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Cleaver-Brooks CBH 100, Operation, Service And Parts Manual, Page: 16 / 75

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Summary of Contents for CBH 100

Page 1: ...25 00 CLEAVER BROOKS MODEL PACKAGED BOILERS Manual Part No 750 99 Printed in U S A...

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Page 3: ...OOKS MODEL CBH PACKAGED BOILERS Operation Service and Parts Manual Please direct purchase orders for replacement manuals to your local Cleaver Brooks representative Manual Part No 750 99 12 93 Printed...

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Page 5: ...40 Oil or Gas 3 4 E Flame Loss Sequence 3 6 CHAPTER 4 STARTING AND OPERATING INSTRUCTIONS 4 1 A General Preparation Initial Start up 4 1 B Control Settings All Fuels 4 1 C Oil Burner Start up 4 2 D G...

Page 6: ...ced Draft Fan 5 22 P Fireside Cleaning 5 22 Q Lubrication 5 22 CHAPTER 6 TROUBLE SHOOTING 6 1 A Burner Does not Start 6 1 B No Ignition 6 1 C Pilot Flame But No Main Flame 6 2 D Burner Stays in Low Fi...

Page 7: ...y for proper operation On the other hand a thorough understanding ofthis manual is required before attempting to operate maintain service or repair this equipment Because of state local or other appli...

Page 8: ...ir through the rotary air damper and the diffuser into the combustion chamber The main fire tube or combustion chamber constitutes pass one Baffling allows gases to pass to the front of the boiler onl...

Page 9: ...y A boiler equipped to burn oil and gas includes equipment for each distinct fuel Since the burner uses only one type of fuel at a time a gas oil selec tor switch is incorporated in the combination un...

Page 10: ...of fuel for which it is equipped and whether it is a hot water or steam boiler Boilers having optionally ordered features may 1 2 have control components not listed here PROGRAMMING AND FLAME SAFEGUAR...

Page 11: ...DAMPER LINKAGE BUTTERFLY GAS VALVE BLOWER MOTOR STARTER Chapter 1 General Description and Principles of Operation FORCED DRAFT FAN MOTOR STARTER Figure 1 1 Energizes forced draft fan blower motor DAMP...

Page 12: ...s as a low fire switch to prove that the damper is in a closed position before ignition can take place An oil fired boiler has additional switches that control oil solenoid valves for high fire operat...

Page 13: ...pter General Description and Principles of Operation operate at either high or low fire rate in accord ance with load requirements MODULATING CONTROL Figure 1 2 Senses changing boiler pressures or tem...

Page 14: ...ushed regularly to assist in maintaining cross connecting piping and float bowl clean and free of sediment A LOW GAS PRESSURE SWITCH GAS PILOT PRESSURE REGULATOR similar drain valve is furnished with...

Page 15: ...ples of Operation in the oil fuel flow section later in this chapter FUEL OIL SHUT OFF COCK Figure 1 1 For manually shutting off oil supply to burner LOW OIL PRESSURE SWITCH Optional Figure 1 3 Switch...

Page 16: ...sure to suit the pilot s requirement of between 5 to 10 W C BUTTERFLY GAS VALVE Figure 1 l The pivoted disc in this valve is actuated by con necting linkage from the damper motor to regulate the rate...

Page 17: ...mbustion air flow into and mix with the pilot gas stream to provide a suitable flame At the beginning of the ignition cycle the pilot gas solenoid valve and ignition transformer are simultaneously ene...

Page 18: ...ECK VALVE OIL sUPPLY __ OIL RETURN FIGURE 1 8 SCHEMATIC OIL FLOW DIAGRAM MODEL CBH 25 40 AND 50A MANIFOLD BLOCK MANUAL OIL SHUTOFF VALVE INTERMEDIATE 1 L_j j__J HIGH FIRE I OIL VALVE HFOV 1 HIGH FIRE...

Page 19: ...GAS MAIN GAS SHUTOFF VALVE Chapter 1 General Description and Principles of Operation Figure 1 8 shows the valves used on the 25 through 40 and 50A size boilers The orifice block between the valves pre...

Page 20: ...to the burner depends upon the position of the vane in the butterfly valve This is mechanically controlled by the damper motor and varied in the same maimer as the air damper thus properly proportion...

Page 21: ...d the system must be operated as intended by its designer to avoid shock or severe possibly damaging stresses occurring to the pressure vessel The operator should familiarize himself with this chapter...

Page 22: ...horse power can be used to determine the minimum con tinuous flow rate through the boiler under an operating conditions Before initial firing or refiring after boiler has 2 2 been drained the operator...

Page 23: ...to the system and or other boilers prior to cutting in It is advisable to have a thermometer installed in the return line to indicate return water tem perature With this determined and with the sup pl...

Page 24: ...t is illegal to operate the boiler with closed or unsealed open valves D WATER TREATMENT Maximum effectiveness and long trouble free life of pressure vessels at the lowest cost consistent with good en...

Page 25: ...o be alert to system water losses and a water meter is recom mended for water make up lines E ClEANING Hot Water and Steam Piping Steam and water piping systems connected to the boiler may contain oil...

Page 26: ...BH 50A 295 2460 CBH 50 375 440 3125 3665 CBH 60 350 420 2920 3500 CBH 70 550 650 4625 5420 CBH 80 535 630 4460 5250 CBH 100 610 715 5085 5960 CBH lOOA 595 4960 2 6 2 When dissolving chemicals the foll...

Page 27: ...nsultant or feed Chapter 2 The Pressure Vessel water treatment company and in extreme cases it may be necessary to resort to acid cleaning Professional advice is recommended if acid cleaning is requir...

Page 28: ...conomy and results frequent short blows are preferred to in frequent lengthy blows This is particularly true 2 8 when suspended solids content of the water is high With the use of frequent short blows...

Page 29: ...ale or deposits from the waterside surfaces and check for internal or external corrosion and leakage Chapter 2 The Pressure Vessel The fireside surfaces should also be thoroughly cleaned so that metal...

Page 30: ...re by placing moisture absorbing materials such as quick lime at 2 pounds for 3 2 10 cubic feet of volume or silica gel at 5 pounds for 30 cubic feet of volume on trays inside the vessel Fireside surf...

Page 31: ...grams request Cleaver Brooks Bulletin C17 4095 The burner and control system are in starting condition when the following conditions exist Boiler water is up to correct level closing the low water cut...

Page 32: ...sed in the running interlock circuit are Blower motor starter interlock BMSI Combustion air proving switch CAPS Not used on some 100 series 3 2 C SEQUENCE OF OPERATION Oil or G s Applicable to a stand...

Page 33: ...nterlock circuit to terminal 14 The timer will stop until the damper motor has returned to the low fire position and the contacts of the low fire switch are closed NOTE A burner start cannot be made i...

Page 34: ...otor The motor returns to the low fire position if it is not already in that position At the end of the operating cycle terminal 8 circuit opens and de energizes the blower motor The 3 4 timer stops a...

Page 35: ...f the optional purge extender is not used the purge jumper provided with the re lay must be installed When the high fire switch closes the purge ex tender is activated to provide the additional purge...

Page 36: ...K and 4K drop out The main fuel valve s is de energized and closes Flame is ex 3 6 tinguished and flame relay 2K drops out The blower motor continues to force air through the boiler in a post purge pe...

Page 37: ...rammer and other controls in the system can be obtained by studying the contents of the manual and this bulletin Knowledge of the system and its controls will make troubleshooting much easier in the e...

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Page 39: ...til escape of steam is noted after burner is operating CAUTION Prior to firing make certain the dis charge piping from safety or relief valves and discharge piping from all blowdown or drain valves is...

Page 40: ...damper motor will return to the low fire position after this pre purge is com pleted The low fire switch must be closed for ac tion to continue Now check for ignition spark When the pilot ignition le...

Page 41: ...mer and gas pilot valve are energized The gas pilot flame may be viewed through the sight glass on the rear door The main burner will not light since the main gas shut off cock is closed When the time...

Page 42: ...o Section E of this chapter for normal start ing operating and shutdown information E NORMAl OPERATION All fUElS START UP Check water level and supply Check setting of all operating controls Check all...

Page 43: ...aximum operating efficiency and economy Prior to placing the boiler into initial service a complete inspection should be made of all controls connect ing piping wiring and aU fastenings such as nuts b...

Page 44: ...ently prior to shutdown Cleaver Brooks boilers are designed engineered and built to give long life and excellent service on 5 2 the job Good operating practices and con scientious maintenance and care...

Page 45: ...make certain that it is clean and free of obstruction D WATER GAGE GLASS A broken or discolored glass should be replaced at once Periodic replacement should be a part of the maintenance program Alway...

Page 46: ...con trol on a cold start it will immediately move to 5 4 high fire as soon as the program control releases the circuit that holds the burner in low fire during ignition The high low fire control will...

Page 47: ...operating limit control so that the burner will return to the low fire position prior to shutting off at the operating limit The cut in pressure the point at which the bur Chapter 5 Adjustment and Mai...

Page 48: ...ING SWITCH Air pressure against the diaphragm actuates the switch which when made completes a circuit to prove the presence of combustion air Since the 5 6 pressure of the combustion air is at its min...

Page 49: ...tment and Maintenance sure to open the main power supply switch since the control is hot even though the burner switch is off A periodic safety check procedure should be established to test the comple...

Page 50: ...18 5 0 45 PLP 899 18 70 6 0 45 PLP 899 35 6 0 45 PLP 899 35 80 7 0 45 PLP 899 61 7 0 45 PLP 899 61 100 8 3 45 PLP 899 39 8 3 45 PLP 899 39 made to the burner drawer however a check should be made to...

Page 51: ...on voltage Car bon is an electrical conductor so it is necessary to keep the insulating portion of electrode wiped Chapter 5 Adjustment and Maintenance clean if any is present Ammonia will aid in remo...

Page 52: ...mp is able to clear the line of air If the condition persists after a long period of opera tion it may indicate a leak in the suction line 1 7 8 PILOT GAS INLET OIL PUMP BELT The V belt driving the oi...

Page 53: ...mer and electrode are tight GAS PILOT FLAME ADJUSTMENT The size of the gas pilot flame is regulated by ad justing the gas flow through the pilot gas regulator The flame must be sufficient to ignite th...

Page 54: ...s GAS PRESSURE AND FlOW INFORMATION Because of variables in both the properties of gas and the supply system it will be necessary to regulate the pressure of the gas to a level that produces a steady...

Page 55: ...Factor 1 59 1 66 1 72 1 81 1 86 1 93 2 00 Chapter 5 Adjustment and Maintenance As an example assume that a 70 horsepower boiler is installed at 2 000 feet above sea level is equipped with a standard g...

Page 56: ...int in the motor arm is to the hub the less distance it will travel To increase the valve arm travel move the connecting rod closer to the hub or away from it if decreased travel is required This low...

Page 57: ...white plastic located near the center of the motor Each slot in the cam equals ap proximately 20 degrees of motor rotation 3 Move cam the correct number of degrees by moving cam in the direction of th...

Page 58: ...cam SCALEPLATE BLACK SCALE DIFFERENTIAL CAM LOCKING SCREW CAM ROLLER SWITCH if necessary to assure oil valve opening and closing at the desired point If the switch is used for proving that the air da...

Page 59: ...CALE OPERATING CAM LOCKING SCREW DIFFERENTIAL CAM BRASS OIL VALVE SWITCH HFOV Chapter 5 Adjustment and Maintenance motor travel This switch is used to prove damper opening during pre purge Connect the...

Page 60: ...the screw to allow the damper to further close until a slight haze appears in the stack Gradually open the damper until the haze disappears Lock the ad justment screw in this position Turn the damper...

Page 61: ...uator is not field repairable nor should it be disassembled To remove the actuator loosen the two 5 32 allen setscrews that hold the actuator collar to the valve bonnet Chapter 5 Ad iustment and Maint...

Page 62: ...irline cracks This by no means indicates improper design or workmanship Since refractory materials expand and contract to some degree with changes in temperature they should be expected to show minor...

Page 63: ...the burner flame If replacement is necessary refer to Chapter 7 and Chapter Adjustment and Maintenance order proper replacement materials Remove exist ing refractory and thoroughly clean that portion...

Page 64: ...ations should be removed Any soot or other deposits should be removed from the furnace and tube sheets Refer to Section N of this chapter for instructions on properly closing front and rear heads 5 22...

Page 65: ...rrect If an obvious condition is not apparent check the continuity of the circuits with a voltmeter or test lamp Each circuit can be checked and the fault isolated and corrected Most circuitry checkin...

Page 66: ...or See Section F 4 Defective high low fire control 5 Binding or loose linkage cams setscrews etc 6 Check appropriate relay contacts 6 2 E SHUTDOWN OCCURS DURING FIRING 1 Loss or stoppage of fuel suppl...

Page 67: ...ks representative or Cleaver Brooks of Canada Ltd 161 Lorne Ave Stratford Ontario attention Parts Center A purchase order or a letter authorizing repairs and giving complete details should be mailed t...

Page 68: ...70 H P 80 80 H P 100 100 H P These sizes have 48 Diameter Shells PRESSURES HOT WATER UNIT Indicates Indicates Indicates LOW PRESSURE UNIT i e 15 lbs Max Pressure HIGH PRESSURE UNIT i e 150 lbs Max Pre...

Page 69: ...Split 9 64 x 3 4 Rivet Split 1 4 x 7 8 Fastener Rear Head Gasket Diffuser Diffuser Diffuser Diffuser Diffuser Diffuser BURNER PARTS Nozzle Burner See Chart Electrode Electrode Electrode Gas Pilot Elec...

Page 70: ...ure 0 15 lb MH L404A Control Pressure 5 150 lb MH L404A Control Pressure 10 300 lb MH L404A Control Pressure 0 15 lb MH L404C Control Pressure 5 150 lb MH L404C Control Pressure 10 300 lb MH L404C Swi...

Page 71: ...rogrammer CB 3 Control Programmer 6080C Cell Lead Sulfide Fireye Flame Detector Assembly Fireye Tube Electron 12AX7 Tube Electron 12BH7A The following are factory rebuilt controls available on a trade...

Page 72: ...rive Shaft LINKAGE Arm Damper Motor Gas Linkage Arm Damper Motor Gas Linkage Arm Damper Shaft Arm Damper Shaft Arm Damper Counter Shaft Arm Gas Butterfly Valve Arm Gas Butterfly Valve Cam Oil Valve Sw...

Page 73: ...5 3 60 3600 Motor 3 HP 115 230 1 60 3600 Motor 3 HP 208 220 440 3 60 3600 Motor 3 HP 575 3 60 3600 Motor 3 HP 115 230 1 60 3600 Motor 3 HP 205 220 440 3 60 3600 Motor 3 HP 575 3 60 3600 Motor 5 HP 200...

Page 74: ...Gauge 3 1 2 0 200 PSI 60 260 F Gauge 3 1 2 0 60 PSI 0 70 Ft 60 260 F Gauge 3 1 2 0 30 PSI 0 30 ln Thermometer 3 200 700 F Thermometer 3 1 2 100 300 F Remote Bulb Well Refractory Oven Refractory Oven...

Page 75: ...le 50 100 15 PSI H W Yoke Handhole 50 100 Power U S Yoke Handhole 50 100 Power Can Nut Head Bolt 5 8 Capscrew Head Bolt 5 8 x 4 Capscrew Head Bolt 5 8 x 4 1 2 IMPORTANT NOTICE The manufacturer s bulle...

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