Columbia L-24 Owner's manual

Columbia/Shenandoah

®™

Waste Oil-Fired Boiler

Owner's Manual

WL-60 / L-24 Boiler

All Installations Must Be In Accordance With State and Local Codes and it is

the responsibility of the installer to assure all codes are met

For service, call your dealer or installer at:

or Columbia Boiler at (610) 323-2700 to find the distributor for your area

Date Installed: ____________________________

WARRANTY NOTICE

Use of Columbia Boiler Company equipment on equipment not manufactured or designed for use by

Columbia Boiler, VOIDS the warranty - property or personal damage could occur.

Sizing of the boiler is the responsibility of the purchaser.

A complete heat loss calculation for the structure or process is necessary to select the proper unit size.

Columbia Boiler Company

P O Box 1070

Pottstown, PA 19464 USA

TABLE OF CONTENTS

SUBJECT PAG E

PACKING LIST 3

SPECIFICATIONS WL 60 / L 24 4-6

BOILER CONTROLS 9

BOILER FLAME & BRICK INSTALLATION INSTRUCTIONS 10-11

CONTROL LOCATIONS & PORTS WL 60 13

NOTES 17

CONTROL LOCATIONS & PORTS L 24 18-19

COIL INSTALLATION L24/WL60 20

BASIC BOILER & RADIANT HEAT INFORMATION 21

CABINET / JACKET ASSEMBLY 23

WATER TREATMENT 23-25

BOILER MAINTENANCE and MODEL 24 SWING DOOR OPERATION 26-28

BURNER / PUMP / CHIMNEY , AIR & OIL SUPPLY 28-34

ELECTRICAL / WIRING DIAGRAMS 34

START UP 40

BURNER MAINTENANCE 42

TROUBLE SHOOTING GUIDE 49

PA RT S 51

APPENDICIES A/B : WARRANTIES A/B

ATTACHMENTS : OEM CONTROLS INSTRUCTIONS

3

PACKING LIST

1 Boiler (coils installed if ordered)

1 Carton of cabinet panels

1 Temp/Pressure Gage

1 ASME Relief Valve (15 psi steam or 30 psi water)

1 Operating Aquastat w/ Thermowell or Steam Control

1 High Limit Aquastat w/ Thermowell or High Limit Steam Control

1 Low Water Cutoff w/ remote sensor (manual reset unless specified)

1 Water Level Gauge (glass) When boiler ordered as steam

1 Boiler Manual

1 3/4 X 1/2 FPT Swivel

1 Shenandoah Logo Label, white

1 Electric Junction Box w/ inner Bracket and Cover

1 Terminal Strip

1 Model Label (WL 60 / L 24) white

1 1/4 x 1/4 x 1/8 tee

1 1/4 NPT Hex Nipple

1 1/4 Nipple

1 1/2 Nipple

1 Suction Screen

1 Oil Filter w/ Gage

1 3/4 Check Valve

1 Vac/Air Gage

1 Oil Pump

24 Fire Brick

12 Split Firebrick (Model 24 series only)

1 Burner

1 Burner Swing Door (mounted)

1 Burner Cord (Quick Connect)

1 Boiler Cleaning Brush

1 Relay

4

COLUMBIA WL-60 WASTE OIL-FIRED BOILERS

Product Specifications

1. Boiler Construction:

1. Boiler shall meet EPA exemption guidelines for safe disposal (40 CFR 266) of used oil.

2. The boiler shall be ASME, I.B.R., ETLM approved and stamped to conform with the National Board of

Boiler and Pressure Vessel Inspectors.

3. The boiler shell and tubes shall be designed for burning #1, #2 fuel oil, used crank case oils, used

transmission, hydraulic and gear oils and any weight combinations up to SAE #50.

4. The cabinet shall be constructed of a minimum of 20 gauge galvaneal steel with a heat and

mar-resistant finish.

5. The boiler shall be of an inclined water tube design for self cleaning action.

6. Tankless coils shall be available and field replaceable.

2. Burner Construction:

1. U.S. and Canadian patented burner with slide out gun assembly providing a 36" oil preheat.

2. Burners shall be of the low pressure, air atomizing type using a thermostatically controlled combustion

air and oil preheat gun assembly.

3. The burner oil gun must have an automatic pre and post flame purge cycle.

4. The preheat assembly shall prevent overheating and over-pressurization of both air and oil. This design

must also limit internal carbonization and nozzle plugging associated with overheated fossil fuel

mixtures.

5. Access shall be provided to easily remove the gun assembly and allow routine maintenance without

removing the burner.

6. Burner shall be supplied to fire at the input rate specified.

7. Burner shall have a non-condensing exhaust.

8. Air for atomization must be designed to connect into an existing pressurized air source.

9. A quick disconnect cord shall be provided for electrical service to the burner.

3. Heat Exchanger:

1. Heat exchanger shall be of a multi water tube design.

2. Firing chamber shall be a welded construction with a minimum of 1/4" boiler plate.

3. Flame target area shall be refractory or brick and shall be replaceable. Replacement materials shall be

available.

4. The heat exchanger shall have welded multi path 2" minimum diameter ERW ASTM 176.66 tubes with

a minimum of 3/16 inch wall.

5. Three easy access, clean out panels shall be provided for exterior tube cleaning maintenance.

6. Must have a flame inspection port for visual inspection of flame without opening door or disturbing

draft.

7. Flue is 10" with a minimum 11 gauge connector.

8. Shall have a removable hinged burner mount for fire chamber access.

9. Shall have a minimum of (4) 2" washouts.

10. Shall have available a 4" supply and 3" return water connection.

11. Hinged Burner Extension factory attached to Boiler.

12. Combustion chamber modifications include field installation of firebrick on back wall and sides of

firing chamber.

5

4. Controls:

1. Shall be provided with an adjustable Operating Aquastat or Steam Pressuretrol that is UL recognized

for 8A at 120v.

2. Shall be provided with an adjustable High L imit Aquastat or High Limit Steam Pressuretrol that is UL

recognized for 8A at 120V.

3. Shall be provided with a Temperature/Altitude Gauge of 0-60 psi and 60-260° F.

4. Shall be provided with an adjustable Safety Relief Valve that is ASME listed for 1,000,000 BTU/H.

5. Shall be provided with a Low Water Cutoff rated at 5.8A at 120VAC, approved UL, CSA, and FM,

manual reset.

6. All burners will have cadmium flame sensors for positive, fail safe, combustion verification.

7. Burner shall have three indicator lights to monitor burner operation.

8. A thermostat shall be provided to allow convenient space temperature control and must be of the

mercury type with on/off switch.

9. An oil transfer pump shall be available to meet the following minimum requirements: 18 GPH @ 35

psi, minimum 1/4 hp heavy duty.

10. High range oil and air gauges shall be provided. These shall be interchangeable and capable of reading

vacuum and pressure.

11. Hour meter shall be standard to record burn time.

12. Oil filter shall be provided with 100-micron stainless steel, washable element. Must include a port for a

vacuum gauge.

5. Warranty:

1. The fire chamber and pressure vessel shall have a (5) five year limited warranty. (See written

warranty for details.)

2. All mechanical parts and burner are covered the first year for full part replacement.

6

COLUMBIA L-24 WASTE OIL-FIRED BOILERS

Product Specifications

A. Boiler Construction:

1. Boiler shall meet EPA exemption guidelines for safe disposal (40 CFR 266) of used oil..

2. The boiler shell and tubes shall be ASME, I.B.R., ETLM and stamped to conform with the National

Board of Boiler and Pressure Vessel Inspectors.

3. The boiler shall be designed for burning #1, #2 fuel oil, used crank case oils, used transmission,

hydraulic and gear oils and any weight combinations up to SAE #50.

4. The cabinet shall be constructed of a minimum of 20 gauge galvaneal steel with a heat and

mar-resistant finish.

5. The boiler shall be of an inclined water tube design for self cleaning action.

6. Tankless coils shall be available and field replaceable.

B. Burner Construction:

1. U.S. and Canadian patented burner with slide out gun assembly providing a 36" oil preheat.

2. Burners shall be of the low pressure, air atomizing type using a thermostatically controlled combustion

air and oil preheat gun assembly.

3. The burner oil gun must have an automatic pre and post flame purge cycle.

4. The preheat assembly shall prevent overheating and over-pressurization of both air and oil. This design

must also limit internal carbonization and nozzle plugging associated with overheated fossil fuel

mixtures.

5. Access shall be provided to easily remove the gun assembly and allow routine maintenance without

removing the burner.

6. Burner shall be supplied to fire at the input rate specified.

7. Burner shall have a non-condensing exhaust.

8. Air for atomization must be designed to connect into an existing pressurized air source.

9. A quick disconnect cord shall be provided for electrical service to the burner.

C. Heat Exchanger:

1. Heat exchanger shall be of a multi water tube design.

2. Firing chamber shall be a welded construction with a minimum of 1/4" boiler plate.

3. Flame target area shall be refractory or brick and shall be replaceable. Replacement materials shall be

available.

4. The heat exchanger shall have welded multi path 2" minimum diameter ERW ASTM 176.66 tubes with

a minimum of 3/16 inch wall.

5. Two easy access cleanout panels shall be provided for exterior tube cleaning maintenance.

6. Must have a flame inspection port for visual inspection of flame without opening door or disturbing

draft.

7. Flue is 9” with a minimum 11 gauge connector.

8. Shall have a minimum of (4) 1-1/2" washouts.

9. Shall have available a 4" supply and 3" return water connection.

10. Hinged burner door provided for fire chamber access.

11. Combustion chamber modifications include field installation of firebrick on back wall, base, and sides

of firing chamber.

7

D. Controls:

1. Shall be provided with an adjustable Operating Aquastat or Steam Pressuretrol that is UL recognized

for 8A at 120v.

2. Shall be provided with an adjustable High Limit Aquastat or High Limit Steam Pressuretrol that is UL

recognized for 8A at 120V.

3. Shall be provided with a Temperature/Altitude Gauge of 0-60 psi and 60-260° F.

4. Shall be provided with an adjustable Safety Relief Valve that is ASME listed for 1,000,000 BTU/H.

5. Shall be provided with a Low Water Cutoff rated at 7.4A at 120VAC, approved UL, CSA, and FM,

manual reset.

6. All burners will have cadmium flame sensors for positive, fail safe, combustion verification.

7. Burner shall have three indicator lights to monitor burner operation.

8. A thermostat shall be provided to allow convenient space temperature control and must be of the

mercury type with on/off switch.

9. An oil transfer pump shall be available to meet the following minimum requirements: 18 GPH @ 35

psi, minimum 1/4 hp heavy duty.

10. High range oil and air gauges shall be provided. These shall be interchangeable and capable of reading

vacuum and pressure.

11. Hour meter shall be standard to record burn time.

12. Oil filter shall be provided with 100-micron stainless steel, washable element. Must include a port for

a vacuum gauge.

E. Warranty:

1. The fire chamber and pressure vessel shall have a (5) five year limited warranty. (See written

warranty for details.)

2. All mechanical parts and burner are covered the first year for full part replacement.

WASTE OIL-FIRED BOILERS

SPECIFICATIONS SUMMARY

MODEL 24 MODEL 60

Waste Oil GPH (approx) 1.25 to 2.5 1.68 to 5.7

Gross BTUH Input (approx) 175,000 to 350,000 to

350,000 / hour 800,000 / hour

Gross HP 4 to 8 6 to 20

Water Volume in Shell, Gallons 55 133

GPM Single Coil; Temp Rise 100 F 4.4 Max 6.5 Max

GPM (2) Coils; Temp Rise 100 F x 13 Max

Width w/o Controls Cab 27 32

Depth with Burner & Smoke Outlet 58 80

Height 57 63.6

Burner Model B5 B5 Single or B10

Single Nozzle Dual Nozzle

Boiler Weight (dry) (approx.) 1,450 1,730

Total Shipping Weight (approx.) 1,800 2,475

Agency Listing (Operation, Safety, & ETLM, ASME, ETLM, ASME,

Performance) IBR IBR

________________________________________________________________________

8

BOILER ROOM REQUIREMENTS

A. Room should be well lighted and should have a source of emergency light.

B. Convenient water supply available for boiler and to clean the boiler room floor.

C. Unobstructed floor drains.

D. Since the combustion process requires a supply of air at all times, it is essential that provisions are made to

supply adequate air to the boiler room. This air supply is necessary to insure complete combustion, a clean

fire and to prevent nuisance shut downs due to excessively dirty burner parts. Air from the outside may be

provided through ducts, fixed louvers or motorized louvers.

E. Adequate space around the unit should be provided for inspection and service. We suggest 3 foot walkway

for service.

F. Do not allow your boiler room to become a “junk” room.

G. Provide 3” thick concrete pad for boiler (optional) or place on noncombustible surface.

H. Proper operation depends on adequate draft to maintain a negative pressure in the fire chamber. A

commercial draft inducer may be needed if natural draft is inadequate.

UNIQUE CHARACTERISTICS OF BURNING USED OIL IN A BOILER

A. Accumulation of ash produces numerous adverse affects:

1. Reduced heat transfer (U.S. Bureau of Mines) Research by the U.S. Bureau of Mines has determined

that 1/32-inch of soot coating causes 9.5% loss of boiler efficiency. The following table shows how

soot thickness effects efficiency

1/32-inch of soot 9.5% loss of efficiency

1/16-inch of soot 26% loss of efficiency

1/8-inch of soot 45% loss of efficiency

3/16-inch of soot 69% loss of efficiency

2. Reduced air flow also causes incomplete combustion

B. Conventional boilers are not appropriate for waste oil for the following reasons:

1. Improper heat exchanger design can not provide adequate gas exhausting.

2. Combustion chamber too small.

3. Water backed uninsulated combustion chamber condenses flue gas.

4. Poor accessibility for routine cleaning.

C. Shenandoah waste oil boiler features address all the problems

1. Heat exchanger designed to prevent ash buildup and achieve high transfer efficiency

2. Large access doors provide easy access for maintenance and cleaning

3. Refractory lined large combustion chamber produces high temperature combustion zone

4. Water tube design for efficiency, improved draft and minimal floor area used with its vertical design

9

Frequently Used Boiler Terms

BTU - British Thermal Unit, amount of energy to raise one lb. of water one degree F.

1000 BTU = 1 lb. of steam 150 BTU = 1 sq. ft. of hot water

34.5 lbs. steam/hr. = 1 boiler horsepower 1 Boiler hp = 140 sq. ft. steam radiation

240 BTU = 1 sq. ft. of steam 34,500 BTU = 1 Boiler horsepower

1 Gallon of #2 Oil = 140,000 BTU 1 Cu. ft. LP gas = 2,550 BTU

1 Cu. ft. Natural Gas = 1,000 BTU 1 KWH = 3,413 BTU

1 Therm. Natural gas = 100,000 BTU

BOILER CONTROLS

(Provided) Safety Relief Valve

Steam boiler gets (1) @ 15 psi/1,000,000 Btu limit relief.

Hot water boiler gets (1) @ 30 psi/1,000.000 Btu limit relief.

They are nonadjustable. Place on top of boiler in vertical position. Never reduce pipe size entering or exiting

the valve.

(Provided) Temperature/Altitude Gauge (temperature/pressure gauge).Mount in any convenient port. Typical

location is on front of boiler.

(Provided w/ steam boilers only) Water Level Glass - visibly allows water level to be seen. Mounts vertically

on upper left corner of boiler in (2) 1/2” ports.

(Provided w/ hot water boilers) M&M Model 750, Low Water Cutoff (LWC) This is a manual reset design.

5.8 Amp/115V protects boiler from low water levels that could cause boiler damage. Control has an alarm or

water feed switch (N.O.) between no’s 2 & 4 and a burner shut down switch (N.C.) between 5 and 2. The LWC

control box can mount anywhere near or on the boiler, and the remote sensor threads into any 3/4” port in

plates on front of boiler. Additional Model 767 or 764 float LWC may be ordered for special applications or

codes.

(Provided w/CWH & water boilers) L4006A Aquastat: Operating. 8.0 amp at 120 cycles burner to maintain

water temp in the boiler jacket. Mount in 3/4” port on front of boiler.

(Provided w/CWH & water boilers) L4006E Aquastat: High limit (has manual reset button). 8.0 Amps/120V,

shuts down burner if operating aquastat fails. Do not set above 200 or risk steam formation in water boilers.

Mount in 3/4” port on front of boiler.

(Provided w/steam boilers) L404A Operating Pressuretrol. 2 to 15 psi, 1 to 6 psi differential, 8 Amp at 120 V,

SPST. Cycles burner to maintain steam pressure in the boiler. Mount above boiler using 1/2” or 3/4” port.

(Provided w/steam boilers L404C) High Limit Pressuretrol: Manual reset, 2 to 15 psi, 8 Amps 120V, SPST.

Shuts down burner if operating control fails Mount above boiler using 1/2” or 3/4” port.

(Provided w/ steam boilers only) Warrick 26C1D1C Low Water Cutoff (LWC) with probe and manual reset,

26K sensitivity, 120VAC, NEMA1, normally closed push button. Additional Model 767 float LWC or

M&M42S LWC/Pump Control may be ordered for special applications or codes.

10

Items Not Provided That Should be Considered: Pressure Reducing Valve - used to automatically maintain

a desired pressure in the system, acts as a make-up water supply. Tempering Valve - allows hot water from

boiler to accurately mix with returning cool water to make desired water ready to go to the application. The hot

water should be at least 20 degrees warmer than the return water for smooth operation. Water Circulator -

used to circulate boiler water. Expansion Tank - used to absorb expanding water when heating it.

Water and Flame Locations In Boilers

11

Brick Lining Location In WL 60

12

Model WL60 Boiler Connection Ports

(Port, Quantity, NPT, Suggested Uses *)

A (3) 1/2” Water level glass, make-up water inlet

B (4) 3/4” Aquastats (water), Controllers (Steam), 750 LWC probe

C (3) 1” Relief Valve, pr./temp gauge

D (1) 1-1/4” Relief Valve (alternate)

E (4) 2” Drains or Alternate Returns

F (1) 2-1/2” Optional 764, 767 LWC

G (1) 3” Primary return water or condensate

H (1) 4” Heated water or steam to application

I (4) 1” Optional tankless coil(s) w/boilers, std. w/CWH

Model L24 Boiler Connection Ports

(Port, Quantity, NPT, Suggested Uses *)

A (3) 1/2 “ Water level glass, make-up water inlet

B (3) 1/2" Aquastats (water), Controllers (Steam), 750 LWC probe

C (3) 1” Relief Valve, pr./temp. gauge

D (4) 1-1/2” Return water or condensate

E (1) 1-1/4” Relief Valve, (alternate)

F (1) 2-1/2” Optional 764, 767 LWC

G (1) 4” Heated water or steam to application

H (2) 1” Optional tankless coil w/boilers, (upper rear of boiler)

* Note that the above is suggested uses of the ports. As can be seen in our photos there are

many acceptable ways to install the piping and controls. An experienced plumber and con-

trols person should be used to assure the design is functional and meets needs. One must

allow for initial cleaning and purging of oils and dirt from the water loop and then refill

and treat the water as needed to preserve boiler life. Read all the following pages carefully

and plan plumbing and control locations before starting.

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17

Notes

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PRESSURE GAUGE AQUASTATS LWC SENSOR ELEC. BOX

Columbia L-24, WL-60 Owner's manual

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