEAR button to clear all alarms on the
screen.
When an alarm occurs, the following screen is displayed:
The alarm condition must be cleared and the E-STOP must be pushed in/pulled out to close this
screen.
On the Fill/Run screens in manual mode, the Fill rate or Firing rate can be changed by pressing the
numeric pushbutton.
A numeric entry pop-up screen will appear:
The operator can select the Fill or Run and Manual or Automatic mode from this screen.
PERIODIC MAINTENANCE LOG
Refer to instruction manual for maintenance procedure details.
MODEL:
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. SERIAL NUMBER:
Some of the items described may not apply to each model. MONTH / YEAR:
FMB FEEDWATER TREATMENT CONDENSATE NOTES

AIR INTAKE
FILTER VISUAL CHEMICAL CHEMICAL
CUMULATIVE OPERATING COIL FEED STEAM TRAP VOLUTE/BURNER PRESSURE BURNER INSPECTION pH TDS SULFITE PUMP RATE PUMP RATE WALK-
DAILY OPERATING PRESSURE PRESSURE PRESSURE STACK TEMP. PRESSURE DROP TEMP. (SIGHT (10.5 - (3,000 - 6,000) (50 - 100) (STROKE/ pH (STROKE/ SOOT AROUND
o o
DATE DAY/TIME HOURS (PSI) (PSI) (PSI) ( F) (w.c.i.) (w.c.i.) ( F) GLASS) HARDNESS 12.5) (ppm) (ppm) SPEED) (8.0 MINIMUM) SPEED) BLOW COIL INSPECTION
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
FMB VISUAL ANNUAL (OR SEMI-ANNUAL)

ROTATE FUEL CHECK MOTOR CHECK COUPLING INSPECTION PARTIALLY DRAIN WATER METER WEEKLY RUN (INDICATE DATES)
WEEKLY FILTER ALIGNMENT ALIGNMENT CHECK BELT TENSION (BURNER OFF) HOT-WELL TANK (gal.) HOURS
1
2 REPLACED: Burner Nozzle(s)
3 Pump Check-valve Seats and Discs
4 Pump Diaphragms/Washers
5 Pump Standpipe Seals
Pump Surge Chamber/Discharge Snubber
Crankcase Oil
OPERATING Burner Electrode
TEMPERATURE CONTROLLERS INTAKE SURGE Burner Photocell
STLC CHAMBER /
VOLUTE PRESSURE ATS SETTING MTLC1 MTLC2 VTLC (AFTER COIL DISCHARGE
(w.c.i.) (oF) FLAME SAFEGUARD (oF) (oF) (oF) WASH) (oF) SNUBBER TESTED: Pump Relief Valve
Safety Relief Valve(s)
MONTHLY NON-OPERATING (UNIT SHUT DOWN)
STRAINERS / FILTERS
(REMOVE AND CLEAN) DRAIN AND FLUSH BLOWER BURNER FMB
CLEAN CLEAN
BOOSTER CONTINUOUS PUMP BLOWER LUBRICATE BURNER CLEAN FMB MANIFOLD
PUMP FEED PUMP(S) BLOWDOWN FUEL OIL ATOMIZING AIR HOT-WELL HEADS WHEEL MOTOR(S) NOZZLES ELECTRODE GAP W/ COMPRESSED AIR PUMP LEVEL SWITCH COIL WASH
R0007517H
NOTES
Back Cover
17477 Hurley Street, City of Industry, California 91744-5106, USA

Phone: +1 (626) 435-1200 Fax: +1 (626) 435-0180
Internet: www.claytonindustries.com
Email: sales@claytonindustries.com

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MODEL: _______________________ SERIAL NUMBER: _____________________

FIRE AND EXPLOSION DANGER

HIGH PRESSURE DANGER

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

A Clayton Steam Generator is manufactured in conformance with the ASME (American

NBBI certification and UL compliance assures that a Clayton Steam Generator is

© Copyright 2011, 2012, 2013 Clayton Industries. All rights reserved.

FACTORY DIRECT SALES AND SERVICE

LICENSEES, AFFILIATES, SALES and SERVICE DISTRIBUTORS WORLDWIDE

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

Section 1 Introduction ....................................................................................................................... 1-1

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

Section 3 Initial Firing ....................................................................................................................... 3-1

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

Section 5 PLC / OIU Operating Instructions ....................................................................................... 5-1

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

Section 8 Troubleshooting ................................................................................................................ 8-1

Appendix A - Supplemental Instructions ......................................................................................... A-1

Appendix B - Reference Tables and Charts ..................................................................................... B-1

Appendix D - KSB Multitec Pump IOM ............................................................................................. D-1

Appendix E - Delta Electronics OIU ................................................................................................... E-1

1.2 FEEDWATER PUMP

10/21/2013 Sect01_1004_b.fm 1-1

1.3 INSTALLATION INSTRUCTIONS

1.4 FEEDWATER TREATMENT

2.2 WATER AND STEAM SYSTEM

2.2.2 Feedwater Pump

03/31/2016 Sect02_1004_c.fm 2-1

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

2.2.3 Hot-well Tank

2.2.4 Heating Coil

2.2.5 Steam Separator

2.2.6 Separator Level Control System

Table 2-1: Pressure-Temperature

2.3 FUEL SYSTEM - GAS-FIRED MACHINES

Fig. 2-3 Flow Diagram - Fuel System (gas-fired machines)

2.4 FUEL SYSTEM - OIL-FIRED MACHINES

Fig. 2-4 Flow Diagram - Fuel System (Oil-fired machines)

2.5 AUTOMATIC BURNER MODULATION

2.6 BURNER MANIFOLD - GAS- OR OIL-FIRED MACHINES

2.7 DESCRIPTION - ELECTRICAL DEVICES

2.7.2 Atomizing Air Pressure Switch (AAPS) - oil operation only

2.7.4 Air Pressure Switch (APS)

2.7.5 Air Relief Solenoid Valve (ARSV)

2.7.6 Air Solenoid Valve (ASV) - oil operation only

2.7.7 Auxiliary Thermostat Switch (ATS)

2.7.8 Auxiliary Relay (AR) - (optional equipment)

2.7.9 Bleed Valve (BV)

2.7.10 Cooling Water Solenoid Valve (Special Applications)

2.7.11 Electrical Interlock Switch (EIS)

2.7.12 Electronic Safety Control (ESC)

2.7.13 Feedwater Pressure Switch (NPSH) (optional feedwater pump only)

2.7.14 Fuel Pressure Switch (FPS) - oil operation only

2.7.15 Galvanic Isolation Relay (GIR)

2.7.16 Group Motor Protectors (GMP)

2.7.17 Gas Pressure Switch - High (GPSH)

2.7.18 Gas Pressure Switch - Low (GPSL)

2.7.19 Ignition Electrode (IE)

2.7.20 Ignition Transformer (IT)

2.7.21 Limit Pressure Switch (LPS)

2.7.22 Magnetic Controller (M1)

2.7.23 Magnetic Controller (M2)

MODEL: ___ SERIAL NUMBER: _