Clayton Steam Master CSMG-15, Steam Master Series, Steam Master CSMG-30, Steam Master CSMG-40 User Manual

STEAM MASTER SERIES

USER MANUAL

Cover

CSMG-15/30/40

R027880B-20190603

For your convenience, enter your unit’ s spe cific model a nd serial number in the sp ace below. The model and serial
number are located on the right-hand side of the electronic controls cabinet.

MODEL: _______________________ SERIAL NUMBER: _____________________

SAFETY SUMMARY

EMERGENCY STOP

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

HIGH PRESSURE VESSEL

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

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

DANGEROUS VOLTAGES

230/460 volts in the electronic control box. Use extreme care when a ccessing the control
box for maintenance. Disconnect and lock out main power circuit switch before performing
any disassembly of the steam generator.

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

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

Equipment may start automatically at any time.

HEARING PROTECTION

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

CORROSIVE LIQUIDS

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

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

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

i

Personnel must become thoroughly familiar with all aspects of safe and proper

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

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

FAILING TO INSTALL, OPERATE, AND MAINTAIN MACHINERY ACCORDING TO
MANUFACTURE’S INSTRUCTIONS COULD RESULT IN HAZARDOUS WORKING
CONDITIONS THA T LEAD TO BODILY HARM OR DEATH.

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

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

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

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

operating and maintenance procedures before attempting to operate or maintain this
machine.

ii

IMPORTANT INFORMATION

PLEASE READ THIS PAGE CAREFULLY

1. READ THIS INSTRUCTION MANUAL AND THE INSTALLATION MANUAL CAREFULLY BEFORE INSTALL­ING, OPERATING, OR SER VICING THE STEAM GENERAT OR 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 S tan da rd AN SI Z2 23 .1 /N FPA54, Nation al Fu el G as Co de, or AN SI/

NFPA 31, “Installation of Oil Burning Equipment,” for clearances between heating unit, vent connector, and
combustible material.

B. Current edition of the American National Standard ANSI/NFP A 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 Mec hanical Engineers ASME CSD-1, “Controls and Safety

Devices for Automatically Fired Boilers,” for assembly and operations of controls and safety devices.

CANADA BOILERS

A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equip-

ment,” for recommended installation practices.

B. The equipment shall be installed in accordance with the current installation code for gas burning appliances

and equipment, CGA B149, and applicable provincial regulations for the class, which should be followed in
all cases. Consult the proper authorities having jurisdiction over the installation site prior to installing any
steam generator.

3. Heating systems should be designed by licensed contractors, only. Installation of a steam generator should be performed
only by persons qualified in the layout and installation of boile r syste m s (i nc luding ASME code).

4. The steam generator must be properly vented in accordance with the National Fuel Ga s Code a nd local c odes. Fa ilure to
adhere to these codes may result in serio us 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 MATE­RIAL; SUCH AS, RAGS, PAPERS, AND WOOD SCRAPS, AT ALL TIMES.

iii

RECEIVING AND UNPACKING

Your Clayton Steam Master Steam Generator arrives anchored to a shipping pallet. It is typically

packaged in protective plastic wrap—unless otherwise specified (See below.).

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

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

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

iv

Overview of Unit Features

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

See page viii for description of unit features.

v

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

vi

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

vii

Description of Unit Features

1 Gas Train, Main Gas Supply
2 Gas Inlet, Main
3 Compact Burner, Weishaupt
4 Steam Outlet
5 Exhaust Outlet
6 OIU (Operator Interface Unit)
8 Condensate Return, Steam Trap
9 Economizer Drain

10 Blowdown Drain

11 Separator
12 Exhaust Duct/Economizer
13 Pump and Motor Assembly
14 Heating Coil
20 Water Inlet, Pump
24 Feedwater Pressure Gauge
25 Maintenance Drain Valve
26 Coil Feedwater Valve
29 Test Valve
30 Safety Relief Valve
32 Separator Drain Valve
38 Steam Pressure Gauge
41 Steam Trap Pressure Gauge
47 Steam Outlet Valve
48 Steam Trap

B24 Pressure Transducer (OPX1)
B29 Temperature Transmitter
F21 Temperature Switch (LPS)
F31 Thermocouple
F95 Temperature Switch
Y15 Blowdown Valve, Manual
S10 Main Switch

S101 Emergency Stop Button

viii

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, California 91744-5106

USA

Phone: [phone]

Fax: [phone]
Internet: www.claytonindustries.com
Email: [e-mail]

© Copyright 2018 Clayton Industries. All rights reserved.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means

(electronic, mechanical, photocopy, recording, or otherwise) without written permission from Clayton Industries.

The descriptions and specifications shown were in effect at the time this publication was approved for printing. Clayton

Industries, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or

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

FACTORY DIRECT SALES AND 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

SPECIFICATIONS

Units of

Measure-

ment

Boiler Horsepower bhp 15 15 30 30 40 40
Heat Input: Gas Btu /hr 619,907 590,735 1,239,815 1,181,471 1,653,086 1,575,294
Net Heat Output Btu / hr 502,125 502,125 1,004,250 1,004,250 1,339,000 1,339,000
Equivalent Output (From and at 212°F

feedwater and 0 psig steam.)

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

Design Pressure (See Note 1.) psig 150 150 150 150 150 150
Steam Operating Pressure psig 65 –125 65 – 125 65–125 65– 125 65 – 125 65–125
Gas Consumption — at maximum steam

output (See Note 2.)

3

ft

Burner Controls (modulating gas) 4:1 turndown 4:1 turndown 4:1 turndown 4:1 turndown 4:1 turndown 4:1 turndown
Efficiency (gas fired) % 818581858185
Electric Motors — design pressure 150 psi hp Blower = 0.67

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

vac 101011111515

Gas Supply Pressure Required psig 2 2 2222
Water Supply Required gph 133 133 265 265 353 353
Heating Surface

Customer Connections:
Feedwater Inlet in. 1.5 1.5 1.5 1.5 1.5 1.5
Steam Trap Discharge in. 1.0 1.0 0.75 0.75 1.0 1.0
Separator Blowdown in. 1.0 1.0 0.75 0.75 1.0 1.0
Economizer Drain in. 1.0 1.0 1.0 1.0 1.0 1.0
Supply Gas Inlet in. 0.75 0.75 0.75 0.75 1.0 1.0
Steam Discharge Outlet in. 1.5 1.5 1.0 1.0 1.5 1.5
Safety Relief Valve in. 1.0 1.0 1.0 1.0 1.0 1.0
Exhaust Gas Outlet in. 7.88 7.88 9.88 9.88 9.88 9.88
Overall Rough Dimensions
length in. 69 69 77 77 85 85
width in. 50 50 56 56 56 56
height in. 828289899797
Weight
Installed (wet) lbs 2,502 2,689 3,328 3,548 3,567 3,791
Shipping lbs 2,424 2,601 3,152 3,350 3,350 3,593

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

/hr

ft

2

620 591 1,240 1,182 1,653 1,575

Pump = 0.5

Blower = 0.67

Pump = 0.5

Blower =0.67

Pump = 0.75

Blower = 0.67

Pump = 0.75

Blower = 0.83

Pump = 1.5

78.6 110.9 141.0 199.1 152.8 228.2

Blower = 0.83

Pump = 1.5

NOTE:

1. Design pressure is currently limited to 150 psig.

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

3

.

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

Specifications_CSM_a.fm xi 11/22/2018

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Specifications_CSM_a.fm xii 11/22/2018

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

xiii

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

3.1.12 Water H ammer . ............. ................. ................ ................ ................ ............. ....... 3-2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

xiv

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

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

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

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

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

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

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

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

6.3.1 Record Operating/ Steam Press ure ....................................... ................... ........... 6-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

xv

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Fig. 06 - TDS Control System—Equipment Opt ion .... .................... ................... ................... B-4

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

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

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

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

xvi

Section I USING THIS MANUAL

1.1 Graphic Symbols

The following graphical symbols and their

definitions are used throughout this manual:

WARNING paragraphs provide information on
potentially hazardous conditions that may
cause severe bodily injury if precautions are not
taken while working on the equipment.

CAUTION paragraphs provide instructions for
proper handling of equipment to prevent dam­age or destruction of the equipment that may
lead to loss of operating effectiveness.

These paragraphs warns of dan­gerous voltage environments.

Extreme care must used when
working in these conditions to avoid
bodily injury.

These paragraphs highlight operat­ing conditions, recommendations,
and suggestions for efficient oper­ating procedures.

1.2 General

This manual contains instructions for operat­ing and maintaining a Clayton Steam Generator.
Recommendations given herein result from many
years of experience in the manufacture and service
of this type of equipment. The efficiency and ser-

vice 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 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 dis­cussion 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 Generator, then you should
familiarize yourself with its controls by reviewing
Section IV. This section discusses machine startup,
filling, wet shutdown, dry shutdown, and introduces
the Operator Interface Unit (OIU).

Section V provides some common trouble­shooting procedures for problems that may occur
during the machine’s operation. Section VI dis­cusses the scheduled maintenance requirements that
will help maintain the efficiency and reliability,
increase the operating life, and minimize the down­time of the machine. Section VII contain procedures
for maintaining, repairing, or replacing components
and assemblies on the machine.

The appendices at the end of this manual con-

10/02/2018 1-1 Sect01_CSMG_a.fm

Steam Master Instruction Manual

tain supplemental instructions, reference tables and
charts, and the parts catalog, which is used for
ordering replacement parts. The parts catalog con­tains illustrations of steam generator assemblies and
their corresponding parts list.

1.3 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
shutdowns. 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 guide­lines on scheduled feedwater maintenance, and the
appropriate chemicals required for treatment to min­imize the down time of your machine.

Sect01_CSMG_a.fm 1-2 10/02/2018

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,
excessive 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. Chemically treated feedwater is
pumped directly into the heating coil, flowing
through the spiral single-passage section of the coil
in a direction opposite that of the combustion gases
(counterflow principle). As the steam-water mixture
leaves the generating section, it passes 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 hot­well tank through the steam trap mounted on the
steam separator.

A reciprocating pump diaphragm displaces feedwa­ter through the discharge side of the check-valve
housing into the heating coil. Corrosion-resistant
springs, discs, and seats are used in the check-valve
housings.

Tubular water columns (standpipes) separate
the check-valve housings from the pump heads to
keep excessive temperature from the diaphragms.
Discharge snubbers absorb pressure pulsations to
stabilize feedwater delivery. Intake surge chambers
on the pump suction help stabilize feedwater sup­ply. A relief valve protects the pump against over­pressure.

2.2.3 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, mono­tube 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 down­ward direction. The heating coil is constructed to
allow free expansion.

2.2.2 Feedwater Pump

The Clayton positive displacement, dia­phragm-type, feedwater pump ensures a wet-tube
heating coil by delivering the required volume of
water to the heating coil under all load conditions.

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Steam Master Instruction Manual

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

OPTIONAL ECONOMIZER

A

B

C

D

E

A– Steam Discharge Valve
B– Coil Feed Valve
C– Feedwater Pump
D– Feedwater Valve
E– Separator Drain Valve
F– Coil Drain Valve

F

Fig. 2-2. Thermocouple Assembly

2.2.3.1 Main Temperature Limit Controller
(MTLC2)

This over-temperature safety controller (see

1

Fig. 2-2) has a fixed trip-point

. It will interrupt the

motor and burner control circuits on a severe over­temperature condition. It must be manually reset

before normal operation can be resumed. This is
done through 010. A “STEAM COIL TEMP. -

OVER LIMIT-” safety shutdown condition will be
indicated on the OIU, and an audible alarm will
sound.

1

See the Table of Reference Values in Appendix B for MTLC trip­point value.

Sect02_CSMG_b.fm 2-2 04/19/2019

Section II–Desc ription

2.2.3.2 Thermocouple sensor

MTLC2 and MTLC1 each use one-half of a
dual-element thermocouple sensor. The sensor is
inserted in the coil steam discharge outlet. See Fig.
2-2.

2.2.4 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 nozzle 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 cascades to the

Table 2- 1: Pressure-Temperature

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

The excess water in the separator is recircu­lated back to the hot-well tank when the fluid level
rises high enough to activate the inverted bucket in
the steam trap. This method of mechanical separa­tion prevents carry-over of liquid and chemical
treatment into the steam system.

Under normal operating conditions, the indi­cated temperature should be close to the saturation
temperature relative to the pressure at the separator
(See Pressure - Temperature Table 2-1.). A substan­tial temperature rise above the saturation
temperature for the corresponding operating pres­sure indicates a water shortage condition.

GAUGE

PRESSURE

PSIG TEMP F

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

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

GAUGE

PRESSURE

kPa TEMP C

GAUGE

PRESSURE

PSIG TEMP F

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

GAUGE

PRESSURE

kPa TEMP C

GAUGE

PRESSURE

PSIG TEMP F

GAUGE

PRESSURE

kPa TEMP C

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Steam Master Instruction Manual

2.2.5 Steam Trap

The steam trap returns excess water from the
steam separator to the hot-well tank. Some trapping
is necessary to ensure that a sufficient volume of
feedwater is circulating through the heating coil and
that dissolved solids are being carried through the
heating coil back to the hot-well tank. The actual
amount of trapping depends on operating condi­tions, steam pressure, feedwater temperature, pump
conditions and firing rate.

A trap (discharge) pressure gauge is provided
to indicate when the steam trap is either open or
closed. A rising pressure on the gauge indicates that
the steam trap is discharging water. When the pres­sure begins to drop, the trap is closed. If the steam
trap is not opening and closing in the normal man­ner, this may indicate that one of the above
mentioned variables has changed.

On initial start of the machine, after the cor­rect air-fuel rate has been established, the operating
temperature and trap-open time should be recorded.
These figures should be checked regularly to assure
that the machine is operating properly.

If the steam generator is connected to an open
(hot-well) system where the feedwater temperature
is 180°–200° F (82°–93° C), the steam trap should
be open for 30–40 minutes (accumulated) of each
hour at high-fire operation (100% rate). At steady
low-fire operation (20% rate), the steam trap should
be open for six to eight minutes (accumulated) of
each hour, or a proportionate length of time for any
intermediate firing rate.

Checking and recording for the duration that
the steam trap remains open under normal operating
conditions helps to determine if a component, such
as the feedwater pump (which has a fixed pumping
rate), is malfunctioning.

A reduction in the firing rate due to a decrease
in fuel pressure will increase the trapping time. A
decrease in the pump rate will decrease trapping
time. Trap-open time should not fall below twelve
minutes per hour at high fire and four minutes per
hour at low fire (accumulated) under any
conditions.

2.3 Control Devices

2.3.1 Group Motor Protectors (GMP)

The group motor protectors function as a
3-phase, manual, motor starter/protector for control
and protection 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.

2.3.2 Gas Pressure Switch - High (GPSH)

This normally-closed safety switch is con­nected in series with the combustion control circuit.
It is situated between the main gas cock and modu­lating gas valve.

NOTE

The GPSH is located inside the gas burner
housing. Gaining access to the GPSH
requires removal of the housing cover.

This switch will open to interrupt burner oper­ation in the event of high burner gas pressure. A
manual reset is required after each interruption. The
GPSH is factory set to actuate at approximately
50% above the normal burner operating pressure at
the maximum firing rate.

2.3.3 Gas Pressure Switch - Low (GPSL)

There are two GPSL safety switches installed
in series with the combustion control circuit. These
normally-closed safety switches will open in the
event of a low supply gas pressure, disrupting
burner operation.

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

The GPSL is factory set to actuate at approxi­mately 50% below the normal burner operating
pressure at the maximum firing rate.

Sect02_CSMG_b.fm 2-4 04/19/2019

Section II–Desc ription

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

transformer

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

transformer

2.3.8 Variable Speed Drive (VSD)

2.3.4 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.

2.3.5 Main Gas Valve (MGV)

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

2.3.6 Power Supply

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

2.3.7 Stepdown Transformer (115 VAC)

ST1 is a 230/115 vac step-down transformer
that supplies 115 vac to control circuit voltage. (See
Fig. 2-4 for connection points.)

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 information on operation, programming,
and troubleshooting is provided in VSD manufac­turer’s operators manual provided at time of initial
startup.

2.4 PLC (Programmable Logic

Controller)

The PLC is responsible for the monitoring and
managing a machine’s operation. The primary oper­ation that the PLC oversees is synchronization of
the burner and feedwater pump. The proper feedwa­ter flow rate to firing rate is important for meeting
the steam load.

Another task the PLC performs is alarm
annunciation. The PLC monitors the various safety
devices installed on the machine. When a safety
parameter is exceeded, the PLC causes an alarm
condition. Depending on the alarm, the PLC may
also cause a machine shutdown.

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

04/19/2019 2-5 Sect02_CSMG_b.fm

Steam Master Instruction Manual

(This page intentionally left blank.)

Sect02_CSMG_b.fm 2-6 04/19/2019

Section III SAFETY

PRECAUTIONS

3.1 GENERAL SAFETY PRECAUTIONS

A steam generator and its parts are based on
physical processes, each with typical characteristics
and potential hazards. All necessary safety
precautions were taken during the design and
construction of the generator. However, during
certain manipulations or maintenance, there are still
remaining risk factors. These are described below:

3.1.1 Hot Components

Fire injury let hot components cool down to
ambient temperature. Use insulating or heat
repellent protective clothing, especially gloves. Do
not wear short sleeves.

3.1.2 Poorly-vented Boiler Rooms

Ambient temperature rise, lack of oxygen,
dehydration, fainting, combustion gases
accumulates in boiler room leading to suffocation
and poisoning.

Construct permanent or temporary ventilation
openings in the wall or ventilators with sufficient
capacity. The generator must be able to function
normally during ventilation. Insufficient oxygen can
lead to poisonous CO gas.

3.1.3 Frost

Supercooling and exhaustion. Wear warm
clothing. Contact with cold metals can lead to stiff
and, hence, less sensitive hands, creating a greater
chance for hand injury.

the key from the switch. If you need to work on parts
without protective screens, make sure not to wear
loose clothing such as ties, open coats, etc. Only
authorized personnel should be present near the
generator.

3.1.5 Protruding Parts

Body/head injury. Wear a helmet to prevent

head injuries.

3.1.6 Sharp Parts and Rough Edges

Rough edges from mechanical wear or
dismantling of parts. Wear gloves and use the right
tools.

3.1.7 Welding and Grinding

Hot metal sparks are inherent for these
operations. Wear protective clothing, no short
sleeves. Wear a face mask with side shields and
make sure it has the appropriate color filter when
welding. Glowing metal parts can cause fire. Make
sure a second person is present with fire suppression
equipment on-hand. Make sure vital emergency
contact information is available and visible in case
of fire.

3.1.8 Uneven Surfaces and Physical

Obstructions

Injury from falling down or tripping over.
Evaluate the situation before taking actions and
inform other workers accordingly. Make sure to
have the proper equipment available if you need to
work on heights.

3.1.4 Moving Parts

Injury to body or clothing. All rotating parts
are screened off. If screens are removed for
maintenance or repair, make sure to cut the ele ctrical
power on this particular part. Use a lock or remove

11/22/2018 3-1 Sect03_CSMG_a.fm

3.1.9 Pressurized Gases and Liquids

Skin penetration resulting in injuries,

poisoning, and eye damage.

Steam Master Instruction Manual

Fluids or gases under pressure can cause
severe skin or eye damage due to their impact when
flowing through fine openings. They can even enter
the body, resulting in poisoning. Evaluate the
situation before taking any action.

Wrap pieces of cloth around the parts that need
to be opened so that possible fluids or gases get
diffused. Close off isolated areas, so the fluids can be
drained away and the pressure has dissipated.

3.1.10 Heavy or Loose Parts

Injuries by mechanical impact from twisting
or carrying heavy weights.

Use pulleys and gloves when assembling
heavy parts. Save your strength. Use tools, such as,
crowbars and hydraulic pumps as lever or power
intensifier. Appoint a coordinator when several
persons are working on the same job. Watch out for
injuries from crushing during assembly work.

3.1.11 Vacuum Created By Steam or Hot Water

Cooling Down

Injuries by under pressure. A vacuum can be
created in machine parts that are closed off from the
atmosphere and are cooling down, after they were
filled with steam or hot water. By opening these
areas, severe suction can be created by under
pressure. Make sure not to expose body parts to
these openings, since this could cause skin injury.

3.1.12 Water Hammer

Improper ratio of steam to water inside piping
can create water hammer. This is a ball of water
blocking an entire section of the pipe. It moves
forward via the steam against the steam speed. At
seams or curves in the pipes, this ball of water can
create an impact or become a water-hammer. Piping
can be so that the steam escapes and the fixing of the
piping gets damaged.

3.1.13 Pre-stressed Springs

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

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

3.1.14 Electrical Parts

Death from electrocution. Lock out electrical
power before working on equipment.

Electrocution. Always cut the electrical power
before working on electrical components. This can
be done by locking the main switch or by removing
its key , when there is o ne available. Should repair or
maintenance be needed when the equipment is under
current, use rubber gloves, isolated tools and
isolation between the body and the earth.

3.1.15 Chemicals

Risk of poisoning and burning limbs from
mishandling of chemicals.

Burns and poisoning. Wear face mask,
chemical gloves and protective clothing when
manipulating chemicals. Keep the technical data on
all chemicals used available for persons working
with them. Make sure to note down the phone
number of the poison control center and local aid
services.

3.1.16 Loud Excessive Noise

Deafness and communication problems. Wear
ear protection. When working with multiple
personnel in an excessively loud environment, make
sure to communicate clearly. If required, exit the
loud environment to communicate clearly so
instructions are not misinterpreted.

3.1.17 Human Error

Poor maintenance behavior or
misinterpretation of circumstances is a result of
human error. Human error can be avoided with
proper training of personnel.

Sect03_CSMG_a.fm 3-2 11/22/2018

Section III - Safety Precautions

3.1.18 Automation

Potential unexpected automatic start ups can
occur if equipment is not secured properly. A steam
generator and its parts can cause all of the safety
hazards explained above, during maintenance or
inspection. Although this equipment is well
protected, caution is needed at all times. Only
trained personnel should operate or maintain the
generator, its devices or parts.

An explanation of specific safety hazards of
equipment component assemblies are in the
following sections.

3.2 FEEDWATER PUMP

3.2.1 Hot Surface

The feedwater pump receives hot water from
the hot-well. Allow feedwater pump to cool before
attempting repair.

3.2.2 Freezing Conditions

Proper freeze protection maintenance is
required if the feedwater pump will be placed under
storage conditions. Ice will form within the
feedwater pump if moisture or water is present.

3.2.3 Fluid Under Pressure

Pressurized fluid may be present in the
feedwater pump. Potential high pressure fluid
discharge can occur when dismantling pump.

3.2.4 Handling Heavy and Loose Parts

The check-valve/standpipe subassembly of
the feedwater pump is heavy. Make sure proper
lifting apparatus is used when performing feedwater
pump maintenance and repair. If required, seek
additional personnel for assistance.

3.2.7 Human Error

Only personnel who are properly trained to
work on Clayton feedwater pumps should handle its
maintenance and repair.

3.2.8 Automation

The feedwater pump operates automatically in
relation to feedwater requirements. The feedwater
starts and stops automatically.

3.3 HEATING COIL AND STEAM

SEPARATOR

Hearing loss will result from actuating safety
relief valve. Wear hearing protection to protect
against hearing loss.

3.3.1 Hot Fluids

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

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

3.3.2 Hot Surfaces

Heating coil, separator, and plumbing surfaces
are HOT! Although the heating coil, separator, and
some plumbing are insulated, treat these surfaces
with extreme caution.

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

3.2.5 Compressed Springs

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

3.3.3 Freezing Conditions

Evacuate the heating coil, separator, and all
plumbing of fluid and moisture before long term
storage. Install a nitrogen flush as needed.

3.2.6 Electrical Parts

Lock out the main circuit power before
working on feedwater pump to prevent unexpected
motor start.

11/22/2018 3-3 Sect03_CSMG_a.fm

Steam Master Instruction Manual

Damage to heating coil, separator, and other
parts will result from moisture or fluid inside the
coil and pipes.

3.3.4 Fluid Under Pressure

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

3.4.3 Falling Risk

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

3.3.5 Water Hammer

Improper ratio of steam to water inside piping
can create water hammer. This is a ball of water
blocking an entire section of the pipe. It moves
forward via the steam against the steam speed. At
seams or curves in the pipes, this ball of water can
create an impact or become a water-hammer. Piping
can be so that the steam escapes and the fixing of the
piping gets damaged.

3.3.6 Vacuum

A vacuum condition occurs when a heated coil
and plumbing is tightly sealed and cools to ambient
temperature. This creates a strong suction at various
access point openings.

3.4 FUEL AND AIR PIPING

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

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

3.4.1 Poorly-vented Boiler Room

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

3.4.2 Explosion Risk

Death from explosion. Electrical sparks will
ignite gas fumes.

Sect03_CSMG_a.fm 3-4 11/22/2018

Section IV OPERATING

Fig. 4-1. Main Menu screen.

INSTRUCTIONS

4.1 GENERAL

The instructions in this section describe the
standard startup and shutdown procedures for your
Clayton Steam Master steam generator.

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

The manual operating mode is reserved
for more advanced, knowledgeable
users who are thoroughly familiar with
the Clayton Steam Master steam
generator.

4.2 MAIN MENU SCREEN

icon at the bottom-right corner of the various
operating screens.

Not all icons will appear on the main menu
screen, as shown in Fig. 4-1. The icons will be
either active or inactive depending on the operator
access level. The advanced-level screens require
user login. Once logged in, the icons for the
advanced-level screens will become active.

4.3 START UP AUTO MODE

The default start is auto mode. The unit
may be transferred into manual mode
by the AUTO/ MANUAL button on the
main menu once the unit is started.

Manual mode operation requires the operator
to be present and actively monitoring the unit
throughout this period.

The start-up screen in Fig. 4-2 displays after
power-on. Verify and set, as needed, the valve
positions as indicated on the screen. Acknowledge
each valve on the screen following verification that
the indicated valve is in the correct position; i.e.:
the valve is either open or closed.

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

The main menu provides basic Clayton
contact information, machine information, and
access points to selected operation screens. This
screen is accessed by pressing the MAIN MENU

11/15/2018 4-1 Sect04_CSM_a.fm

Steam Master Instruction Manual

Fig. 4-2. Start up screen.

Fig. 4-3. Filling in auto screen.

Fig. 4-4. Firing in auto screen.

Fig. 4-5. Firing in auto screen.

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

The unit will start the light-off sequence. The
FIRING IN AUTO screen will display (Fig. 4-5).
The burner unit will proceed through its
preprogrammed light-off sequence and light off
when the sequence is completed.

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

Once the coil fill is complete, an operator
screen will display (Fig. 4-4) prompting the
operator to set the control valves to the indicated
positions. Once each valve is set and verified to be
in the correct position, acknowledge that valve on
the screen.

4.4 START MODE

The unit offers two start modes, easy start and

operator start. The start mode is selected from the

Sect04_CSM_a.fm 4-2 11/15/2018

Section IV–Operating Instructions

Fig. 4-6. Start mode selection.

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

4.4.1 Easy Start

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

4.5 MANUAL MODE OPERATION

The manual operating mode is reserved
for more advanced, knowledgeable
users who are thoroughly familiar with
the Clayton Steam Master steam
generator.

Clayton recommends transferring over
to manual mode operation ONLY
AFTER the unit has completed its start
process and is running normally.

Manual mode operation requires the operator
to be present and actively monitoring the unit
throughout this period.

Easy start enables the operator to start the unit
and “walk-away.” The unit requires minimum user
interaction with easy start. The BPR will allow the
unit to build up the required back pressure before
releasing steam into the main header.

4.4.2 Operator Start

Operator start requires the operator to be at
the unit to open and close control valves during
filling and light off periods. The operator start
screens will identify which valves are required to be
opened or closed during operator start. See also
Section 4.3, Start up Auto Mode.

Your Clayton Steam Master may be operated
manually for maintenance, troubleshooting, and
repair purposes. Manual mode operation enables
the operator to dictate the fill rate and firing rate of
the unit.

4.5.1 Manual Fill Mode

To transfer the unit into manual fill mode, go
to the main menu by pressing the MAIN MENU
icon at the bottom-right corner of the screen. Press
the AUTO /MANUAL icon. The manual fill screen
will display (Fig. 4-7).

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

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

11/15/2018 4-3 Sect04_CSM_a.fm

Steam Master Instruction Manual

Fig. 4-7. Filling in manual screen.

Fig. 4-8. Firing in manual screen.

Fig. 4-9. Restart with ST ART SKIP FILL (A) and ST ART

WITH FILL (B) options.

4.5.2 Manual Firing Mode

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

On the main menu screen (See Fig. 4-1 on
page 4-1.), press the FILL TO RUN icon to transfer
to manual firing mode. The manual fire screen will
display (Fig. 4-8).

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

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

The unit may be transferred back to
manual fill mode at any time during the
manual firing mode by returning to the
main menu and selecting the RUN TO
FILL icon.

4.6 RESTART AFTER MOMENTARY SHUT DOWN

The firing rate may be adjusted by pressing

the “%” icon on the upper-right of the image on the

Sect04_CSM_a.fm 4-4 11/15/2018

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

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

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

Section IV–Operating Instructions

Fig. 4-10. Firing in manual screen.

Fig. 4-11. Dry shut down screen.

4.7 INTERMITTENT FILL/WET LAY-UP

Intermittent fill maintains a “wet” coil. This
operation is active when the unit is in wet lay-up.
Wet lay-up is used when the unit will be shut down
for only a short period. The INTERMITTENT
FILL WATER PUMP ON message appears on the
left of the screen (Fig. 4-10) while the unit is in wet
lay-up.

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

A dry shut down should be performed
by Clayton service personnel or other
personnel who are thoroughly trained in
Clayton steam generators.

A dry shut down maintains a “dry” coil when

a unit will be shut down for a prolonged period —

usually exceeding 14 days.

The dry shut down process is initiated by
pressing the DRY SHUT DOWN icon on the main
menu screen (Fig. 4-1 on page 4-1).

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

Verify the bypass valve is open. Verify the
header valve, dry shut down valve, and
maintenance drain valve are tightly closed. Make
sure feedwater quality is maintained throughout the
wet lay-up period. Verify there are no leaks
anywhere in the plumbing during wet lay-up.

4.8 DRY SHUT DOWN

The unit will develop rust or other forms of
oxidation inside the coil tubing if dry shut down
is executed improperly.

11/15/2018 4-5 Sect04_CSM_a.fm

The operator must be present
throughout this process to perform
required operations as indicated on the
screen (Fig. 4-12) and verify and
acknowledge the control valves during
the dry shut down.

Steam Master Instruction Manual

Fig. 4-12. Slowly close steam header valve to maintain

pressure during dry shutdown.

Fig. 4-13. Modulation setpoints screen. Enter

modulation setpoint, cut-out setpoint, and cut-in

setpoint from this screen.

Fig. 4-14. PID Parameters screen. The PID trend

button will display a chart of the steam pressure, PID

setpoint, and PID control output

Fig. 4-15. PID Trend screen.

4.9 ADVANCED-LEVEL SCREENS

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

4.9.1 Modify Set Point and Tune PID Screens

Sect04_CSM_a.fm 4-6 11/15/2018

4.9.2 Calibration Screens

Fig. 4-16. PID Process Trend screen.

Fig. 4-17. Calibration Screen 1: machine hours, service

telephone number, SPS limit setpoints, steam pressure

transducer (OPX) scaling, rate turn down, and fill time

are entered from this screen.

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

release pressure, delay rate, ramp release

temperature, ramp release pressure, ramp release

steam temperature Delta-T, ramp release time, and

stack temperature alarm setpoint can be entered on this

screen.

Fig. 4-19. Calibration Screen 3: post fill temperature,

post run temperature, water level relay delay time,

water level relay alarm time, water level relay

temperature limit, maintenance drain interval (2–26

weeks), maintenance drain duration (01–99 seconds),

and dry shutdown duration (0–99 seconds) are entered

from this screen.

The following calibration screens are Clayton

Technician level access.

Section IV–Operating Instructions

11/15/2018 4-7 Sect04_CSM_a.fm

Steam Master Instruction Manual

Fig. 4-20. Alarm screen.

Fig. 4-21. Alarm history screen.

Fig. 4-22. Maintenance Drain screen.

4.10 ALARM SCREENS

4.10.1 Alarm Annunciation

This screen displays the alarm condition. The
alarm condition must be corrected before pressing
the RESET icon.

4.11 MAINTENANCE DRAIN

The maintenance drain screen is typically
used for maintenance procedures, such as TDS
control.

4.10.2 Alarm History

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

Sect04_CSM_a.fm 4-8 11/15/2018

Section V TROUBLESHOOTING

5.1 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 trouble

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

Thermostat

MTLCs fail to stop motor or
burner

Pump motor overload

Low NPSH to water inlet Check for a ruptured diaphragm in

feedwater section of pump. Check
for loose pump head stud nuts.

Low NPSH to water pump inlet causing
intermittent pump operation.

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

Pump relief valve leaking. Adjust to proper pressure (See Sect.

Feedwater pump not primed. Prime feedwater pump.
Strainer partially plugged. Hot-well tank

drain open. Float valve strainer plugged.
Low water condition. Correct cause of low water or water

MTLCs or thermocouple are malfunction­ing.

VSD over current (ground fault) or exces­sive current due to overload has caused the
instantaneous or over current trip unit in the
GMP to secure the VSD and burner.

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

Sect. 7.2.).

7.3.), or replace if faulty.

Correct accordingly.

failure condition.
*Possible causes:

1.Empty hot-well tank.

2.Clogged inlet strainer.

3.Worn check-valve seats and discs.

4.Malfunctioning booster pump(s).
Check and replace faulty MTLC

(See Sect. 7.4.).
Check, adjust, or replace thermocou­ple (See Sect. 6.5.3.).

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

Sect05_CSMG_a.fm 5-1 11/26/2018

Steam Master Instruction Manual

Trouble Possible Cause Remedy

VSD overload

Limit pressure

High/Low gas pressure

5.2 WATER SYSTEM

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

Excessive discharge pressure in the separa­tor caused LPS to actuate.

GPSH or GPSL shuts down machine. Check for faulty GPSH/GPSL and

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

Relieve the separator pressure. Ver­ify 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.

gas pressure regulator. Replace
faulty GPSH/GPSL switch or
replace faulty gas pressure regulator.

Trouble Possible Cause Remedy

Noisy feedwater pump
operation

Excessive pump vibration;
Feedwater pressure gauge nee­dle jumping erratically

Overheating hot-well tank

Feedwater pump intake surge chamber
malfunctioning.

Feedwater pump discharge snubber
malfunctioning.

Worn bearings in crankcase. Replace bearings if necessary.
Restricted heating coil causing exces-

sive back pressure.
Feedwater boiling or too hot. Correct cause of excessive heat in con-

Intake surge chamber or discharge
snubber malfunction.

Modulating system malfunction. Check and readjust modulating system

Temperature regulator valve not work­ing properly.

Check rubber insert deflection (Sect.

6.5.7) and replace intake surge cham­ber, if required.

Check rubber insert deflection (Sect.

6.5.7) and replace discharge snubber, if
required.

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

densate return line from system. Inspect
valves and traps on equipment.

Check rubber insert deflection (Sect.

6.5.7) and replace intake surge
chamber/discharge snubber, if required.

controls for proper water rate or over
firing.

Adjust temperature regulator for proper
temperature.

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

Sect05_CSMG_a.fm 5-2 11/26/2018

Section V–Troubleshooting

Trouble Possible Cause Remedy

Steam trap pressure gauge
reads zero pressure

Steam trap pressure gauge
registers fixed pressure reading

Weeping safety relief valve

Steam trap closed. Ensure feedwater pump is discharging

at normal capacity.
Blowdown valve partially open. Close

it.
Check for possible malfunctioning of

steam trap.

Machine overfired. Check temperature on separator tem-

perature gauge. Correct fuel input rate if
necessary.

Trap gauge sensing line obstructed or
trap gauge defective.

Steam trap open. Ensure feedwater pump is discharging

Valve seat or disc contamination. Replace valve. The valve seat/disc may

Clean sensing line. Replace gauge if
defective.

at normal capacity.
Check for possible malfunctioning of

steam trap, or loss of trap prime.
Check modulating system controls.
Check burner operation for possible

reduced heat input (under firing).

be resurfaced if the damage is minor.

5.3 FUEL SYSTEM - GAS-FIRED MACHINES

REFER TO MANUFACTURER OPERATIONS AND MAINTENANCE MANUAL FOR TROU-

BLESHOOTING PROCEDURES.

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

11/26/2018 5-3 Sect05_CSMG_a.fm

Steam Master Instruction Manual

WARNING

5.4 ELECTRICAL SYSTEM

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

Trouble Possible Cause Remedy

Burner purge cycle fails to occur

Motor fails to start, or stops during
operation

Motor noisy or running hot

Excessive system pressure variation

Magnetic Controller fails to contact

GPSL actuated. Reset GPSL. Check supply gas

pressure. GPSL must be reset on
any loss of gas pressure.

GPSH actuated. Reset GPSH. Be sure regulator is

not hung open.
Power failure or blown fuse. Check fuses in lines to machine.
Safety shutdown caused by thermal

trip unit in the GMP.

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

Check for low voltage. Correct cause.
Motor running single phase. Check for blown fuse in feeder

Insufficient lubrication or bearing fail­ure.

Modulating Pressure Setting Differen­tial out of adjustment.

Operating coil failure. Also see trou­bles and remedies under “Motor Fails
to Start.”

Wait for elements to cool; then

manually reset and restart. Check

cause of overload. Check motor for

overheat due to possible shorted or

grounded winding.

overpressure.

lines.

Lubricate bearings. Check for worn

bearings.

Adjust based on existing steam load

conditions.

Replace coil. Be sure the coil is

properly rated for the installation.

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

Magnetic Controller fails to
disconnect

Magnetic Controller noisy

Sect05_CSMG_a.fm 5-4 11/26/2018

Welded contacts, due to arc, or
mechanical binding.

Poor alignment, wrong coil, mechani­cal binding, or gummy guide surfaces.

Replace contacts.

Replace contacts. Correct cause of

binding.

Check and clean magnetic control-

ler.

Section V–Troubleshooting

WARNING

Trouble Possible Cause Remedy

Burner purge cycle fails to occur

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

ESC locked out. Reset. Circuit complete when

5.5 WEISHAUPT PACKAGED BURNER UNIT

Modulating motor must be in low­fire position.

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

burner flame safeguard display
reads “standby.”

Check for cause of burner lockout.

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

REFER TO MANUFACTURER OPERATIONS AND MAINTENANCE MANUAL FOR TROU-

BLESHOOTING PROCEDURES.

11/26/2018 5-5 Sect05_CSMG_a.fm

Steam Master Instruction Manual

NOTES

Sect05_CSMG_a.fm 5-6 11/26/2018

Section VI PERIODIC

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

MAINTENANCE

6.1 Introduction

Periodic inspections and regularly scheduled
maintenance on the Clayton steam generator is
essential for maintaining its peak performance and
reliability. The following service recommendations
require only a few minutes each day to maintain the
efficiency of the steam generator, as well as, mini­mize unscheduled repairs. A monthly maintenance
log sheet can also be found in the back of this man­ual. Proper use of these sheets provides an accurate
record and serves as a daily reminder of the routine
maintenance requirements. Cumulative hours of
operation can viewed from the OIU.

6.2 Feedwater Treatment

The Feedwater Treatment Manual discusses
the importance of feedwater treatment. To prevent
internal corrosion and to eliminate scale formation,
proper control of feedwater must be given serious
consideration before start-up.

6.3.4 Manual Blowdown

A manual bleed blowdown is used to control
dissolved solids and to remove suspended solids
and sludge. Manual bleed blowdown may be elimi­nated from daily operation if an automatic bleed
device (optional equipment) is used and the feedwa­ter is tested daily for TDS (Total Dissolved Solids)
content.

6.3 Daily Service

6.3.1 Record Operating/ Steam Pressure

Record the operating pressure in the Periodic

Maintenance Log (R027906).

6.3.2 Trap Timing

(See paragraph 2.1.6 in Section 2 for details.)
Record the trap pressure in the Periodic Main-

tenance Log.

6.3.3 Test and Record Feedwater

Record tested feedwater characteristics indi-

cated in Periodic Maintenance Log.

Refer to Clayton Feedwater Treatment Man-

ual, R015216, for details.

04/22/2019 6-1 Sect06_CSMG_b.fm

Adjust continuous bleed blowdown valve
opening (See Fig. 6-1.) or auto TDS controls to
maintain desired TDS levels. See Feedwater Man­ual (R015216), Section 4.1 System Blowdown, for
details.

6.3.5 Walk-Around Inspection

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

Steam Master Instruction Manual

NOTE

NOTE

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

NITROGEN LAYUP– If unit is laid-up with a
nitrogen blanket, verify pressure is maintaining
35 psig (240 kPa). Take appropriate action to rem­edy condition if a loss of pressure has occurred due
to system leakage.

6.4 Weekly Service

6.4.1 Steam Generator Unit

Purge sludge settlement at the steam generator
unit. Open the steam generator unit maintenance
drain valve fully for about one minute (may be done
while in operation). This purges settlement buildup
from low points in the steam generator system.

Purge process may be required more often
depending on the application of the steam
generator.

6.4.2 Hot-well Tank

Partially drain the hot-well tank. Open the hot­well tank drain valve fully for about one minute
(may be done while in operation). This flushes
loose solids from the tank. Make sure fluid is
always visible in the sight glass of the fluid level
gauge.

6.4.3 Belt Tension

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

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

a. Remove the five Allen screws that

attaches the top cover to the feedwater

pump compartment.
b. Remove the top cover.
c. Check belt tension. Belt play, checked

midway between the two pulleys, should

be no more than the thickness of the belt.

d. Adjust belt tension, as required. See Sec-

tion 7.1 in Section 7 for procedure.

e. Replace the top cover when done.

6.5 Monthly Service

6.5.1 Check Coil Feed Pressure

Check the coil feed pressure at the high fire
rate. Record and compare with the original reading
for an indication of internal scaling.

The normal feed pressure may vary slightly
with each installation. It is advisable to make a note
of the feed pressure right after the steam generator
has been installed. This will provide an accurate
base reference value to check for coil restriction for
the particular machine.

Always note the feed pressure after
the steam generator has operated
for a period of time and is thoroughly
heated; and always note at the same
feed pressure, feedwater
temperature, and at full load.

Sect06_CSMG_b.fm 6-2 04/22/2019

Section VI–Periodic Maintenance

NOTE

Fig. 6-3. The thermocouple sensor is installed in the

steam discharge line at the top of the steam genera-

tor unit.

A constant steam pressure discharge must be
maintained under a steady load condition that will
prevent burner modulation. To check the feed pres­sure, open the valve to the feed pressure gauge just
enough to allow a steady reading on the gauge. Coil
scaling is present if the feed pressure is 30 psi
(2 bar) or more above the normal feed pressure base
reference value (noted right after installation, or
when the coil was completely clean). For example,
it is noted that feed pressure was 300 psi (21 bar)
when the machine was in the new condition. Coil
descaling (Section 6.8) is required if the current
feed pressure reading is 330 psi (22.8 bar), or
higher, for that same given steam pressure.

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.
Consider the following measures:

a. Carefully check to be sure the feedwater

treatment is adequate and is being used
properly and consistently. See that the
water softener is regenerating at regular
intervals. To be effective, feedwater treat­ment must be consistent and continuous.

quently. If drain cocks are plugged, remove cocks
and use a stiff wire to dislodge sediment. (Water
pump may be operated and coil feed valve throttled
to provide pressure to purge cock if not severely
plugged.)

Stop machine before attempting to remove
drain cocks.

6.5.3 Check Dual Element Thermocouple Sensor

The integrity of the dual element thermocou­ple sensor must be checked monthly. The sensor is
installed in the steam discharge line at the top of the
steam generator unit. See Fig. 6-3. A temperature
test meter/indicator is required. The thermocouple
sensor check is conducted under two conditions,
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.

b. Blowdown the machine more frequently.

It is sometimes necessary to blowdown
more often than specified in this manual to
remove solids that are precipitated in the
form of sludge. The blowdown operation
is not a cure-all, but it will remove some
scale and thereby delay coil restriction.

The Feedwater Treatment Manual
contains detailed information with
regards to the importance of
feedwater treatment and the
recommended procedures and
equipment necessary to prevent
scale and corrosion within the steam
generator.

6.5.2 Flush Water Pump Heads And Columns

Open drain cocks at base of water pump until
clear water appears, if heavy accumulations of
sludge appears, repeat this operation more fre-

04/22/2019 6-3 Sect06_CSMG_b.fm

Steam Master Instruction Manual

NOTE

6.5.3.1 Steam temperature reading with steam
generator in operation

a. Connect the test meter to the primary el-

ement of the dual element thermocouple
sensor.

b. Record the steam temperature. Remove

the meter leads from the primary element
when temperature is recorded.

c. Connect the test meter to the secondary

element of the dual element thermocou­ple sensor.

d. Record the steam temperature. Remove

the meter leads from the secondary ele­ment when done.

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 Table) in
Section 2. Make a note of the differences
for evaluation in paragraph 6.5.3.3.

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

The machine should be in wet lay-up
for at least two hours following a
burner shut down. The cool-down
time may be reduced by increasing
the FILL rate.

e. Record the feedwater temperature read-

ing on the thermometer on or near the
feedwater pump.

Alternatively, a feedwater temperature
reading from the thermometer on the hot­well tank may be used.

6.5.3.3 Evaluate recorded values

a. The results from steps 6.5.3.1b and

6.5.3.1d should fall within 40 degrees of
the recorded steam temperature or the
value obtained from Table 2-1 Pressure/

Temperature Table (in Section 2).

b. The results from steps 6.5.3.2b and

6.5.3.2c should fall within 10 degrees of
the recorded incoming feedwater tem­perature taken in step 6.5.3.2e.

c. If one of the coil temperature readings,

from either the primary element or the
secondary element, exceed the accepted
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, exceed the accepted 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 that is
inserted in the tube. (See Fig. 2-2 in Sec­tion 2.)

a. Connect the test meter to the primary el-

6.5.4 Check Main Temperature Limit Controllers (MTLC)

ement of the dual element thermocouple
sensor.

a. Remove on thermocouple lead wire from

the MTLC.

b. Record the steam temperature. Remove

the meter leads from the primary element
when temperature is recorded.

c. Connect the test meter to the secondary

element of the dual element thermocou-

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.

ple sensor.

d. Record the steam temperature. Remove

the meter leads from the secondary ele­ment when done.

Sect06_CSMG_b.fm 6-4 04/22/2019

Section VI–Periodic Maintenance

NOTE

NOTE

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.

6.5.5 Clean Strainers

Turn off the water supply to the strainer(s), if
applicable. Remove the strainer cap and remove the
screen from strainer. Rinse the strainer screen thor­oughly with clean water, removing all the sludge
and solids. Reassemble screen and cap. Turn on
water supply, if applicable.

6.5.6 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 water conditions must be
maintained in the feedwater (boiler water) 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

Review the Clayton Industries
Feedwater Treatment Reference
Manual (P/N: R015216) for
additional feedwater quality
requirements.

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 com-

pletely drain.
b. Close the drain valve.
c. Fill the tank with clean potable water.
d. Open the drain valve to drain the tank.

Verify the water draining from the tank 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 chem-

ically treated water.

Make sure TDS is brought back to
the proper levels, see above, and
optimum feedwater conditions are
met before placing the machine back
into operation.

6.5.7 Inspect Intake Surge Chamber and Snubber

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

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

a. Remove the top cover, right-side panel,

and front panel of the pump compartment
to allow access to the discharge snubber
and intake surge chamber.

04/22/2019 6-5 Sect06_CSMG_b.fm

Steam Master Instruction Manual

NOTE

NOTE

Fig. 6-4. Feedwater pump relief valve.

Fig. 6-5. Feedwater pump relief valve.

COIL FEED VALVE

b. Obtain a 3/16 in. x 6 in. (4 mm x 150 mm)

rod, dowel, pencil, or similar device. This
rod will be inserted through the breather
hole for testing.

ify the drain lines are clear of blockage for proper
draining. See Section 7.2 adjustment and mainte­nance procedures.

Increase maintenance intervals to
three months on older feedwater
relief valves.

Fully open the coil feed valve after feedwater

pump relief valve check is complete.

6.7 Annual Service

Perform this annual service semi­annually if the steam generator is in
use 24 hours a day, 7 days a week
(or similarly continuous operation).

POTENTIAL LOSS OF OFF FINGERS!
Fingers caught between belt and pulley may be
cut off. This procedure is performed while the
feedwater pump is operating.

c. With the feedwater pump operating, insert

the rod into the breather hole in the base of
the intake surge chamber/discharge snub­ber housing until it stops.

d. Verify the rod modulates in an up and

down motion. If the rod fails to do this,
then the intake surge chamber /discharge
snubber requires replacement.

6.6 Semi-annual Service

Test feedwater pump relief valve (Fig. 6-5)
operation. Slowly, close the coil feed valve until the
feedwater discharge pressure exceeds the relief
valve’s set pressure, typically 275 psi (1,896 kPa).
Verify relief valve is discharging properly and ver-

Sect06_CSMG_b.fm 6-6 04/22/2019

Section VI–Periodic Maintenance

NOTE

NOTE

6.7.1 Replace Check-valves

Replace check-valve seats and discs on both
the feedwater discharge check-valve and feedwater
pump check-valves. (See paragraphs 7.2.1 and

7.2.2.)

6.7.2 Replace Feedwater Pump Diaphragms

and Seals

Replace feedwater pump diaphragms every
7,000 hours of operation or once a year, whichever
occurs first, during scheduled preventative mainte­nance shutdowns (See paragraph 7.2.3).

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

Tighten pump head stud nuts regularly, as
needed. Torque pump head stud nuts to 200 lb-ft

(271 N•m).

6.7.3 Test Steam Safety Valve

Set the Limit Pressure Switch (LPS) to exceed
the steam relief valve pressure setting. Allow pres­sure to increase (by throttling discharge valve) until
steam safety relief valve actuates.

6.7.4 Service Compact Burner Unit

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

1

Standard maintenance of the -Weishaupt-

compact burner unit to be performed once a year
by qualified and experienced personnel.

Servicing to be performed according to the
guidelines outlined in the -Weishaupt- Installation
and Operating Instructions Manual provided with
your Clayton Steam Master unit.

6.8 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. See Fig. 6-6A/B for hookup diagram.

The heating coil maintenance
process requires 8–10 hours.

Hearing will be damaged from loud burst of
steam discharging. Wear ear protection to
protect against potential hearing damage. W ear
eye protection to protect against potential hot
water spray from relief valve discharge.

6.8.1 Setting Up Machine For Descaling

a. Start the machine in the FILL mode (with-

out burner operation). Allow cold water to
circulate through the entire system until it
is cooled. Stop the machine and close the

If valve does not actuate after exceeding pres­sure setting, open separator discharge valve
immediately.

After test is accomplished, regulate steam
pressure to desired working pressure. Reset the LPS
to its original settings. Fully open separator dis-

feedwater inlet valve (D).

b. Obtain a non-galvanized, acid-resistant,

55-gallon (200 liter) container and place it
nearby the feedwater pump. Make sure
this container can withstand fluid tem­peratures above 150°F (65°C).

charge valve. Service or replace steam safety valve
if test fails.

04/22/2019 6-7 Sect06_CSMG_b.fm

1

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

Steam Master Instruction Manual

NOTE

NOTE

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

OPTIONAL ECONOMIZER

A

B

C

D

E

A– Steam Discharge Valve
B– Coil Feed Valve
C– Feedwater Pump
D– Feedwater Inlet Valve
E– Separator Blowdown Drain
F– Maintenance Drain Valve

F

DRAIN/RETURN HOSE

SUCTION

HOSE

55-gal.

container

INTAKE SURGE
CHAMBER

Larger containers maybe required if
severe scaling exists. Review this
entire descaling procedure to
determine if a larger container is
needed.

c. 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 (2.5 –5 cm) from the bottom of

the container for acid suction.

d. Remove and replace the intake surge

chamber with a suction hose. Make sure

the hose is manufactured from acid-resis­tant materials.

e. 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.

A shutoff valve may be installed at
the outlet of the container. This will
aid in preventing any acid spillage
from the container when the suction
hose is disconnected from the
container.

f. 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.

Sect06_CSMG_b.fm 6-8 04/22/2019

g. Separate the separator blowdown drain

NOTE

NOTE

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

D

FEEDWATER
INLET VALVE

E

SEPARATOR
BLOWDOWN

INTAKE SURGE
CHAMBER

COIL FEED

B

VALVE

(E) line at the union, which is located
inside the feedwater pump compartment.

Section VI–Periodic Maintenance

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.

Wear protective clothing. Mishandling of the
acid may cause serious personal injury.

c. Mix 3 ounces (89 milliliters) of KleenKoil

Inhibitor to one gallon (3.8 liters) of
hydrochloric acid (HCl), or one can of
KleenKoil Inhibitor to 5 gallons (19 liters)
of HCl.

d. SLOWLY add this acid solution to the con-

tainer. Monitor the feedwater in the
container for foaming. Continue adding
the acid solution until foaming stops.

h. Attach a second acid-resistant type hose to

the separator blowdown line. A pipe union
adapter may have to be fabricated to
attach the hose. This hose must be long
enough to reach the containers.

i. 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.

j. Close the separator blowdown valve and

the trap discharge valve.

The completed hose hookups should
create a closed loop system
consisting of the heating unit,
feedwater pump, and 55-gallon (200
liter) container(s).

6.8.2 Descaling The Machine

a. Start the machine in the FILL mode (with-

out burner operation).

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

Depending on the severity of the coil
scaling, this procedure can require
50–100 gallons (190–380 liters) of
the acid solution.

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 reaction 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.

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Steam Master Instruction Manual

NOTE

NOTE

e. Continue the circulation for 4–6 hours. A

longer circulation time is required if bub­bling still occurs in the discharge solution.

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. Re­open 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 no foaming
reaction takes place, the acid has been
neutralized 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
(65° C). Continue circulation for an addi­tional two hours, cycling the burner
whenever necessary to keep the solution
hot.

6.8.3 After Descaling Is Complete

Acid solution will burn face, arms, and other
body parts. Carefully disconnect hoses to avoid
spilling acid solution. If a shutoff valve was
installed at the container , close the valve before
disconnecting suction hose.

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 blowdown/drain valve.

Allow as much of the solution to drain
from the separator 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

Boiling acid solution will cause serious burns
and damage equipment. DO NOT allow acid
solution to boil.

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. Flush the feedwater

h. Shut down the machine after the acid solu-

tion has circulated for the two additional
hours.

pump standpipes by opening the drain
cocks to allow water to run until clear. Be
sure the feedwater pump remains primed.

g. Stop the machine and remove the dis-

charge hose. Reinstall the coil drain valve
and plumbing.

h. Open the separator blowdown valve and

the automatic dump isolation valve.

Sect06_CSMG_b.fm 6-10 04/22/2019

NOTE

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

Section VI–Periodic Maintenance

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(This page intentionally left blank.)

Sect06_CSMG_b.fm 6-12 04/22/2019

Section VII COMPONENT

Fig. 7-1. Remove covers for pump compartment.

Fig. 7-2. Use of Clayton seat puller and seat driver

MAINTENANCE

7.1 Feedwater Pump Belt Replacement

Fingers will be crushed by spinning pump belt.
Prevent losing fingers by cutting power to the
feedwater pump motor. Lock out main electrical
power to prevent the machine from
automatically starting.

The feedwater pump belt should be replaced
approximately every 7,000 hours of operation. The
feedwater pump is located in the feedwater pump
compartment on the right side of the heating sec­tion. Feedwater pump belt adjustment and
replacement is performed as follows:

a. Remove the five Allen bolts securing the

top cover and remove cover. (See View A
in Fig. 7-1.)

b. Remove the two Allen bolts securing the

side cover and remove cover. (See View B
in Fig. 7-1.)

c. Loosen the four motor base adjusting nuts

to lower the motor base. (See Fig. 7-2.)

d. Loosen each of the four adjusting nuts to

relieve the belt tension.

e. Remove old belt and replace with new

belt.

f. Adjust each of the for nuts to raise the

pump motor until the belt is taut. DO NOT
OVERTIGHTEN.

g. Replace feedwater pump compartment

covers.

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Steam Master Instruction Manual

Fig. 7-3. Pump Check-valve Maintenance

1. Check-valve Seat

2. Intake Spring

3. Check-valve Cap

4. Gasket

5. Discharge Spring

6. Check-valve Disc

PUMP ASSEMBLY

INTAKE/DISCHARGE

CHECK-VALVE

FEEDWATER
DISCHARGE
CHECK-VALVE

7.2 Feedwater Pump Maintenance

Avoid bodily injury. Always lock-out main
electrical power to the machine to prevent
accidental machine startup when repairing or
performing maintenance on the machine.

7.2.1 Check-Valve Maintenance

(See Fig. 7-3.)

a. Unscrew check-valve caps (3) from

check-valve housings and disassemble
discs (6) and springs (2 and 5) from caps.
Remove scale and pits from discs by rub­bing them in a “figure 8” motion on a
piece of fine sandpaper (wet-or-dry no.
400 or finer) placed on plate glass. Discs
must be perfectly smooth and flat for
proper water pump operation.

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

b. Inspect springs (2 and 5) for distortion and

for free length. Free length of discharge
springs (5) should be 3/4 inch; free length
of intake springs (2) should be 1/2 inch.
Replace broken or distorted springs.

c. Damaged seats (1) may be removed with a

screw extractor (E-Z Out). Turn extractor
while lifting firmly until seat is removed.
Drive replacement seats in place with a
special seat driving tool (part no. UH-

18389) to avoid damage to the seat face.

7.2.2 Replacing Check-Valve Seats

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

a. Adjust puller stem counterclockwise until

retracted catch extends below valve seat
when puller is inserted into check-valve
housing (Inset A, Fig. 7-4).

b. Extend catch and turn stem clockwise in

body until catch meets the bottom of the
valve seat (Inset B, Fig. 7-4)

Sect07_CSMG_b.fm 7-2 04/26/2019

Section VII–Component Maintenance

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

c. Hold stem and turn jam nut clockwise

until valve seat is free of check-valve
housing (Inset C, Fig. 7-4).

d. Drive in seat using seat driving tool (Inset

D, Fig. 7-4) using care to avoid damaging
seat face.

e. After seats have been properly installed,

assemble springs to check-valve caps with
check-valve discs. Install correct springs
and caps in proper ports of check-valve
housings.

7.2.3 Diaphragm Replacement

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

outs.)

a. Disconnect piping connected to the check-

valve housing (1).

b. Remove the drain plug (18) at the base of

the pump head (17) and allow the fluid to
drain.

HOT pumphead fluid can cause scalding. Allow
ample time for pumphead fluid to cool before
draining and disassembling pumphead.

c. Unscrew the eight attaching pumphead

hex nuts (15) and remove pumphead/

check-valve assembly.

d. Unscrew the cap screw (14) and remove

the top diaphragm washer (3) and the old
diaphragm (4). Note the orientation of the
top diaphragm washer as it is installed.

e. Install the new diaphragm and the top dia-

phragm washer. Make sure the top
diaphragm washer is installed with the
tapered-edge side facing the diaphragm
(See Fig 7-6 on page 7-5.).

When installing the new diaphragm,
apply a coating of gasket compound to
the joining surfaces of the connecting
rod, diaphragm, and diaphragm washer
before reassembly.

f. Install the diaphragm cap screw and

washer. Torque cap screw to 30 ft-lb (41
N•m).

g. Install the pumphead/check-valve

assembly over the pumphead studs.

h. Apply “Never-Seez” thread lubricant to

each stud.

04/26/2019 7-3 Sect07_CSMG_b.fm

Steam Master Instruction Manual

1. Check-valve Housing

2. Standpipe

3. Diaphragm Washer, Top

4. Diaphragm

5. O-ring Packing

6. Diaphragm Spacer

7. Diaphragm Washer, Bottom

8. Connecting Link

9. Crankcase

10. Washer

11. Screw

12. Retaining Plate

13. Washer

14. Screw

1

15. Nut

2

16. Stud

17. Pump Head

18. Pipe Plug

19. Bearing Spacer, End

20. Washer

21. Connecting Link Bearing

22. Crankshaft Bearing

23. Crankshaft

24. Check-valve Seat

25. Intake Spring

26. Check-valve Cap

27. Gasket

28. Discharge Spring

29. Check-valve Disc

30. Plug

31. Check-valve Housing–ported

1

Torque 30 ft-lb

2

Torque 35 ft-lb

Fig. 7-5. C2 feedwater pump assembly

Sect07_CSMG_b.fm 7-4 04/26/2019

Section VII–Component Maintenance

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

i. Finger-tighten the stud nuts initially.

Using a wrench, tighten each nut 1/2 to 3 /

4 turn. Make sure the next nut to be tight­ened is always opposite of the one that
was just tightened. This is to ensure that
pressure will always be evenly distributed
across the pumphead. Maintain this pat­tern until all nuts are tight. Finally,
continuing in the same tightening pattern,
torque each nut to 45 ft-lb (61 N•m).

j. See Section IV for start up procedures.

d. From the pulley end of the crankshaft,

strike the crankshaft with a heavy­weighted hammer to unseat the connect­ing link-bearing-crankshaft assembly
from the crankcase.

DO NOT strike crankshaft shaft directly.
Striking the crankshaft end directly can
cause flaring, which can interfere with
the pulley installation. Instead, place a
piece of 2x4 lumber against the shaft
end and strike the piece of lumber.

e. Remove the crankshaft bearing (22) that is

farthest from the pulley with a bearing
pulling tool.

f. Remove the connecting link-bearing-

crankshaft assembly from the crankcase.

g. Pull the remaining crankshaft bearing

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

7.2.4 Pump Disassembly

(Refer to Fig. 7-5.)

a. Remove the pump pulley from the

crankshaft.

b. Remove the pumpheads/check-valve

assembly, diaphragms, and diaphragm
washers from the connecting link, as
described in paragraph 7.2.3.

c. Remove bearing retainer plates (12) from

each side of the pump.

7.2.5 Inspect and Repair Pump

a. Spin the bearings by hand to check for

roughness or grinding. Replace the bear­ing(s) if roughness is felt while spinning
the bearing, or if the bearings show wear.

b. Replace the crankshaft (23) or the con-

necting link (8), or both, if they are scored
or damaged due to seized bearings.

c. Replace the diaphragm washers (3, 7) if

they are damaged or if the face of the
washers are in a condition that will cause
the diaphragm to chafe.

d. Check the diaphragm (4) for pliability.

Replace the diaphragm if some rigidness
is evident. See paragraph 7.2.3 (page 7-3).

7.2.6 Pump Reassembly

a. Apply Loctite Bearing Mount-Grade B to

the inside surface of the connecting link.
Press the bearing (21) into the connecting
link (8). Wipe off the excess Loctite from
the connecting link surfaces.

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Steam Master Instruction Manual

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

b. Apply Loctite Bearing Mount-Grade B to

the inside surface of the bearing hole on
the crankcase (9). Press the connecting
link and bearings onto the crankshaft.
Wipe off excess Loctite from the crank­shaft and bearing surfaces.

c. Position the crankshaft and connecting

link assemblies in the crankcase and press
the crankshaft bearings (22) onto the ends
of the crankshaft and into the crankcase.

d. Assemble the diaphragm and pumphead

as described in paragraph 7.2.3 (page 7-3).

e. Install the pump pulley onto the

crankshaft.
f. Align the pulley and install the drive belt.
g. Connect piping to the check valves.
h. Start and run the steam generator in the

standard mode of operation. Verify the

pump is properly primed. Inspect all con-

nections for leaks and retighten as needed.

7.2.7 Install High Strength Studs

Required tools:

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

• Stud driver (1-14 thread)

a. Thoroughly clean both the studs and the

threaded crankcase holes of all dirt, oil,
and other debris. Use clean solvent.

b. Spray primer (Locquic “T” Primer) only

on the short threaded end of the cleaned
stud. Do not over prime. A very thin film
is best.

Inhaling primer fumes will cause loss of
consciousness. Use primer in a well ventilated
area.

c. Apply adhesive (Loctite # 242) at lead

threads in the threaded hole.

d. Spread Loctite to the rear of the threads

with a clean plastic tie wrap, or similar
device. (See Fig. 7-7.)

e. Apply Loctite to the stud (primed end).

Fill ninety percent (90%) of the threads
with Loctite. Work with one stud at a
time.

f. Hand thread the stud into the crankcase

several rotations clockwise, then reverse
the direction counterclockwise allowing
any entrapped air to escape. Repeat this
procedure until the stud is fully seated in
the case. Wipe away all excess Loctite.

g. Double-nut the stud and tighten into

crankcase. DO NOT OVER TIGHTEN.
Torque the stud to 250 lb-ft (338 N•m).
Repeat this process for all studs.

h. Install pump head as described in steps g –

i in paragraph 7.2.3 (page 7-3).

Sect07_CSMG_b.fm 7-6 04/26/2019

Section VII–Component Maintenance

Fig. 7-8. Feedwater Pump Relief Valves

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

7.3 Feedwater Pump Relief Valve

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

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

b. To raise the pressure adjustment, turn the

adjusting screw clockwise. Similarly, to
lower the pressure adjustment, turn the
adjusting screw counterclockwise. Secure
the adjusting screw with the lock nut after
adjustment process.

It is best to make these pressure
adjustments while the feedwater pump
is off. A feedwater pump that is running
places more resistance against the
adjusting nut.

c. Fully open the coil feed valve. Regularly

inspect the relief valve for leakage during
normal operation.

7.4 Temperature Controllers (MTLC1, MTLC2)

7.3.1 Adjustment

Under certain conditions, when starting
the machine, the feed pressure may
surge sufficiently to cause the relief
valve to release a small amount of
water. The feed pressure will return to
normal, however, after the machine
heats and the system becomes
stabilized.

a. Start the machine in the FILL position and

slowly close the coil feed valve until the
relief valve begins to discharge. When the
discharge begins, check the pressure on
the feed pressure gauge.

The MTLCs are installed in the electrical
control box.

7.4.1 Check Main Temperature Limit Controllers

a. Remove one thermocouple lead wire from

the MTLC. See Fig. 7-9 below.

b. Verify that a shutdown occurs and an

alarm is initiated within one minute.

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Steam Master Instruction Manual

c. Replace the thermocouple lead wire.
d. Repeat steps a, b, and c for the other

MTLC.

If any of the MTLCs are suspected of
being faulty, remove it and conduct
further bench testing. Replace the
MTLC if it is faulty.

7.5 Operating Pressure Switch (OPS) Adjustment

The OPS can be adjusted to open and stop

the burner at any desired maximum steam pressure
within the operating range of the switch and in
accordance with Clayton prescribed switch setpoint
parameters. The switch has a fixed differential and
will close and restart the burner when steam pres­sure drops about 8 psi (0.55 bar) below the OPS
setpoint.

To adjust, turn the large slotted screw at the

top of the switch until the dial pointer on the switch
is opposite the maximum desired operating pres­sure. The dial setting is approximate and final
adjustment should be made (if necessary) by reset­ting the switch to shut off the burner when desired
maximum pressure is reached on the operating pres­sure gauge.

7.6 Limit Pressure Switch (LPS) Adjustment

The LPS is part of the motor circuit. In the

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

7.6.1 Adjustment

To set the switch (using scale on switches)

manually increase the OPS and LPS setpoints to
some value above the desired LPS setting (a pres­sure that is about halfway between the original OPS
setpoint and the opening pressure of the steam
safety relief valve(s)). Operate the machine and

slowly throttle the steam discharge valve to increase
the steam pressure to de sired LPS setpoint. Set the
limit pressure switch (dial down) to open (shutting
machine off). Reset the OPS to its original setting
(See paragraph 7.5.).

7.7 Gas Pressure Switches

Damage to burner unit and steam generator will
result from improperly adjusted gas pressure
switches.

Maintenance and repair of the
packaged burner system and its
ancillary devices should ONLY be
performed by Clayton Service or by
Clayton-authorized service technicians.

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

The low gas pressure switch (GPSL) closes
on an excessive drop in supply gas pressure; the
high gas pressure switch (GPSH) opens on an
excessive rise in 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.

A manual reset is required on the GPSL
installed at the main gas supply inlet. A manual
reset is required on the GPSH. The GPSH is found
inside the housing of the packaged burner unit.

Note: Manual reset can be accomplished
without removing the clear cover. To manually
reset the pressure switch, press the spot on the cover
immediately above the red manual reset button
(Fig. 7-10).

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

Sect07_CSMG_b.fm 7-8 04/26/2019

a. Remove clear cover from the switch to

Fig. 7-10. GPSL/GPSH adjustment dial and manual reset button. The GPSL installed at the

main gas inlet requires a manual reset. The GPSH, located inside the packaged burner unit

housing, requires a manual reset.

gain access to adjustable (yellow) dial
(Fig. 7-10).

b. Turn dial until the desired pressure set-

point is aligned with the white line on the

yellow dial face.
c. Verify the switch operates as intended.
d. Replace cover.

Section VII–Component Maintenance

04/26/2019 7-9 Sect07_CSMG_b.fm

Steam Master Instruction Manual

(This page intentionally left blank.)

Sect07_CSMG_b.fm 7-10 04/26/2019

Steam Generator List of Parts

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

A-1

Fig. 01A - Main Heating Section–SM15

HeatingSect_SM15_a.fm A-2 04/30/2019

FIG. 01A - Main Heating Section–SM15

04/30/2019 A-3 HeatingSect_SM15_a.fm

Fig. 01B - Economizer Stack Outlet Kit–SM15

HeatingSect_SM15_a.fm A-4 04/30/2019

FIG. 01B - Economi zer Stack Outlet Kit–SM15

04/30/2019 A-5 HeatingSect_SM15_a.fm

Fig. 01C - Main Heating Section–SM30

HeatingSect_SM30_b.fm A-6 12/05/2018

FIG. 01C - Main Heating Section–SM30

12/05/2018 A-7 HeatingSect_SM30_b.fm

Fig. 01D - Economizer Coil–SM30

HeatingSect_SM30_b.fm A-8 12/05/2018

FIG. 01D - Economizer Coil–SM30

12/05/2018 A-9 HeatingSect_SM30_b.fm

Fig. 01C - Main Heating Section–SM40

HeatingSect_SM45_b.fm A-10 04/30/2019

FIG. 01C - Main Heating Section–SM40

04/30/2019 A-11 HeatingSect_SM45_b.fm

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

HeatingSect_SM45_b.fm A-12 04/30/2019

FIG. 01D - Economizer Coil–SM40

04/30/2019 A-13 HeatingSect_SM45_b.fm

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

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

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

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

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

Sep-Trap-PressMfld_SM153040_b.fm A-16 04/30/2019

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

04/30/2019 A-17 Sep-Trap-PressMfld_SM153040_b.fm

Fig. 02C - Steam Tra p and Control Valve Hookup

Item Part N o. Description Qty.

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

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

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

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

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

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

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

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

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

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

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

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

1

4

5

1

3

2

6

FIG. 02C - Steam Trap and Control Valve Hookup

Sep-Trap-PressMfld_SM153040_b.fm A-18 04/30/2019

Fig. 02D - Safety Relief Valve Hookup

FIG. 02D - Safety Relief Valve Hookup

04/30/2019 A-19 Sep-Trap-PressMfld_SM153040_b.fm

Fig. 02E - Pressure Indicating System

Sep-Trap-PressMfld_SM153040_b.fm A-20 04/30/2019

FIG. 02E - Pressure Indicating System

04/30/2019 A-21 Sep-Trap-PressMfld_SM153040_b.fm

Fig. 04A - Feedwater Pump Hookup– C1

Item P art No. Description Qty.

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

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

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

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

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

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

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

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

1

2

4

3

7

8

5

6

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

FIG. 04B - Feedwater Pump Hookup–C1

Fig. 04B - Feedwater Pump Hookup– C2

Item Part N o. Description Qty.

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

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

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

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

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

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

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

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

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

1

2

3

4

5

7

8

6

FIG. 04B - Feedwater Pump Hookup–C2

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

Fig. 05A - Pump Assy –C1

PumpHkup-C1-C2_parts_a.fm A-24 03/05/2019

FIG. 05A - Pump Assy–C1

03/05/2019 A-25 PumpHkup-C1-C2_parts_a.fm

Fig. 05B - Pump Assy –C2

03/05/2019 A-26 PumpHkup-C1-C2_parts_a.fm

FIG. 05B - Pump Assy–C2

PumpHkup-C1-C2_parts_a.fm A-27 03/05/2019

Fig. 06 - Check Valve

Item Part No. Description Qty.

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

UH23304 VALVE, Check, 1 1/4 in., 300# ................................ Ref.

UH30530 VALVE, Check, 1 1/2 in., 350# ................................ Ref.

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

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

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

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

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

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

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

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

Item Part No. Description Qty.

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

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

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

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

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

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

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

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

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

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

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

FIG. 06 - Check Valve

Fig. 07 - Relief Valve

FIG. 07 - Relief Valve

CheckValve_ReliefValve_b.fm A-28 11/20/2018

Fig. 09 - Fuel Gas System

3

6

7

5

2x

2x

9

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

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

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

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

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

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

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

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

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

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

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

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

(Clayton equivalent part no.: 0032792)

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

0–3 psi (0–20.5 kPa)

8

4

2

1

2

FIG. 09 Fuel Gas System

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

Fig. 13 - Electrical Control Box

1

5

13

13

22

4

7 7

20

21

23

25 24

18

11
14
15
16
17

2x

10x
3x
50x

29

31

12

27

28

30

6

10

9

8

4x

26

ControlBox_CSM_a.fm A-30 11/20/2018

FIG. 13 Electrical Control Box

Fig. 18 - Separator High Level Alarm Kit

Item Part No. Description Qty.

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

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

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

3

1

2

INSIDE LEFT DOOR

OIU

E-STOP

PUSHBUTTON

SHLA_a.fm A-31 02/08/2019

FIG. 18 Separator High Level Alarm Kit

(This page intentionally left blank.)

Blank_Left.fm A-32 08/16/2017

Feedwater Skid Option List of Parts

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

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

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

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

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

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

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

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

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

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

B-1

Fig. 01 - Vertical Hotwell

Fig. 1 - Vertical Hotwell

Table 1

1 UH40252 Hotwell and Base-Vertical, 50 bhp
2 0030484 Valve, Ball, 1 1/2 in.

0030485 Valve, Ball, 2 in.

1

2

Fig. 2 - Water Softener Plumbing Hookup

Table 2

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

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

0040841 Water Softener, 90,000 grain, EFC-90-1-F
2 0040829 Valve, Solenoid, 2 way, 1/2 in. (Make-up Water Valve)
3 0029872 Valve, Ball, 1 in., 1000 psi

0033793 Valve, Ball, 3/4 in., 1000 psi
4 0037877 Valve, Ball, 1/4 in., 1000 psi
5 0029872 Valve, Ball, 1 in., 1000 psi
6 0016389 Gauge, Pressure, 2 in.
7 0003440 Valve, Ball, 1/4 in.
8 0033793 Valve, Ball, 3/4 in., 1000 psi

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

0043721 Meter, Flow, pulse, 0.22 –22 gpm (optional equipment)

1

2

3

8

4

5

6

9

*

*

Optional Equipment

7

25–75 bhp Feedwater Skid Option

Fig. 02 - Water Softener Plumbing Hookup

FeedwtrSkid_VHtwl_25-75bhp_a.fm B-2 11/26/2018