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