Clayton Steam Master CSMG-15 User manual

STEAM MASTER SERIES
USER MANUAL
Cover
CSMG-15/30/40
R027880B-20190603

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

i
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 accessing the control
box for maintenance. Disconnect and lock out main power circuit switchbefore 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.

ii
Personnel must become thoroughly familiar with all aspects of safe and proper
operating and maintenance procedures before attempting to operate or maintain this
machine.
IF A STRONG SMELL OF GAS IS DETECTED, IMMEDIATELY OPEN DOORS 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 THAT 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.

iii
IMPORTANT INFORMATION
PLEASE READ THIS PAGE CAREFULLY
1. READ THIS INSTRUCTION MANUAL AND THE INSTALLATION MANUAL CAREFULLY BEFORE INSTALL-
ING, OPERATING, OR SERVICING THE STEAM GENERATOR UNIT. KEEP ALL INSTRUCTIONS IN LEGIBLE
CONDITION AND POSTED NEAR THE STEAM GENERATOR FOR REFERENCE BY OWNER AND SERVICE
PERSONNEL.
2. All steam generator units must be installed in accordance with ASME, national, state, and local plumbing, heating, and
electrical codes and regulations. Consult the proper authorities having jurisdiction over the installation site prior to
installing any steam generator.
IN ALL CASES, REFERENCE SHOULD BE MADE TO THE FOLLOWING STANDARDS:
USA BOILERS
A. Current edition of the American National Standard ANSI Z223.1/NFPA54, National Fuel Gas Code, or ANSI/
NFPA 31, “Installation of Oil Burning Equipment,” for clearances between heating unit, vent connector, and
combustible material.
B. Current edition of the American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid
Fuel Burning Appliances,” for Chimney requirements, types of venting material and clearances between vent
connector pipe and combustible materials.
C. Current edition of the American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety
Devices for Automatically Fired Boilers,” for assembly and operations of controls and safety devices.
CANADA BOILERS
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equip-
ment,” for recommended installation practices.
B. The equipment shall be installed in accordance with the current installation code for gas burning appliances
and equipment, CGA B149, and applicable provincial regulations for the class, which should be followed in
all cases. Consult the proper authorities having jurisdiction over the installation site prior to installing any
steam generator.
3. Heating systems should be designed by licensed contractors, only. Installation of a steam generator should be performed
only by persons qualified in the layout and installation of boiler systems (including ASME code).
4. The steam generator must be properly vented in accordance with the National Fuel Gas Code and local codes. Failure to
adhere to these codes may result in serious property damage.
5. The Contractor will be responsible for verifying that all operating and safety controls are correctly installed and are
functioning properly before signing off on a project.
6. Do NOT tamper with the steam generator or its controls. To assure the steam generator is maintained properly, only
qualified service personnel should perform adjustments and maintenance on the equipment.
7. KEEP THE AREA AROUND THE STEAM GENERATOR FREE AND CLEAR OF ALL FLAMMABLE MATE-
RIAL; SUCH AS, RAGS, PAPERS, AND WOOD SCRAPS, AT ALL TIMES.

iv
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.)

v
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.

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

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

viii
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

ASME Conformance Statement
A Clayton Steam Generator is manufactured in conformance with the ASME (Ameri-
can Society of Mechanical Engineers) Power Boiler Code, Section I. Construction
and inspection procedures are regularly monitored by ASME certification officials
and by authorized inspectors commissioned by the jurisdiction and the NBBI
(National Board of Boiler and Pressure Vessel Inspectors). The NBBI is responsible
for enforcement of all ASME code sections applicable to steam boiler manufactur-
ing.
The NBBI is a nonprofit organization. Its chief boiler and pressure vessel inspectors
are responsible for administering the boiler and pressure vessel safety laws of their
jurisdiction.
Clayton Steam Generators are designed with electrical and combustion safeguards
which comply with UL (Underwriters Laboratories) and other such agency require-
ments as specified in a customer's order.
NBBI certification and UL compliance assures that a Clayton Steam Generator is
reliable and capable of producing the high quality steam it was designed to deliver.
All Clayton Steam Generators are built to conform to the rules and practices for
safety and durability of the highest recognized regulatory authority.

CLAYTON INDUSTRIES
17477 Hurley Street
City of Industry, California 91744-5106
USA
Phone: [phone]
Fax: [phone]
Internet: www.claytonindustries.com
Email: [email protected]
© Copyright 2018 Clayton Industries. All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means
(electronic, mechanical, photocopy, recording, or otherwise) without written permission from Clayton Industries.
The descriptions and specifications shown were in effect at the time this publication was approved for printing. Clayton
Industries, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or
change specifications or design without notice and without incurring any obligation.
FACTORY DIRECT SALES AND 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_CSM_a.fm xi 11/22/2018
SPECIFICATIONS
Units of
Measure-
ment CSM-15 CSM-15-SE CSM-30 CSM-30-SE CSM-40 CSM-40-SE
Boiler Horsepower bhp 15 15 30 30 40 40
Heat Input: Gas Btu/hr 619,907 590,735 1,239,815 1,181,471 1,653,086 1,575,294
Net Heat Output Btu/hr 502,125 502,125 1,004,250 1,004,250 1,339,000 1,339,000
Equivalent Output (From and at 212°F
feedwater and 0 psig steam.) lbs/hr 518 518 1,035 1,035 1,380 1,380
Design Pressure (See Note 1.) psig 150 150 150 150 150 150
Steam Operating Pressure psig 65–125 65–125 65–125 65–125 65–125 65–125
Gas Consumption—at maximum steam
output (See Note 2.) ft3/hr 620 591 1,240 1,182 1,653 1,575
Burner Controls (modulating gas) 4:1 turndown 4:1 turndown 4:1 turndown 4:1 turndown 4:1 turndown 4:1 turndown
Efficiency(gasfired) % 818581858185
Electric Motors—design pressure 150 psi hp Blower=0.67
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 Blower=0.83 Pump=1.5
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 ft278.6 110.9 141.0 199.1 152.8 228.2
Customer Connections:
Feedwater Inlet in. 1.5 1.5 1.5 1.5 1.5 1.5
Steam Trap Discharge in. 1.0 1.0 0.75 0.75 1.0 1.0
Separator Blowdown in. 1.0 1.0 0.75 0.75 1.0 1.0
Economizer Drain in. 1.0 1.0 1.0 1.0 1.0 1.0
Supply Gas Inlet in. 0.75 0.75 0.75 0.75 1.0 1.0
Steam Discharge Outlet in. 1.5 1.5 1.0 1.0 1.5 1.5
Safety Relief Valve in. 1.0 1.0 1.0 1.0 1.0 1.0
Exhaust Gas Outlet in. 7.88 7.88 9.88 9.88 9.88 9.88
Overall Rough Dimensions
length in. 69 69 77 77 85 85
width in. 50 50 56 56 56 56
height in. 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
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/ft3.
3. Continuous running 230 vac/1 ph/60 Hz power supply required.

Specifications_CSM_a.fm xii 11/22/2018
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xiii
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

xiv
3.1.11 Vacuum Created By Steam or Hot Water Cooling Down ...................................... 3-2
3.1.12 Water Hammer ................................................................................................... 3-2
3.1.13 Pre-stressed Springs .......................................................................................... 3-2
3.1.14 Electrical Parts ................................................................................................... 3-2
3.1.15 Chemicals .......................................................................................................... 3-2
3.1.16 Loud Excessive Noise ......................................................................................... 3-2
3.1.17 Human Error ....................................................................................................... 3-2
3.1.18 Automation ......................................................................................................... 3-3
3.2 Feedwater Pump ......................................................................................................... 3-3
3.2.1 Hot Surface ........................................................................................................ 3-3
3.2.2 Freezing Conditions ............................................................................................ 3-3
3.2.3 Fluid Under Pressure .......................................................................................... 3-3
3.2.4 Handling Heavy and Loose Parts ........................................................................ 3-3
3.2.5 Compressed Springs ........................................................................................... 3-3
3.2.6 Electrical Parts ................................................................................................... 3-3
3.2.7 Human Error ....................................................................................................... 3-3
3.2.8 Automation ......................................................................................................... 3-3
3.3 Heating Coil and Steam Separator ............................................................................... 3-3
3.3.1 Hot Fluids ........................................................................................................... 3-3
3.3.2 Hot Surfaces ....................................................................................................... 3-3
3.3.3 Freezing Conditions ............................................................................................ 3-3
3.3.4 Fluid Under Pressure .......................................................................................... 3-4
3.3.5 Water Hammer ................................................................................................... 3-4
3.3.6 Vacuum .............................................................................................................. 3-4
3.4 Fuel and Air Piping ...................................................................................................... 3-4
3.4.1 Poorly-vented Boiler Room ................................................................................. 3-4
3.4.2 Explosion Risk .................................................................................................... 3-4
3.4.3 Falling Risk ......................................................................................................... 3-4
Section 4 Operating Instructions ......................................................................................................4-1
4.2 Main Menu Screen ...................................................................................................... 4-1
4.3 Start up Auto Mode ...................................................................................................... 4-1
4.4 Start Mode ..................................................................................................................4-2
4.4.1 Easy Start ........................................................................................................... 4-3
4.4.2 Operator Start ..................................................................................................... 4-3
4.5 Manual Mode Operation .............................................................................................. 4-3
4.5.1 Manual Fill Mode ................................................................................................ 4-3
4.5.2 Manual Firing Mode ............................................................................................ 4-4
4.6 Restart After Momentary Shut Down ............................................................................ 4-4
4.7 Intermittent Fill/Wet Lay-up ......................................................................................... 4-5
4.8 Dry Shut Down ............................................................................................................ 4-5
4.9 Advanced-Level Screens ............................................................................................. 4-6
4.9.1 Modify Set Point and Tune PID Screens .............................................................. 4-6
4.9.2 Calibration Screens ............................................................................................ 4-7
4.10 Alarm Screens .............................................................................................................4-8
4.10.1 Alarm Annunciation ............................................................................................. 4-8
4.10.2 Alarm History ...................................................................................................... 4-8
4.11 Maintenance Drain ...................................................................................................... 4-8

xv
Section 5 Troubleshooting ................................................................................................................5-1
5.2 Water System .............................................................................................................. 5-2
5.3 Fuel System - Gas-fired Machines ............................................................................... 5-3
5.4 Electrical System ......................................................................................................... 5-4
5.5 Weishaupt Packaged Burner Unit ................................................................................ 5-5
Section 6 Periodic Maintenance ........................................................................................................6-1
6.2 Feedwater Treatment .................................................................................................. 6-1
6.3 Daily Service ...............................................................................................................6-1
6.3.1 Record Operating/ Steam Pressure ..................................................................... 6-1
6.3.2 Trap Timing ........................................................................................................ 6-1
6.3.3 Test and Record Feedwater ............................................................................... 6-1
6.3.4 Manual Blowdown ............................................................................................... 6-1
6.3.5 Walk-Around Inspection ...................................................................................... 6-1
6.4 Weekly Service ........................................................................................................... 6-2
6.4.1 Steam Generator Unit ......................................................................................... 6-2
6.4.2 Hot-well Tank ...................................................................................................... 6-2
6.4.3 Belt Tension ........................................................................................................ 6-2
6.5 Monthly Service ........................................................................................................... 6-2
6.5.1 Check Coil Feed Pressure .................................................................................. 6-2
6.5.2 Flush Water Pump Heads And Columns .............................................................. 6-3
6.5.3 Check Dual Element Thermocouple Sensor ........................................................ 6-3
6.5.4 Check Main Temperature Limit Controllers (MTLC) ............................................. 6-4
6.5.5 Clean Strainers ................................................................................................... 6-5
6.5.6 Drain and Flush Hot-well Tank ............................................................................ 6-5
6.5.7 Inspect Intake Surge Chamber and Snubber ....................................................... 6-5
6.6 Semi-annual Service ................................................................................................... 6-6
6.7 Annual Service ............................................................................................................ 6-6
6.7.1 Replace Check-valves ........................................................................................ 6-7
6.7.2 Replace Feedwater Pump Diaphragms and Seals ............................................... 6-7
6.7.3 Test Steam Safety Valve ..................................................................................... 6-7
6.7.4 Service Compact Burner Unit ............................................................................. 6-7
6.8 Heating Coil Scale Removal ........................................................................................ 6-7
6.8.1 Setting Up Machine For Descaling ...................................................................... 6-7
6.8.2 Descaling The Machine ...................................................................................... 6-9
6.8.3 After Descaling Is Complete .............................................................................. 6-10
Section 7 Component Maintenance ...................................................................................................7-1
7.2 Feedwater Pump Maintenance .................................................................................... 7-2
7.2.1 Check-Valve Maintenance ................................................................................... 7-2
7.2.2 Replacing Check-Valve Seats ............................................................................. 7-2
7.2.3 Diaphragm Replacement .................................................................................... 7-3
7.2.4 Pump Disassembly ............................................................................................. 7-5
7.2.5 Inspect and Repair Pump .................................................................................... 7-5
7.2.6 Pump Reassembly .............................................................................................. 7-5
7.2.7 Install High Strength Studs .................................................................................. 7-6

xvi
7.3 Feedwater Pump Relief Valve ...................................................................................... 7-7
7.3.1 Adjustment ......................................................................................................... 7-7
7.4 Temperature Controllers (MTLC1, MTLC2) .................................................................. 7-7
7.4.1 Check Main Temperature Limit Controllers .......................................................... 7-7
7.5 Operating Pressure Switch (OPS) Adjustment ............................................................. 7-8
7.6 Limit Pressure Switch (LPS) Adjustment ...................................................................... 7-8
7.6.1 Adjustment ......................................................................................................... 7-8
7.7 Gas Pressure Switches ............................................................................................... 7-8
Steam Generator List of Parts ........................................................................................................... A-1
Fig. 01A - Main Heating Section–SM15 ............................................................................... A-2
Fig. 01B - Economizer Stack Outlet Kit–SM15 ..................................................................... A-4
Fig. 01C - Main Heating Section–SM30 .............................................................................. A-6
Fig. 01D - Economizer Coil–SM30 ...................................................................................... A-8
Fig. 01C - Main Heating Section–SM40 ............................................................................ A-10
Fig. 01D - Economizer Coil–SM40 (Sht 1 of 2) ................................................................. A-12
Fig. 02A - Steam Discharge and Separator Hookup—SM-15 ............................................. A-14
Fig. 02B - Steam Discharge and Separator Hookup—SM-30/40 ........................................ A-16
Fig. 02C - Steam Trap and Control Valve Hookup .............................................................. A-18
Fig. 02D - Safety Relief Valve Hookup ............................................................................... A-19
Fig. 02E - Pressure Indicating System ............................................................................... A-20
Fig. 04A - Feedwater Pump Hookup–C1 ........................................................................... A-22
Fig. 04B - Feedwater Pump Hookup–C2 ........................................................................... A-23
Fig. 05A - Pump Assy–C1 ................................................................................................. A-24
Fig. 05B - Pump Assy–C2 ................................................................................................. A-26
Fig. 06 - Check Valve ........................................................................................................ A-28
Fig. 07 - Relief Valve ......................................................................................................... A-28
Fig. 09 - Fuel Gas System ................................................................................................. A-29
Fig. 13 - Electrical Control Box .......................................................................................... A-30
Fig. 18 - Separator High Level Alarm Kit ............................................................................ A-31
Feedwater Skid Option List of Parts ................................................................................................. B-1
Fig. 01 - Vertical Hotwell ..................................................................................................... B-2
Fig. 02 - Water Softener Plumbing Hookup .......................................................................... B-2
Fig. 03 - Water Level Indication and Control ........................................................................ B-3
Fig. 04 - Water Temperature and Blowdown Tank Hookup .................................................... B-3
Fig. 05 - Sparger Tubes–Water Heating .............................................................................. B-4
Fig. 06 - TDS Control System—Equipment Option .............................................................. B-4
Fig. 07 - Circulation Pump Hookup - TDS System ................................................................ B-5
Fig. 08 - Booster Pump Hookup ........................................................................................... B-5
Fig. 09 - Sample Cooler/Water Sampling ............................................................................ B-5
Fig. 10 - Optional Sparger Tube–Water Heating .................................................................. B-5

10/02/2018 1-1 Sect01_CSMG_a.fm
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 dam-
age or destruction of the equipment that may
lead to loss of operating effectiveness.
These paragraphs warns of dan-
gerous voltage environments.
Extreme care must used when
working in these conditions to avoid
bodily injury.
These paragraphs highlight operat-
ing conditions, recommendations,
and suggestions for efficient oper-
ating procedures.
1.2 General
This manual contains instructions for operat-
ing 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 mainte-
nance requirements of the Clayton Steam Genera-
tor. The information contained in this manual
applies to gas-fired machines. Section II of this
manual acquaints you with the machine. This sec-
tion provides an overview and descriptions of a
machine’s systems, such as the water supply and
fuel system. The machine overview includes a dis-
cussion 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 pro-
cedure and other pre-startup requirements are dis-
cussed 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 trouble-
shooting procedures for problems that may occur
during the machine’s operation. Section VI dis-
cusses the scheduled maintenance requirements that
will help maintain the efficiency and reliability,
increase the operating life, and minimize the down-
time of the machine. Section VII contain procedures
for maintaining, repairing, or replacing components
and assemblies on the machine.
The appendices at the end of this manual con-

Sect01_CSMG_a.fm 1-2 10/02/2018
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 con-
tains 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 equip-
ment 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 num-
ber: R015216) is provided with every Clayton Steam
Generator. This manual covers the available water
treatment packages from Clayton, general guide-
lines on scheduled feedwater maintenance, and the
appropriate chemicals required for treatment to min-
imize the down time of your machine.