Clayton EO-100-1M User manual

Clayton Steam Generator model EO-100-1M PAGE 1 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
Order ref nr :
PR18206
INSTRUCTION MANUAL
STEAM GENERATOR
EO-100-1M
EUROPE, AFRICA & MIDDLE EAST HEADQUARTERS
CLAYTON OF BELGIUM NV
Rijksweg 30
B-2880 Bornem
Belgium
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
www.clayton.be
CLAYTON DE FRANCE s.a.r.l. CLAYTON DEUTSCHLAND Gmbh
160, rue du Tuboeuf Lindemannstraβe 75
F-77170 Brie Comte Robert D-40237 Düsseldorf
France Germany
Tel.: [phone] Tel.: [phone]
Fax: [phone] Fax: [phone]
E-mail: [email protected]r E-mail: [e-mail]
www.clayton.fr www.clayton-deutschland.de
CLAYTON NEDERLAND B.V. p/a CLAYTON THERMAL PRODUCTS Ltd.
Rijksweg 30 5, Boleyn Court
B-2880 Bornem Manor Park Industrial Estate
Belgium Runcorn, Cheshire WA7 1SR, U.K.
Tel.: [phone] Tel.: [phone]
Fax: [phone] Fax: [phone]
E-mail: [e-mail] E-mail: [e-mail]
www.clayton.nl www.claytonindustries.co.uk

Clayton Steam Generator model EO-100-1M PAGE 2 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
TABLE OF CONTENTS.
TABLE OF CONTENTS. ................................................................................................................................... 2
TECHNICAL SPECIFICATIONS...................................................................................................................... 4
CHAPTER 1 : INTRODUCTION ...................................................................................................................... 5
CHAPTER 2 : SAFETY INFORMATION.......................................................................................................... 6
2.1 GENERAL, IMPORTANT INFORMATION ............................................................................................ 6
2.2 INSTALLATION ...................................................................................................................................... 6
2.3 OPERATION ........................................................................................................................................... 7
2.4 REST RISKS............................................................................................................................................. 7
CHAPTER 3 : DESCRIPTION........................................................................................................................ 11
3.1 GENERAL.............................................................................................................................................. 12
3.2 WATER AND STEAM SYSTEM............................................................................................................. 12
3.3 FUEL SYSTEM OIL FIRED UNITS ( DRAWING HE-2673 )............................................................. 15
3.4 AUTOMATIC BURNER MODULATION.............................................................................................. 15
3.5 BURNER MANIFOLD........................................................................................................................... 15
CHAPTER 4 : ELECTRICAL SYSTEM & MAIN COMPONENTS ................................................................. 16
4.1 DESCRIPTION OF MAIN COMPONENTS.......................................................................................... 16
4.2 OPERATION ......................................................................................................................................... 16
CHAPTER 5 : INITIAL FIRING...................................................................................................................... 18
5.1 BEFORE FIRING.................................................................................................................................. 18
5.2 CONDITIONING OF NEW INSTALLATIONS OR INSTALLATIONS WITH A NEW COIL................ 18
CHAPTER 6 : OPERATION.& SHUTTING DOWN....................................................................................... 20
6.1 GENERAL.............................................................................................................................................. 20
6.2 BEFORE STARTING............................................................................................................................. 20
6.3 STARTING PLANT................................................................................................................................ 20
6.4 STARTING THE BURNER .................................................................................................................... 21
6.5 AUTOMATIC OPERATION.................................................................................................................. 21
6.6 SHUTTING DOWN THE GENERATOR............................................................................................... 21
CHAPTER 7 : TROUBLE SHOOTING ........................................................................................................... 25
7.1 WATER SYSTEM ................................................................................................................................... 25
7.2 FUEL SYSTEM OIL FIRED UNITS...................................................................................................... 26
7.3 ELECTRICAL SYSTEM......................................................................................................................... 29
7.4 BURNER FAILURE............................................................................................................................... 29
CHAPTER 8 : PERIODIC MAINTENANCE................................................................................................... 34
8.1 GENERAL.............................................................................................................................................. 34

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Instruction Manual, doc.nr.: MAN18206 Rev A PSC
8.2 FEEDWATER TREATMENT................................................................................................................. 34
8.3 DAILY SERVICE ................................................................................................................................... 34
8.4 WEEKLY MAINTENANCE.................................................................................................................... 35
8.5 MONTHLY MAINTENANCE ................................................................................................................ 36
8.6 SERVICE ANNUAL (OR SEMI-ANNUAL FOR SEVERE SERVICE)................................................... 37
8.7 PERIODIC INSPECTION OF SAFETY, CONTROL AND MONITORING DEVICES. ....................... 38
CHAPTER 9 : COMPONENT MAINTENANCE............................................................................................. 42
9.1 FEEDWATER PUMP.J-2...................................................................................................................... 42
9.2 HEATING COIL .................................................................................................................................... 49
9.3 BURNER OIL FIRED UNITS & FUEL PRESSURE REGULATOR..................................................... 55
9.4 AIR DAMPER ADJUSTMENT E-100 ................................................................................................... 60
CONTROLLER ............................................................................................................................................ 61
9.5 START GENERATOR............................................................................................................................ 61
9.6 START BURNER. .................................................................................................................................. 61
9.7 CONFIGURATION OF TEMPERATURE INDICATOR JUMO ( 0202485 ) ...................................... 62
9.8 STEAM PRESSURE SWITCH (F20) ..................................................................................................... 63
9.9 MODULATION PRESSURE SWITCH [F22] ..................................................................................... 63
9.10 LIMIT PRESSURE SWITCH [F21]................................................................................................... 64
9.11 AIR PRESSURE SWITCH [ F81,-FIG 8.22 ] ..................................................................................... 64
9.12 AIR PRESSURE SWITCH HIGH FIRE [F82 - FIG 8.22 ] ............................................................... 64
CHAPTER 10 : RECOMMENDED OILS FOR CLAYTON WATERPUMPS.................................................. 65
10.1 PURPOSE AND SCOPE. .................................................................................................................... 65
10.2 OIL SPECIFICATIONS....................................................................................................................... 65
10.3 OILS FOR FOOD INDUSTRIES......................................................................................................... 65
CHAPTER 11 : INSTRUCTION AND OPERATION FOR PRESSURE VESSELS ........................................ 66
11.1 DESCRIPTION OF PRESSURE VESSEL........................................................................................... 66
11.2 TRANSPORT, HANDLING AND STORAGE. ..................................................................................... 66
11.3 ASSEMBLING AND ERECTION. ....................................................................................................... 67
11.4 TAKING INTO OPERATION. ............................................................................................................. 68
11.5 SUPERVISION AND MAINTENANCE. .............................................................................................. 69
11.6 SUPERVISION AND INSPECTION.................................................................................................... 69
11.7 MAINTENANCE.................................................................................................................................. 69
PSC 04-02-2014 .......................................................................................................................................... 70
End Table of Contents

Clayton Steam Generator model EO-100-1M PAGE 4 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
TECHNICAL SPECIFICATIONS.

Clayton Steam Generator model EO-100-1M PAGE 5 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
CHAPTER 1 : INTRODUCTION
This manual is intended to be used as instruction to operate the Clayton Steam Generator, providing
maximum safety, efficiency, and to guaranty reliable operation over an extended lifetime.
Read this manual carefully before commissioning the Steam Generator, so that the equipment is safely and
correctly installed, operated and serviced from the beginning.
Keep this manual available at all times for the operating and servicing personnel.
Record all important information such as operating conditions, including feedwater treatment analyses,
alarms, service interventions, in a logbook.
All activities (mounting, installation, operation and service work, etc.) must be performed by
qualified and authorized staff only.
Notify the serial number of the steam generator, which is indicated on the certification label / plate, on all
correspondence.
End Chapter - 1

Clayton Steam Generator model EO-100-1M PAGE 6 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
CHAPTER 2 : SAFETY INFORMATION
2.1 GENERAL, IMPORTANT INFORMATION
Read this instructions carefully, and look at the equipment to become familiar with the steam generator
before trying to install, operate, or service it.
Never install or start-up damaged products. Make a complaint about the damage to shipping company
immediately.
Installation, start-up, operation and maintenance may only be performed by qualified and authorized
personnel with the relevant training in accident prevention, in compliance with the valid regulations.
Normal ratings (pressures, temperatures, time settings, etc.) shall be durably marked.
Any modification on the steam generator shall only be performed in agreement with Clayton Industries, and
under supervision of authorized, competent personnel.
The owner is responsible for maintaining the unit in a safe operating condition. Parts and accessories shall be
replaced if unsuitable for safe operation.
Never remove or tamper with the safety devices, guards or insulations fitted on the unit. Every pressure
vessel or auxiliary installed outside the unit to contain gases or liquid above atmospheric pressure shall be
protected by a pressure-relieving device or devices as required.
The following special messages may appear throughout this documentation or on the equipment to warn of
potential hazards or to call attention to information that clarifies or simplifies a procedure.
DANGER Indicates an imminently hazardous situation, which, if not avoided, could result
in death, serious injury, or equipment or environment dammage.
WARNING Indicates a potentially hazardous situation, which, if not avoided, could result in
death, serious injury, or equipment or environment dammage.
CAUTION Indicates a potentially hazardous situation, which, if not avoided, could result in
serious injury or equipment or environment dammage.
2.2 INSTALLATION
Apart from general engineering practice in conformity with the local safety regulations, the following
directives are specially stressed:
A steam generator or its auxiliary equipment shall be lifted only with adequate equipment in conformity with
local safety rules. Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and retardation shall be kept within
safe limits.
Wear a safety helmet when working in the area of overhead or lifting equipment.
Any blanking flanges, plugs, caps and desiccant bags shall be removed before connecting up the pipes.
Distribution pipes and connections shall be of correct size and suitable for the working pressure.
Pipework or other parts with a temperature in excess of 80 degrees celsius and which may be accidentally
touched by personnel in normal operation shall be guarded or insulated.
Other high-temperature pipework shall be clearly marked.

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Instruction Manual, doc.nr.: MAN18206 Rev A PSC
2.3 OPERATION
If remote control is installed, the unit shall bear an obvious sign reading:
DANGER:This machine is remotely controlled and may start without warning.
As a further safeguard, persons switching on remotely controlled units shall take adequate precautions to
ensure that there is no one checking or working on the machine.
To this end, a suitable notice shall be affixed to the start equipment.
On units with automatic start-stop system, a sign indicating
"This machine may start without warning" shall be attached near the instrument panel.
Normal ratings (pressures, temperatures, time settings, etc.) shall be durably marked.
2.4 REST RISKS
2.4.1 GENERAL
A steam generator and its parts is based on physical processes, each with typical characteristics and possible
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 :
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.
Badly ventilated boiler rooms : Ambient temperature rise, lack of oxygen, dehydration, fainting, combustion
gasses accumulate in boiler room : suffocation, poisoning.
Foresee permanent or temporary ventilation through 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.
Frost : supercooling, exhaustion. Wear warm clothing. Contact with cold metals can lead to stiff and hence
less sensitive hands, creating a bigger chance for hand injury.
Rotating or 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 electrical power on this particular part. Use a lock
or remove 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.
Parts sticking out : body/head injury. Wear a helmet to prevent head injuries.
Wire-edges or sharp parts : Cuts. Bramble-edges from mechanical wear or dismantling of parts. Wear
gloves and use the right tools.
Welding and grinding : hot metal sparks. 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 2
nd
person is present with
extinguishing media and communication material so they can call for assistance in case of fire.
Difference in heights/obstacles : injury from falling down or tripping over. Check out 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.

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Instruction Manual, doc.nr.: MAN18206 Rev A PSC
Liquid/gas under pressure : skin penetration resulting in injuries, poisoning, eye damage. Fluids or gasses
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. Before taking any action, check out the situation.
Eventually put pieces of cloth around the parts that need to be opened so that possible fluids or gasses get
diffused. Close off isolated areas, so the fluids can be drained away and the pressure removed.
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.
Vacuum created by steam and/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 and/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.
Water-hammer . A mixture of 2 media such as water and steam in 1 pipe can create a 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.
Seams can be torn so that the steam escapes and/or the fixing of the piping gets damaged.
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.
Electrical parts : electrocution. Always cut the electrical power when working on electrical components.
This can be done by locking the main switch or by removing its key, when there is one 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.
Chemicals : burns and/or 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 centre and local aid services.
Noise hindrance : deafness, communication problems. Wear ear protection. If you work with 2 or more
persons in a noisy environment, make sure to communicate clearly. Eventually leave the noisy area to make
sure communication is not misinterpreted.
Human error : bad maintenance or wrong interpretation of circumstances. Provide training to operators and
maintenance workers.
Automation : unexpected circumstances f.i. automatic start of installation. A steam generator and its parts
can cause all of the safety hazards explained above, during maintenance or inspection. Although the
equipment is well protected, caution is needed at all times. Only trained personnel can operate or maintain
the generator, its devices or parts.
Please find below an explanation of the specific safety hazards, per part :
2.4.2 PUMP
Hot surface : The pump (1 or 2 depending on the model) is fed with hot water from the hotwell.
Frost : Do maintenance if a generator is not used during cold periods, ice can be formed in the parts
containing water

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Instruction Manual, doc.nr.: MAN18206 Rev A PSC
Fluid/gas under pressure : Steam/water can escape when dismantling various parts.
Manipulation of heavy and/or loose parts : When changing diaphragms, heavy pump sides and pipes need to
be disassembled. Make sure to have pulleys and assistance available.
Pre-stressed springs : Between the diaphragms and sides of each cylinder, a pre-stressed spring is mounted.
Electrical parts : Make sure to cut the power of the frequency controller and motor(s) of the pump(s)
Human error : A Clayton pump is fairly complex. Make sure to foresee operator and maintenance training.
Automation : the generator and pumps can be operated via a remote control
2.4.3 COIL AND STEAM / WATER SEPARATOR
CAUTION !
Testing of Safety valves
Open bonnet or spindle guides( Danger from leaking media): Make sure that no danger can arise from
leaking media. Keep a SAFE distance. Wear suitable protective equipment.
Hot medium(Burns or scalding): Wear suitable protective equipment.
Hot surfaces: Burns.
Hot surfaces : Hot feed water from the pump is pumped into the coil under pressure. As mentioned in the
“general” instructions, caution should be taken during repair or maintenance due to the temperature of the
piping and equipment. During dismantling or opening of parts steam and/or water could escape. This
especially goes true for the inspection calibration flange of the steam collector. A calibration pressure gauge
can be installed on this flange to monitor the calibration of the different measuring devices.
Frost : Do maintenance if a generator is not used during cold periods. Be aware of the fact that in cold
periods, the water in the coil/separator can be icy.
Parts sticking out : are present.
Difference in height and obstacles : The coil is mounted vertically. Use ladders or platforms during
maintenance on upper parts.
Fluid/gas under pressure : Be aware of the fact that steam and/or water can escape when opening or
dismantling various parts.
Water hammer : During manual operation of the valves, the steam/water mixtures cause water hammer.
Vacuum : created by the cooling down of steam/hot water. In generator parts closed off from the air and
filled with steam and/or hot water, a vacuum can be created after cooling. When opening these areas, a
strong suction can be created.
Electrical parts : make sure to cut off the electricity from motors and pumps.
Automation : the generator and pumps can be operated from a distance, as well as the steam generator itself.
2.4.4 FUEL AND AIR PIPING
Badly ventilated boiler rooms : The heating coil is surrounded by an air cover under a predefined over
pressure. As a result combustion gasses cannot leave the generator but only escape via the chimney.
However, if this system fails, combustion gasses can get into the boiler room. This problem could occur
when the air supply to the ventilator is blocked and hence no overpressure can be build up. Also poisonous
CO gas can be formed due to lack of oxygen. Therefore always make sure to close the gas street manually
and secure it via a lock, if maintenance or repair is needed.

Clayton Steam Generator model EO-100-1M PAGE 10 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
Frost : Do maintenance if a generator is not used during cold periods.
Rotating or moving parts : These are : motor, ventilator, belts and pulleys, oil fuel pump installed on blower
axe, oil fuel pump (motor + pump assembly). Always disconnect electrical power of the generator during
maintenance.
Height difference and hindrance : Be careful when taking samples of exhaust gasses at the coil outlet, in the
chimney or when inspecting the inlet of the blower.
Parts not strong enough to support body weight : the protective screen at the air blower entry
Electrical parts : Make sure to cut the power from all the motors, ventilators and oil pumps
Automation : Generator ,fuel and air hook-up can be started via remote control.
2.4.5 CERTIFICATION
The Clayton steam generator is designed and manufactured in compliance with:
Pressure Equipment Directive (PED) 97/23 EC
Machine Directive 98/37 EC
Low Voltage Directive 2006/95 EC
Electro Magnetic Compatibility (EMC) 2004/108/EC
Electrical safety EN 60204-1
Reviced Machine Directive 2006/42/EC
End Chapter - 2

Clayton Steam Generator model EO-100-1M PAGE 11 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
CHAPTER 3 : DESCRIPTION.
Flow diagram WATER / STEAM Drawing : HE-2528-C

Clayton Steam Generator model EO-100-1M PAGE 12 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
3.1 GENERAL
The Clayton steam generator will deliver its rated output of 99% quality steam (containing less than one
percent moisture). The generator will develop its full rated pressure within five minutes from a cold start.
Standard equipment includes safety devices for protection against water failure, burner failure, excessive
pressure, and electrical overload. Automatic controls regulate the flow of the feedwater and modulate the
burner in accordance with steam load demand. An attendant in charge, however, must give the equipment
the attention prescribed in this manual.
3.2 WATER AND STEAM SYSTEM
3.2.1 FLOW
Supply water and return condensate blend in the hotwell. Water is pumped directly from the hotwell into the
heating coil, flowing through the spiral single passage section of the coil in a direction opposite to that of the
combustion gases, where it is rapidly heated to steam temperature. As the fluid leaves the generator section,
it passes through the ring thermostat tube and helically wound water wall section, into the separator nozzle in
the steam separator. The centrifugal force in the nozzle separates dry steam from excess water, which
returns to the lower section in the separator. Steam is delivered through the steam discharge outlet located at
the top of the steam separator. The excess water is returned to the hotwell through the steamtrap.
3.2.2 WATERPUMP
The diaphragm type waterpump is designed to
deliver sufficient water to maintain a wet coil at
all operating conditions. The pump is driven by a
electric motor and contains no stuffing boxes.
The diaphragms are operated through hydraulic
oil which is displaced by reprocicating pistons.
Corrosion-resistant springs, discs and seats are
used in the check valve housings. Tubular
columns separate the check valve housings from
the pump heads to keep excessive temperature
from the diaphragms. Snubbers absorb pressure
pulsations to ensure stabilized pump delivery. A
relief valve protects the pump against excessive
pressure. A pump oil level switch, float operated,
is mounted to the waterpump with a sensing tube
plumbed to the pump crankcase. This pump oil
level switch will secure the plant if there is
improper oil level in the waterpump, either too
low or too high.
Heating coil and separator
Fluid is circulated through a single-pass, continuous steel tube (heating coil) where it is progressively heated
to the steam temperature. It is then discharged into the steam separator where steam and liquid are separated.
The heating coil is mounted to allow free expansion. It is arranged to provide maximum heat absorption by a
series of coils with fluid counterflowing the combustion gasses at controlled velocities. A tightly wound
helical section tube forms the fluid wall around the combustion chamber.
A feedwater pressure gauge is mounted on the pump. A higher pressure indication than normal and/or a
leaking relief valve on the waterpump indicates a formation of scale or even partial restriction of the heating
coil.

Clayton Steam Generator model EO-100-1M PAGE 13 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
3.2.3 STEAM SEPARATOR
Steam and fluid entering the separator from the heating coil are discharged through a separating nozzle
where steam is released and excess water is centrifugally separated. The excess water passes to the lower
section of the separator where it is trapped back to the hotwell. This positive control of separation prevents
carry-over of liquid into the steam lines.
3.2.4 STEAM TRAP
The steam trap returns excess water from the separator.
A pressure gauge has been mounted on the steam trap
discharge line. It has been 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
condensate. When the pressure begins to drop, the trap is
closed. If the steam trap is not opening and closing in a
normal matter, this would indicate malfunctioning of the
trap or some other component in the steam generator.
Also the waterpump may not be discharging its normal
capacity or the blowdown valve may be partially open.
On initial start of the plant, after the correct air-fuel and
water rates have been established, a record of the steam
temperature and trap opening time should be recorded.
Periodically, these figures can be checked to assure the
operator that the generator is operating properly.
If the steam generator is connected to an open system where the feedwater temperature is 90 to 95°C, the
steam trap should be open approximately 10 to 15 minutes (accumulated) of each hour at high-fire operation.
At steady half-fire, the accumulated time should be half this amount.
By checking and recording the operation time of the steam trap under normal conditions, malfunctioning of
the generator can be noted. If a component such as the waterpump (which has a fixed pumping rate) does
not work properly, the opening time of the steam trap will differ from above values. An increase in the firing
rate or decrease in the pump rate will likewise decrease the trapping time. Trap open time should not fall
below 3 minutes per hour at high-fire and 2 minutes per hour at low fire (accumulated) under any condition.
When starting the generator, or during periods of abrupt load changes, excess heating coil liquid may enter
the separator, where it is carried off by the steam trap.
3.2.5 TEMPERATURE SENSOR
The temperature sensor protects
the heating unit against
overheating. Temperature sensor
B29 is mounted in the wall of the
heating unit In case of
overheating of the tube wall, at a
temperature approx. 50°C above
saturation temperature , the
generator will shut down. When
the alarm condition is corrected
the generator must be manually
restarted.
Temperature sensor mounted in the wall of the heating unit

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Instruction Manual, doc.nr.: MAN18206 Rev A PSC
Flow diagram FUEL OIL ( HE-2673-C )

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Instruction Manual, doc.nr.: MAN18206 Rev A PSC
3.3 FUEL SYSTEM OIL FIRED UNITS ( DRAWING HE-2673 )
Fuel is delivered to the forced draft burner under pressure. Fuel pressure is governed by an adjustable fuel
pressure regulator [11]. Burner modulation is achieved by the electrically operated low fire [Y42] and high
fire [Y43] solenoïd valves. After manual start, oil will enter through the burner nozzle after a prepurge
period and be ignited by an electric spark. Burner operation is fully automatic and all controls are arranged to
fail safe. Flame failure will cause automatic shut-off within one second. A switch [F81]+[F82] operated by
combustion air pressure is provided to shut down the generator if the motor or blower fails.
Control of the air is accomplished by electrically operated [M83] motor air damper.
3.4 AUTOMATIC BURNER MODULATION
Automatic burner modulation prevents frequent on/off cycling of the burner and provides stable operation
during periods of low load. This is accomplished by controlling the burner by means of the electrically
operated three position (off, low-fire and high-fire) main gas valve with an adjustable low fire position.
When steam pressure rises to the adjusted modulation point [F22] the gas valve will close to the low fire
position. When the burner modulates, the solenoid operated automatic damper restricts the burner air supply
to maintain oil-fuel ratio. The unit will automatically return to high fire operation if low fire operation will
not carry the steam demand. A manually operated switch [S1] on the electrical control box prevents high fire
operation when desired or when making certain burner adjustments.
Control of the air is accomplished by electrically operated [M83] motor air damper.
3.5 BURNER MANIFOLD
Air entering the burner volute from the blower, is centrifugally directed at high velocity to the burner
manifold, where it blends with the fuel. Fuel is automatically ignited by an electric spark. A flame detector is
incorporated to detect the flame and maintain safe burner operation.
Steam pressure
(bar)
Steam temp.
(°C)
Steam pressure
(bar)
Steam temp.
(°C)
1
120
11
188
1,4
126
13
195
1,8
131
15
201
2
134
17
207
2,4
138
19
212
2,8
142
21
217
3
144
23
222
3,5
148
25
226
4
152
27
230
5
159
29
234
6
165
31
237
7
170
33
241
8
175
35
244
9
180
Steam pressure - steam temperature
End Chapter - 3

Clayton Steam Generator model EO-100-1M PAGE 16 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
CHAPTER 4 : ELECTRICAL SYSTEM & MAIN COMPONENTS
4.1 DESCRIPTION OF MAIN COMPONENTS
For the description of the main components, we refer to the electrical drawing(s). in the Clayton Binder
The last pages of these electrical drawings contain the function of the components.
4.2 OPERATION
4.2.1 GENERATOR ON
S10 = POWER ON
S1 = 1-STOP -2- PUMP -3- BURNER -4- High FIRE
S02 = RESET
All the alarms are wired in series. In case one of the alarms opens, it interrupts the power supply to burner
control and motor. Also the specific alarm relay is energized causing a second interruption of the circuit to
burner and motor. Exact cause of failure can be determined from alarm indication light on the control box.
From the [LAL2] combustion controller, via the normally closed contacts of the alarm relais, power is
transmitted via the "no air" contact of [F81] to the motor contactor. (in case a boosterpump is connected, it
now starts). The motor contactor or support relay asures +-30" pre-purge at initial generator start. From this
contact power is transmitted to the burner switch [S01 position burner ]
4.2.2 BURNER ON
- S01 = Burner position
When the switch [S01] is placed in the burner position, power is transmitted through steampressure switch
[F20] to combustion controller, initiating the start-up of the burner..
Now the ignition transformer is energized.. Burner should ignite within 2" and the flame detected by the
[UV-B3 ]flame scanner. Now the burner operates at low fire. Combustion air rate and waterpump rate are at
50%. Waterpump runs at low speed and MOTOR AIR DAMPER [M83]. is energized
4.2.3 BURNER MODULATION
S01 = Position high fire
When [S01] and steampressure switch [F22] are closed and after the high fire delay of +-25 seconds, the air
damper is opened, switching on the high fire oil valve [Y43] . At same time the waterpump operates at full
capacity.( motor at high speed)
When steampressure reaches set point of the modulating steampressure switch [F22], this switch opens and
the high fire oil solenoid valve is de-energized. Simultaneously the waterpump operate at half capacity, low
speed , also the air damper [M83] is energized restricting the air flow to the burner to half rate. This pressure
switch is normally set to operate +/- 1 bar below the steam operating pressure switch [F20.]
4.2.4 BURNER STOP AT MAXIMUM STEAM OPERATING PRESSURE
At maximum steam operating pressure, pressure switch [F20] opens the circuit to the combustion controller,
causing the oil valves [Y42 & Y43] to close and the combustion controller to cycle to its start position.
Simultaneously the waterpump stops.. When steam pressure has fallen +/- 1 bar [F20] restarts the burner and
waterpump according the program described previously.
For this manual the electrical drawing is SW-3192

Clayton Steam Generator model EO-100-1M PAGE 17 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
4.2.5 ALARM STOP
All alarms interrupt the circuit to the combustion controller and the motor, and consequently stop the
steamgenerator. In all these cases the accompanying alarm failure lamp is lit up. After the failure is
corrected the unit can be reset with button [S02].
The unit is equipped with the following alarms :
H-10 : stops the unit in case of generator motor overload or wrong oil level in waterpump
crankcase.
H-21 : stops the unit in case of excessive steam pressure.
H29 stops the unit in case of coil temperature
H-31 : stops the unit in case of high steam temperature.
H-81 : stops the unit in case of insufficient combustion air pressure. or flame failure.
H-200 : stops the unit in case of external conditions.
H-47 : stops the unit in case of minimum fuel pressure / burner failure
End Chapter - 4

Clayton Steam Generator model EO-100-1M PAGE 18 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
CHAPTER 5 : INITIAL FIRING.
5.1 BEFORE FIRING
Every steam generator is thoroughly tested and all adjustments are correctly made under actual operating
conditions before shipment from the factory. Rough handling in shipment may cause loosening of plumbing
connections or change some of the adjustments. It is recommended that the following procedure be carried
out before initial starting to ensure satisfactory operation.
• Visually inspect and tighten any loose plumbing connections and make sure plant has been installed in
accordance with installation manual (ref 191.076), regarding fuel system, exhaust systems, etc...
• Check rotation direction of the blower. This can be checked by removing the inspection cover on the
air inlet duct.
• Verify that all fuel lines are open and fuel circulation through the burner circuit is present. If operated
without fuel, the fuel pump will quickly score and be damaged. When initially starting, disconnect
return line to check flow and thus be sure that fuel is circulating.
• Suitable watertreatment equipment should be installed before steam generator is placed in service.
Adequate water treatment MUST be used from the time the generator is first operated.
It is IMPORTANT that the coil overheating protection be tested after the generator has been initially started
and brought up to operating steam pressure. The sensor ( thermocouple or PT-100 ) should be tested
periodically to ensure continuous protection.
• After proper firing rate has been established, check coil feed pressure at high fire. Record steam
pressure and coil feed pressure for future reference.
5.2 CONDITIONING OF NEW INSTALLATIONS OR INSTALLATIONS WITH A NEW COIL
5.2.1 PURPOSE
To remove residual mill scale, metal shavings, oils and other contamination captured within the heating coil
& feedwater system during installation of the steam generator, its ancillary equipment, and the feedwater
system. It is essential to “boiled out” the plant prior to full commissioning of the generator to prevent
deposits from attaching themselves to the coil tube wall.
5.2.2 STEP 1
• Flush out the hotwell and steam generator system, using soft water.
• Thoroughly dissolve 5 kg (10 lbs) of commercial tri-sodium phosphate (Na
3
PO
4
.10H
2
O) or 2,5 kg (5
lbs) pure (anhydrous) tri-sodium phosphate (Na
3
PO
4
)in softened water in a separate container per m³
(250 gallons) water. Ratio amounts listed above based on the volume required to fill the applicable
coil, separator, and receiver tank being installed.
• In order to ease the dissolving of the product, it is strongly recommended to use hot softened water at
or above 60°C (140°F)
• Add the tri-sodium phosphate mixture to the receiver.
• Operate the steam generator & feedwater system (plant) for at least one hour.
• Blowdown the plant.

Clayton Steam Generator model EO-100-1M PAGE 19 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
With plant operating at normal steam pressure, open separator drain valve
After 30 seconds, shut off burner and close steam discharge valve
Open coil drain valve and close separator drain valve
When steam pressure drops to zero, close coil drain valve
5.2.3 STEP 2
• Mix another solution of tri-sodium phosphate, this time using 2,5 kg (5 lbs) of commercial tri-sodium
phosphate or 1,25 kg (2½ lbs) pure (anhydrous) tri-sodium phosphate per m³ (250 gallons) water.
Again, ratio the volume to fill the applicable coil, separator, & receiver.
• Add this solution to the receiver and allow the plant to operate normally for 10 to 12 hours.
• Blowdown the plant again as instructed
This should completely clean the system of all construction and installation residues.
End Chapter - 5

Clayton Steam Generator model EO-100-1M PAGE 20 / 70
Instruction Manual, doc.nr.: MAN18206 Rev A PSC
CHAPTER 6 : OPERATION.& SHUTTING DOWN
6.1 GENERAL
The guidelines in this section are intended in the first instance to make the service personnel confident with
each phase of the operation of the steam generator. Remarks and notes are inserted to underline the
importance of specific points. Reference numbers in the text refer to the electrical components described in
the electrical plan or to appendices described in the generator’s P&ID diagrams.
Please read the instructions and remarks in the instruction handbook fully before starting up the generator.
Faults arising as a result of failure to observe these instructions relating to maintenance, tests and inspection
of the generator parts will render the guarantee for the installation null and void.
6.2 BEFORE STARTING
- Close : - Soot blower valve [28], only for oil and oil/gas fired units
- Steam discharge valve [47]
- Coil drain valve [25]
- Drain cock at base water pump
- Open : - Water supply to the hotwell
- Coil feed valve [26]
- Valve steam Trap (35)
6.3 STARTING PLANT
• Place all switches in "off" position.
• Start motor by switching [S01]. The generator motor starts now. If motor does not start and the yellow
alarm lamp is lit up, then push [S02],
• Prime feedwaterpump housing [40] by opening bleeder cock, until air is expelled. If pump fails to
prime, loosen intake valve cap two turns (wrench furnished) to eliminate air, then retighten. When
plant is started initially, or if it has been idle for a long time, remove intake and discharge valves from
feedwaterpump housings and wipe the discs and seats with a clean cloth to ensure proper seating. Be
sure check valves are installed into the same port from which they were removed.
• If pump fails to prime after inital start or at any time when the unit is started completely dry, stop plant
and close feedwater intake valve [20]. Remove check valves from feedwater pump. Then open
feedwater intake valve [20] just anough to allow pump columns to fill completely. When pump is full,
replace check valves. Reopen feedwater intake valve and restart plant.
• Check waterpump prime by throttling coil feed valve until pressure rises to XX bar. If feed pressure
does not rise to XX bar, prime waterpump in similar manner as explained. Reopen coil feed valve
[26] after check.(XX See QC-1039 test sheet)
• If plant is completely dry or if plant is restarted (not completely filled with water), allow 20 minutes
for the pump to fill heating coil. Rising pressure registered on the steam pressure gauge indicates that
water has reached the steam separator.
• If plant is wet shut-down, burner can be started immediately
CAUTION : Be sure all fuel lines are open and fuel circulation through burner circuit is
present. If operated without fuel, the fuel pump will be quickly score and be damaged. When
initially starting, disconnect return line to supply tank to check flow and thus be sure that fuel is
circulating