Superior Boiler Works Creek XL User manual

CREEK XL BOILER MANUAL
Condensing Water Boiler
3000-5500 MBtu/Hr.
Gas/Oil
Superior Boiler Works, Inc.
3524 E. 4th Avenue
Hutchinson, KS 67501
[phone]
www.superiorboiler.com
Manufactured in the USA
to the ASME boiler and
pressure vessel code.

Creek XL Boiler Manual
2 Revision 2015.12.01
Contents
GENERAL ...........................................................................................................................................................5
Documents Unique to your boiler ....................................................................................................................5
Supplementary Manuals: ..................................................................................................................................5
Acronyms, Definitions, Standards, & Sources .................................................................................................6
Introduction to safety........................................................................................................................................7
Approvals & Recordkeeping ............................................................................................................................8
1 BOILER SIGNAGE ............................................................................................................................................10
2 BOILER COMPONENT IDENTIFICATION....................................................................................................17
2.1 Boiler Specifications and Dimensions..........................................................................................................17
2.2 Cross Sections ..............................................................................................................................................18
2.3 Typical Instrumentation Spools....................................................................................................................19
2.4 Burner Mounting ..........................................................................................................................................19
2.5 Gas Train ......................................................................................................................................................20
3 SPECIFICATIONS .............................................................................................................................................21
4 BOILER INSTALLATION.................................................................................................................................22
4.1 Receiving the Boiler .....................................................................................................................................22
4.2 Unloading the Boiler-Burner Unit................................................................................................................22
4.3 Boiler Unloading Instructions ......................................................................................................................23
4.4 The Boiler Room ..........................................................................................................................................24
4.5 Extended Storage Procedure for Boilers not yet installed. ...........................................................................24
4.6 Casing Panel Installation ..............................................................................................................................25
4.7 Installation of Loose Shipped Items .............................................................................................................28
4.8 Electrical Installation....................................................................................................................................29
4.9 Miscellaneous Installation Guidelines..........................................................................................................30
4.10 Boiler Stack Connection.............................................................................................................................30
4.11 Vent Material Selection..............................................................................................................................31
5 Plumbing your Boiler ..........................................................................................................................................32
5.1 Fuel Supply & Connections..........................................................................................................................32
5.2 Boiler Connections, General.........................................................................................................................32
5.3 Water Connections .......................................................................................................................................32
5.4 Hot Water Boilers Supply & Return Connections........................................................................................32
5.5 Drains ...........................................................................................................................................................33
5.6 Drain connections.........................................................................................................................................33
5.7 Condensate Drain Connection ......................................................................................................................33
5.8 Safety relief valves (SRV)............................................................................................................................34

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Revision 2015.12.01 3
5.9 SRV Discharge Piping..................................................................................................................................34
6 Boiler Start-up .....................................................................................................................................................35
6.1 Operating Data..............................................................................................................................................35
6.2 Start-up Guidelines.......................................................................................................................................35
6.3 Tools & Gauges............................................................................................................................................36
6.4 Fuel Guidelines.............................................................................................................................................36
6.5 Cleaning and Filling a New Boiler ...............................................................................................................36
6.6 Firing a New Boiler ......................................................................................................................................37
6.7 Boil-out Procedure........................................................................................................................................37
6.8 Start-up of Hot Water Boilers.......................................................................................................................38
6.9 Good practice recommendations for hot water boilers.................................................................................39
6.10 Guidelines for hot water boiler heating system. .........................................................................................39
7 Operation .............................................................................................................................................................40
7.1 Safety Relief Valves .....................................................................................................................................40
7.2 Gauges ..........................................................................................................................................................41
7.2.1 Pressure Gauges.....................................................................................................................................41
7.2.2 Pressure Gauge range ............................................................................................................................41
7.2.3 Pressure Gauge Accuracy......................................................................................................................41
7.2.4 Pressure gauge calibration .....................................................................................................................42
7.2.5 Temperature gauges...............................................................................................................................42
7.2.6 Pressure or altitude gauges ....................................................................................................................42
7.2.7 Stack thermometers ...............................................................................................................................42
7.3 Temperature controls....................................................................................................................................42
7.3.1 High limit: .............................................................................................................................................42
7.3.2 Operator:................................................................................................................................................42
7.3.3 Firing rate control:.................................................................................................................................42
7.4 Maintenance on temperature limiting controls.............................................................................................42
7.5 Example of control set point adjustment procedure .....................................................................................43
7.6 Water level controls......................................................................................................................................43
7.6.1 Electric probe type low-water fuel cutoffs ............................................................................................43
7.6.2 Low-water fuel cutoff and water feeder maintenance ...........................................................................43
7.6.3 Low-water cutoff (LWCO)....................................................................................................................43
7.7 Water level operations..................................................................................................................................44
7.8 Water Treatment...........................................................................................................................................44
7.8.1 Heating boilers.......................................................................................................................................45
7.8.2 Water treatment guidelines....................................................................................................................45

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4 Revision 2015.12.01
7.9 Access openings and Combustion Chamber.................................................................................................46
7.9.1 Burner mounting....................................................................................................................................46
7.9.2 Door Aperture........................................................................................................................................46
8 MAINTENANCE................................................................................................................................................47
8.1 Spare Parts. ...................................................................................................................................................47
8.2 Maintenance schedule ..................................................................................................................................47
8.2.1 Daily procedure .....................................................................................................................................48
8.2.2 Weekly procedure..................................................................................................................................48
8.2.3 Monthly procedure ................................................................................................................................49
8.2.4 Semi-Annual procedure.........................................................................................................................50
8.2.5 Annual procedure ..................................................................................................................................51
8.3 Detailed Empty inspection............................................................................................................................52
8.4 Limit control tests.........................................................................................................................................53
8.4.1 High & Low gas pressure switch limit test & adjustment .....................................................................53
8.4.2 Electrical Limit Controls. ......................................................................................................................54
8.4.3 Oil Pressure Supervisory Switch ...........................................................................................................54
9 TROUBLESHOOTING ......................................................................................................................................55
10 Out of service operations...................................................................................................................................56
10.1 Shutdown....................................................................................................................................................56
10.2 Boiler taken out of service..........................................................................................................................56
10.3 Boiler laid up dry........................................................................................................................................56
10.4 Boiler laid up wet procedure ......................................................................................................................57
10.5 Re-commissioning......................................................................................................................................57

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Revision 2015.12.01 5
GENERAL
The boilers of the CREEK XL series have a horizontal through-flame combustion chamber, a second pass of
tubes, and a condensing section of a special design in stainless steel type AISI 316 Ti. These elements are
immersed in water contained in a horizontal boiler drum with a vertical column to which the system inlet and
outlet connections are fitted.
These boilers reach very high efficiency levels approaching 97% efficient. The flue gases not only are released at
a temperature little higher than that of the system return water but also a large part of the water vapor contained
in the flue gases is condensed. This recovers the latent heat of condensation.
The particular flame path (through the combustion chamber without inversion) limits as much as possible the
formation of Nitrogen Oxides (NOx) that form when the flame remains at high temperature in the combustion
chamber for long periods.
The CREEK XL series boilers place no limit on the return water temperature. However the boilers reach the
highest performance when used with heating systems in which the return temperature is lower than 135 °F. At
higher temperatures, condensation does not occur so the recovery of the latent heat contained in the water vapor,
present in the flue gas, is impossible. While not as effective, the efficiency of the boiler remains high even with
traditional high-temperature heating systems (175/150 °F).
Thank you for purchasing a Superior Boiler Works Inc. (SBW) product. This manual is for the CREEK XL line
of boilers. READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE. These manual and associated
documents are to be kept with the boiler and in legible condition for the life of the boiler.
This manual will refer to the burner’s manual when appropriate. A double asterisk (**) is used to indicate that
your burner manual should also be checked for information on the topic being covered unless otherwise noted. In
addition to the boiler and burner working together, there are controls, switches, valves, and other components on
your boiler assembled specific to each end user. A list of exact components and information about them is
appended to this manual. All of these documents and devices work together to safely operate your boiler.
Documents Unique to your boiler
There are many Superior Boiler Works Inc. (SBW) Documents created unique to each boiler.
These documents are appended to this manual either directly before or after this structured manual.
Document # of pages Page #/Location
Cover page with your information Pages Zero/First
Specification sheets 1 to 2 Appendix 1
Ratings and dimension drawing 1 Appendix 2
Recommended spare parts 1 to 3 Appendix 3
List of component manuals 1 to 4 Appendix 4
ASME data reports 1 to 2 Appendix 5
Firetest report (if tested) 0 to 2 Appendix 6
MSDS Information (if supplied) 0 to 9 Appendix 7
Miscellaneous unique paperwork for this boiler Any Appendix 8
Wiring drawing(s) can be large format Last
Supplementary Manuals:
This manual is intended to be used in conjunction with other documents.
Burner manual and manuals that comes with the burner. Appendix 9
Manuals for every major component supplied with the boiler. Appendix 10

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6 Revision 2015.12.01
The Warranty validation/Start-up report information sheet must be filled out and return to SBW within three
weeks of when the burner is first turned on and within two months of shipment of boiler to maintain your
warranty. Also note that boil-out procedures, a slow initial warm up, and proper water treatment are required
to maintain your warranty.
WARNING
The improper installation, adjustment, service,
maintenance, or operation of this equipment can
result in fire, explosion, series injury, or death.
Acronyms, Definitions, Standards, & Sources
SBW: Superior Boiler Works Inc.
ASME: American Society of Mechanical Engineers
ASME CSD-1: Controls and Safety Devices for Automatically Fired Boilers
BPVC: ASME boiler and pressure vessel code.
Section IV: Portion of BPVC that applies to water boilers not exceeding 160 PSIG or 250°F and Steam boilers
not exceeding 15 PSIG
Heating boiler: hot water boiler
Water boiler: Boiler that supplies hot water
LWCO: Low-water cutoff, or Low-water fuel cutoffs
Aux LWCO: Auxiliary Low water cutoff
LWCO mark: Vertical position on boiler where the primary LWCO operates
ANSI: American National Standards Institute
150# class: ANSI standard of flanged piping connections,
NPS: Nominal pipe size
NPT: National pipe thread (tapered)
MAWP: Maximum allowable working pressure
Set point: A specific value of pressure or temperature used in a control where it will switch on or off.
Aquastat: Water temperature control device
BoHP: Boiler horse power is equivalent to 33,475 Btu/Hr.
PSI: Pounds per square inch
PSIG: PSI gauge reading.
In. WC: Inches of water column. Units of pressure where one (1) PSI = 28 In. WC (28” WC)
UL: Underwriters Laboratories Inc.
UL Mark: Signage on the boiler designating UL approval
UL 795: Commercial-Industrial Gas Heating Equipment
UL 353: Limit Controls
cUL: Verification to Canadian Requirements by Underwriters Laboratories Inc.
CSA: Canadian Standards Association
CSA B140.0-03: Oil-Burning Equipment: General requirements
CSA 3. 1-77-CAN1: Industrial and Commercial Gas-Fire Package Boilers (Reaffirmed 2011)
CSA 22.1: Canadian Electrical Code Part 1
CSA B149: Natural Gas & Propane Code
NFPA: National Fire Protection Agency
NFPA 31: Installation of Oil Burning Equipment
NFPA 54: National Fuel Gas Code
NFPA 70: National Electric Code, AKA: NEC
IFGC: International Fuel Gas Code
R&D drawing: Ratings and Dimensions drawings. AKA: General Arrangement.

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Revision 2015.12.01 7
Introduction to safety
Refer to this manual and the burner manual. For
assistance or additional information consult a qualified
installer, service agency, or fuel supplier as
appropriate.
DO NOT STORE OR USE GASOLINE OR ANY OTHER FLAMMABLE LIQUIDS IN THE VICINITY OF
THIS OR ANY OTHER APPLIANCE.
DO NOT USE GASOLINE, CRANKCASE DRAININGS, OR ANY OIL CONTAINING GASOLINE.
NEVER BURN GARBAGE OR PAPER IN THE UNIT, AND NEVER LEAVE COMBUSTABLE
MATERIAL AROUND IT.
All personnel involved with the startup, maintenance, or adjustment of this boiler must read and understand the
entire contents of this manual prior to any startup or adjustment being made to the boiler and related
components. Installation and service must be performed by a qualified installer, service agency, or the fuel
supplier.
Safe and reliable operation is dependent to a large extent upon the skill and attentiveness of the operator and of
the maintenance personnel. Operating skill implies the following:
 Knowledge of fundamentals
 Familiarity with equipment
 Suitable background of training and experience
Full and effective use should be made of manufacturer's instruction books on operation and maintenance. Of
special importance are written procedures prepared expressly for each installation by the manufacturers' service
engineers and qualified personnel from the operating organization before and during the commissioning period.
These procedures are based on actual experience and often include invaluable information on what the
equipment is expected to do. Limitations critical to safe and reliable operations are also given. Control systems
vary in complexity from computer control to manual operation. Regardless of the type of system used, the
operators should be thoroughly trained so that they can maintain safe and continuous operation during
changeover from automatic to manual control as well as to continue operation by manual control if the automatic
systems are out of service. The operator should have instrumentation at the point of manual operation to permit
him to be aware of operating conditions at all times. Regularly scheduled auto-manual changeover, manual
operation, and emergency drills to prevent loss of these skills are recommended.
What to do if you smell gas:
 Do not try to light any appliance
 Do not touch any electrical switch
 Do not use any phone in your building
 Immediately call your gas supplier from a neighbor’s phone
 Follow the gas supplier’s instructions
 If you cannot reach your gas supplier, call the fire department.
NOTICE! This is used to point out warranty issues
WARNING
The improper installation, adjustment, service,
maintenance, or operation of this equipment can
result in fire, explosion, series injury, or death.
NOTICE!

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8 Revision 2015.12.01
Approvals & Recordkeeping
All SBW boilers are designed, manufactured, and stamped to the ASME BPVC. Refer to the signage
information section to determine the approvals that have been applied to your boiler.
THE INSTALLATION OF THIS BOILER SHALL BE IN ACCORDANCE WITH THE REGULATIONS OF
AUTHORITIES HAVING JURISDICTION.
BOILERS SHALL BE OPERATED BY QUALIFIED PERSONNEL. BOILERS SHALL BE INSTALLED
AND SERVICED BY QUALIFIED PERSONNEL ONLY.
Boilers intended for Canadian markets, refer to the following regulations as applicable:
The equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances
and Equipment, CSA B149, and applicable Provincial Regulations for the class; which should be carefully
followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
Wiring shall be in accordance with the CSA 22.1 Canadian Electrical Cod, Part I.
The installation of the unit shall be in accordance with the regulations of the authorities having jurisdiction
Boilers intended for American markets, refer to the following regulations as applicable:
NFPA54: National Fuel Gas Code
NFPA70: National Electrical Code
IFGC: International Fuel Gas Code
All drawings, wiring diagrams, schematic arrangements, manufacturers’ descriptive literature, spare parts lists,
and written operating instruction should be kept permanently in the boiler room or other suitable location so it
will be available to those who operate and maintain the boiler. Where space permits, drawing and diagrams
should be framed or sealed in plastic and hung adjacent to the related equipment. Other materials should be
assembled and enclosed in a suitable binder. When change or additions are made, the data and drawings should
be revised accordingly.
READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE.
Some states and municipalities require licensing or certification of personnel who operate or maintain heating
equipment. Also, some authorities require posting of inspection certificates in the boiler room. The supervisor in
charge of a given installation should make sure such requirements are met.

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Revision 2015.12.01 9
GENERAL WARNINGS
Each generator is provided with a data plate that can be found in the envelope with the boiler documents. The
plate lists:
Serial number or identification code;
Rated thermal output;
Furnace thermal output;
Types of fuels that can be used;
Maximum operating pressure.
A manufacturer's certificate is also provided which certifies the hydraulic test pressure.
The installation must be performed in compliance with the regulations in force by professionally qualified
personnel. The term “professionally qualified personnel” means persons with specific technical skills in the
sector of heating system components.
Incorrect installation may cause damage to persons, animals or objects for which the manufacturer
cannot be held responsible.
At the first start up, all regulation and control devices positioned on the control panel should be checked for
efficiency. The guarantee shall be valid only upon compliance with the instruction given in this manual.
Should overheating occur or the gas supply fails to shut off, do not turn off or disconnect the electrical supply to
the water pump. Instead shut off the gas supply at a location external to the appliance.
IMPORTANT: This boiler has been designed to heat hot water to a temperature lower than the boiling point of
water at atmospheric pressure and must be connected to a heating plant and/or a domestic hot water plant within
the limits of the boiler performance and output.
WARNING
THE BOILER MAY ONLY BE INSTALLED IN A ROOM WHICH COMPLIES WITH THE
APPROPRIATE VENTILATION REQUIREMENTS. READ THE INSTALLATION AND
USER INSTRUCTION BEFORE INSTALLING AND LIGHTING THE BOILER.

Creek XL Boiler Manual
10 Revision 2015.12.01
1 BOILER SIGNAGE
SBW boiler signage map front view: Figure 1

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Revision 2015.12.01 11
The Serial No. or National Board No. is useful when contacting SBW for spare parts or support.
Location A. ASME hot water boiler rating plate: Figure 2
Refer to SBW
model numbering
system for details
Location B. Warning plate: Figure 3
Every boiler includes this warning mounted on the
front door of the boiler close to eye level.

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12 Revision 2015.12.01
Location C. ETL – ratings and warning plate: Figures 4
This plate is added to include additional ratings and warnings that are required are ETL certified
boilers. This information can also be on two labels with the warnings and ratings listed separately.
Location D. Startup Instructions: Figure 5
These instructions give the general procedure for startup and shutdown of the boiler. It
should not be used for commissioning or extended shutdown procedures.

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Revision 2015.12.01 13
SBW boiler signage map side view: Figure 6
Location E. Logo Sticker: Figure 7

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Location G. Load Bearing Point sticker: Figure 9
Besides the lifting lug, this shows the only locations the
boiler should be lifted from.
Location F. Handling options sticker: Figure 8
This is to make clear how the boiler can be handled.
Location H. LWCO mark: Figure 10
Used to determine the correct elevation of the LWCO switch. Line this
up with the primary level mark on the LWCO. This is located on the
centerline of the pipe on the instrumentation spool.

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Revision 2015.12.01 15
SBW boiler signage map rear view: Figure 11

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16 Revision 2015.12.01
Location L. ASME Drum stamping: Figure 14
The ASME “H” Stamp is riveted directly to the boiler frame in the upper section. It will be located on
the bottom left side as seen looking at the rear of the boiler.
Location M. Supply water sticker: Figure 15
Clear identification of supply water nozzle
Low Temp.
Return Water
From System
To Boiler
Medium Temp.
Return Water
From System
To Boiler
Location K. Low temperature return water sticker: Figure 12
Clear identification of the low temperature return water nozzle
Location J. Medium temperature return water sticker: Figure 13
Clear identification of the medium temperature return water nozzle

2 BOILER COMPONENT IDENTIFICATION
2.1 Boiler Specifications and Dimensions
Figure 16

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2.2 Cross Sections
Figure 20
Figure 21
Twin water return
Water Outlet
Horizontal Furnace
2nd Pass tubes
Furnace sight port
Vertical heat transfer surfaces

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Revision 2015.12.01 19
2.3 Typical Instrumentation Spools
2.4 Burner Mounting
1
4
3
2
Fi
g
ure 23
KEY:
1. Burner
2. Thermo-insulating material
3. Burner Draft Tube
4. Gasket
Ø
b
Low water cutoff
probe connection
Boiler Outlet Exam
p
le of Instrumentation s
p
ool on Creek XL, Fi
g
ure 22.
High Limit control
connection
Firing Rate control
connection
Operating control
connection
Temperature gauge
connection
9⅞-11⅞
Pressure gauge
connection

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20 Revision 2015.12.01
2.5 Gas Train
Figure 24: Example gas train.
Exact mounting location will depend on job specifications.