. Manufactured in the USA to the ASME boiler and pressure vessel code.

1. Superior Boiler Repair

CREEK XL BOILER MANUAL Condensing Water Boiler 3000-5500 MBtu/Hr. Gas/Oil Superior Boiler Works, Inc. 4th Avenue Hutchinson, KS 67501 (620) 662-6693 www.superiorboiler.com. Creek XL Boiler Manual 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. Creek XL Boiler Manual 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. Creek XL Boiler Manual 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. 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. Creek XL Boiler Manual 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. Creek XL Boiler Manual Introduction to safety Refer to this manual and the burner manual. For WARNING assistance or additional information consult a qualified The improper installation, adjustment, service, installer, service agency, or fuel supplier as maintenance, or operation of this equipment can appropriate.

Creek XL Boiler Manual 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. Creek XL Boiler Manual 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. Creek XL Boiler Manual 1 BOILER SIGNAGE SBW boiler signage map front view: Figure 1 Revision 2015.12.01. Creek XL Boiler Manual Location A. ASME hot water boiler rating plate: Figure 2 Refer to SBW model numbering system for details The Serial No. Or National Board No.

Is useful when contacting SBW for spare parts or support. Warning plate: Figure 3 Every boiler includes this warning mounted on the front door of the boiler close to eye level.

Creek XL Boiler Manual 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. Creek XL Boiler Manual SBW boiler signage map side view: Figure 6 Location E.

Logo Sticker: Figure 7 Revision 2015.12.01. Creek XL Boiler Manual Location F. Handling options sticker: Figure 8 This is to make clear how the boiler can be handled.

Load Bearing Point sticker: Figure 9 Besides the lifting lug, this shows the only locations the boiler should be lifted from. Creek XL Boiler Manual SBW boiler signage map rear view: Figure 11 Revision 2015.12.01. Creek XL Boiler Manual Location K. Low temperature return water sticker: Figure 12 Low Temp. Clear identification of the low temperature return water nozzle Return Water From System To Boiler Medium Temp.

Return Water From System Location J. Medium temperature return water sticker: Figure 13. 2 BOILER COMPONENT IDENTIFICATION 2.1 Boiler Specifications and Dimensions Figure 16.

Creek XL Boiler Manual 2.2 Cross Sections Figure 20 Water Outlet Horizontal Furnace Twin water return Pass tubes Figure 21 Furnace sight port Vertical heat transfer surfaces Revision 2015.12.01. Operating control Firing Rate control High Limit control connection connection connection Example of Instrumentation spool on Creek XL, Figure 22. Boiler Outlet 2.4 Burner Mounting 9⅞-11⅞ Figure 23 KEY: 1. Thermo-insulating material 3. Burner Draft Tube 4. Creek XL Boiler Manual 2.5 Gas Train Figure 24: Example gas train.

Exact mounting location will depend on job specifications. Revision 2015.12.01. All Creek XL boilers are constructed to meet CSD-1. Creek XL boilers are equipped with two lifting lugs located below the casing capable of supported the packed boiler’s weight during lift operations. The lugs will be covered by the casing during normal boiler operation.

The operator and firing rate controls can be incorporated into the same device. The water supply nozzles are ANSI class 150# flanges.

Creek XL boilers come with a medium and a low temperature water return nozzle located at the rear of the boiler near the bottom as shown in section 2.2. If only one nozzle is used always use the low temperature return.  Upon arrival, inspect the boiler and any parts shipped with the boiler. If any damage is found, notify Superior Boiler Works Inc. And note damage on the bill of lading and any other receiving papers.  The boiler is designed to be lifted by the lifting lugs only.

The use of tow motors, etc., is not acceptable and can damage the boiler. Creek XL Boiler Manual 4.4 The Boiler Room Local building codes and insurance requirements usually dictate the type of construction and the material to be used in the boiler room. The boiler room floor should be non-combustible and of adequate strength to support the weight of the boiler full of water. 4.6 Casing Panel Installation The Creek XL boiler is shipped with the top casing panels removed so that the lifting lugs are exposed. After the boiler is set, these remaining panels should be installed.

The panels will need to be secured by screws on each end. Creek XL Boiler Manual 4) Fix the special “stave steering” struts to the upper/lower plate proceeding as described above. Then, in the same way, fix the two (front and back) beams.

Revision 2015.12.01. Creek XL Boiler Manual Insert the 4 short staves (previously prepared with the stoppers) between the struts, on each side. Insert the staves, including the one designed for the installation of the control panel.

Revision 2015.12.01. Creek XL Boiler Manual 4.7 Installation of Loose Shipped Items After the final staves are attached, loose shipped items can be installed and the boiler can be connected to your systems. It is preferable to delay installation of any items with glass like gauges until after the piping has been completed to avoid glass breakage. Creek XL Boiler Manual 4.8 Electrical Installation ELECTRICAL INSTALLATION SHALL BE WARNING IN ACCORDANCE WITH THE The improper installation, adjustment, service, REGULATIONS OF AUTHORITIES maintenance, or operation of this equipment can HAVING JURISDICTION. THE result in fire, explosion, series injury, or death.

Superior Boiler Repair

The nameplate lists the clearance to combustibles. However the Creek XL boilers will need an additional clearance to open the door for service. On the Creek XL-3000 and XL-4000, this clearance is 50 inches.

On the XL-5000 and XL-5500, 54 inches of clearance is necessary. (1) to six (6) inches. Honda cb 750 f2.

WARNING The flue gas temperatures produced by CREEK XL boilers are considerably lower than in the case of non-condensing boilers, and have therefore very high relative humidity. For these reasons the chimney must be completely watertight, able to withstand corrosion attack by acid condensate, and adequately heat-insulated to guarantee sufficient draft. Creek XL Boiler Manual 5 Plumbing your Boiler THE INSTALLATION OF THE UNIT SHALL WARNING BE IN ACCORDANCE WITH THE REGULATION OF THE AUTHORITIES The improper installation, adjustment, service, HAVING JURISDICTION.

INSTALLATIONS maintenance, or operation of this equipment can result in fire, explosion, series injury, or death. Condensate from the CREEK XL will be slightly acidic (typically with a pH from 3 to 5). As this will be corrosive hot water, the condensate line needs to be constructed of corrosion resistant material (i.e. Creek XL Boiler Manual 5.8 Safety relief valves (SRV) See the operation instructions for more details on SRV SRV need to be installed so that no significant loads are placed on the outlet. Testing and occasional weeping can create condensate. Drip pan elbows are recommended to handle these issues during installation.

Creek XL Boiler Manual 6 Boiler Start-up The design, manufacture, and assembly of your new unit is the result of years of engineering work and field testing. It is a sophisticated piece of equipment to be serviced only by qualified people. If you don't already have a qualified operator, we recommend that you contact your SBW representative for the name of experienced service personnel in your area. Creek XL Boiler Manual 6.3 Tools & Gauges Before you begin, check that the following tools & gauges are installed or available:  Stack thermometer, 50-500°F  Temperature gauge appropriate for your size of boiler  Flue gas analyzer  U-tube inclined type manometer to measure stack draft and furnace pressure . 6.7 Boil-out Procedure All new boilers must be boiled out or Superior Boiler Works will void the warranty! Before introducing the boil-out chemicals to any drain system, check local environmental regulations to ensure you are in compliance. Creek XL Boiler Manual 15.

Drain the boiler while still warm. Remove washout plugs. Wash interior of boiler with tap water at full pressure through a nozzle. Wash until all evidence of dirt, mud, and impurities are removed through the washout plug opening. Clean any shell mounted probe holders.

Creek XL Boiler Manual 6.9 Good practice recommendations for hot water boilers Use of this hot water boiler for temporary heating of an unfinished building is not NOTICE! Recommended by SBW. Use of the boiler prior to closing the building and balancing of the heating system may lead to thermal shock and leakage. Creek XL Boiler Manual 7 Operation 7.1 Safety Relief Valves Safety relief valves are used to relieve excessive pressure generated within a boiler. The safety relief valve (or valves) is the final line of protection against overpressure in the boiler.

They discharge a volume of hot water when relieving. Creek XL Boiler Manual CAUTION: On boilers with small water storage capacity, very little heat will be required to raise the pressure to the opening pressure of the safety relief valve. If the temperature at the start of the test is below the normal operating temperature, as recommended in (b), it will not be necessary to change or jumper out the operating or high limit temperature controls. Creek XL Boiler Manual 7.2.4 Pressure gauge calibration: The gauge used on a boiler should be calibrated at least once per year. This can be accomplished by comparing it to an inspector gauge or using a deadweight tester. If an inspector gauge is used, the accuracy of that gauge should be verified with a deadweight tester at least once every 2 years. 7.6.3 Low-water cutoff (LWCO) Creek XL boilers are equipped with a probe type LWCO with a manual reset.

In the event this device is activated to shut off the burner, the operator must reset the device. This ensures the operator is aware that the LWCO is not operating as designed. Creek XL Boiler Manual 7.7 Water level operations Every effort should be made to place feedwater control on automatic operation as soon as possible during startup because they require constant operator attention otherwise. Operating without sufficient water to cool pressure parts is the most common way to destroy a boiler. Maintenance of water at a safe level in the boiler is of vital importance. Creek XL Boiler Manual The most common phenomena in heating systems are: Furring (calcareous deposits of Calcium Carbonate) Furring impedes heat exchange between the flue gases and the water, thereby increasing the temperature of parts exposed to the flame and reducing considerably the boiler life. Furring concentrates where the boiler wall temperature is higher, and the best defense against this phenomenon is a boiler design that eliminates high temperature spots.

7.9.2 Door Aperture The Creek XL door can be opened from either side. To open, insert the tool into the support pin as shown in figure 27. Loosen both supports on one side and swing the door open. Both the top door to the furnace and the bottom door to the condensing section open easily in this manner.

Creek XL Boiler Manual 8 MAINTENANCE With proper operation and maintenance you can expect years of trouble-free service from your new boiler. The next few pages give guidelines for typical boiler maintenance.

Cover plates, enclosures, and guards shall be maintained in place except during maintenance. Creek XL Boiler Manual 8.2.1 Daily procedure, also reference the burner manual’s procedures. All gauges, monitors, and indicators should be checked for proper operation. Observe burner starting sequence and flame characteristics to verify normal behavior.

Check furnace for debris and sooting. Creek XL Boiler Manual 8.2.3 Monthly procedure, also reference the burner manual’s procedures. Clean combustion air fan and air inlet assembly.

Clean the air intake filter on the atomizing air if air compressor is present. Replace filter oil with clean compressor lubricating oil. Creek XL Boiler Manual 8.2.4 Semi-Annual procedure, also reference the burner manual’s procedures.

Cool boiler slowly to room temperature. NOTE: Failure to cool boiler slowly can cause plates to leaks. This is very important! To assist cool down, use the Test/Run or Check/Run switch located on the programmer to run the blower. Creek XL Boiler Manual 8.2.5 Annual procedure, also reference the burner manual’s procedures. Follow steps 1 through 6 listed under Semi-Annual Procedure. If the condition of the water in the boiler indicates there is considerable foreign matter in it, the boiler needs the waterside cleaned.

Creek XL Boiler Manual 8.3 Detailed Empty inspection Before commissioning, and as required the boiler can be drained and inspected in detail. The following checklist is what most inspectors will be looking for.

Safety Checklist for Inspection 1. Notify the person in charge at the site when beginning and upon completion of the inspection.

Creek XL Boiler Manual External Checklist: 1. Free access should be provided to the burner front, observation ports, and operating valves. All instrumentation and controls should be complete, operational, and checked for proper calibration and action.

External indicators permanently marked or installed on damper shafts and registers are necessary for positive determination of position while the boiler is in service. Creek XL Boiler Manual Setting and testing the low gas pressure switch: Cycle the burner to high fire and a gas pressure reading.

Using the main manual gas shutoff valve, throttle down the gas flow to a point there the reading is approximately 10% below the full open reading. Then adjust the low gas pressure switch until it breaks and shuts down the burner. Creek XL Boiler Manual 9 TROUBLESHOOTING If burner does not start, check the controller fault code in the burner manual. Check all electric fuses. Check water level in boiler. Check limit controls to make sure they are making circuit.

Creek XL Boiler Manual 10 Out of service operations 10.1 Shutdown When shutting down a boiler, switch the burner to manual, set the burner to low fire for a few moments, and then turn the burner off. As the boiler flow drops toward zero, it will probably be necessary to close the main feedwater isolation valve and manually regulate drum water level with the bypass valve. Creek XL Boiler Manual 10.4 Boiler laid up wet procedure 1. Fill the boiler to overflowing with the highest quality water available.

Steam condensate, soft water, or filtered fresh water all generally acceptable. Raw city water should not be used. Creek XL Boiler Manual MAINTENANCE, TESTING, AND INSPECTION LOG DAILY Building: Month: Year: Address: Boiler No. Emergency contact: Log maintained by: Operator: Operator: DAILY BOILER READINGS: Water level Pressure Temp Water level Pressure Temp Notes: Water level Pressure Temp Revision 2015.12.01. Creek XL Boiler Manual MAINTENANCE, TESTING, AND INSPECTION LOG WEEKLY & MONTHLY Building: Month: Year: Address: Boiler No. Emergency contact: Log maintained by: Operator: Operator: WEEKLY BOILER READINGS: Week 1 Week 2 Week 3 Week 4 Test LWCO Observe Flame. CREEK XL BOILER MANUAL Condensing Water Boiler 3000-5500 MBtu/Hr.

Gas/Oil Installer.