CleaverBrooks CBLE Operation And Maintenance Manual Download

Page: 11 / 194

750-91 (revised 2009)
Model CB-LE Packaged Boiler Manual

8.3 — Water Level Controls

8-3

8.3.1 — Steam Boiler

8-3

8.3.2 — Hot Water Boiler

8-4

8.4 — Water Gauge Glass

8-4

8.5 — Electrical Controls

8-4

8.6 — Flame Safety Control

8-6

8.6.1 — Checking Pilot Flame Failure

8-6

8.6.2 — Checking Failure to Light Main Flame

8-7

8.6.3 — Checking Loss of Flame

8-7

8.7 — Oil Burner Maintenance

8-7

8.7.1 — Oil Strainers

8-7

8.7.2 — Light Oil Strainers

8-7

8.7.3 — Heavy Oil Strainers

8-8

8.7.4 — Cleaning the Oil Nozzle

8-8

8.7.5 — Cleaning Air Purge Nozzle (No. 6 Oil) and Back Pressure Orifice Nozzle (No. 2 Oil)

8-9

8.7.6 — Ignition System

8-9

8.8 — Gas Burner Maintenance

8-9

8.9 — Motorized Gas Valve

8-10

8.10 — Solenoid Valves

8-10

8.11 — Air Control Damper, Linkage, and Cam Spring

8-11

8.12 — Forced Draft Fan

8-12

8.13 — Fan/Motor Cassette Removal

8-14

8.14 — Inspection and Adjustment

8-15

8.15 — Airbox Gasket Installation

8-16

8.16 — Fan/Motor Cassette Installation

8-17

8.17 — Safety Valves

8-18

8.18 — Fuel Oil Metering Valve, Adjusting, and Relief Valves

8-18

8.19 — Air Pump and Lubricating System

8-20

Summary of Contents for CBLE

Page 1: ...ble Of Contents Model CBLE Packaged Boiler 250 350 HP Operation and Maintenance Manual 750 91 12 09 Light OIl Heavy Oil Gas or Combination Compliments of Power Mechanical Inc Used Boilers Rental Boile...

Page 2: ...n external to the boiler DANGER WARNING Do not use this boiler if any part has been under water Immediately call your Cleaver Brooks ser vice representative to inspect the boiler and to re place any p...

Page 3: ...cement manuals to your local Cleaver Brooks authorized representative Manual Part No 750 91 12 09 Printed in U S A Cleaver Brooks 2009 CLEAVER BROOKS Model CBLE 250 350 HP Light Oil Heavy Oil Gas or C...

Page 4: ...ow how a basic burner operates Operating controls will normally function for long periods of time and we have found that some operators become lax in their daily or monthly testing assuming that norma...

Page 5: ...8 Vent Valve 1 7 1 4 9 Stack Temperature gauge 1 7 1 4 10 Auxiliary Low Water Cutoff 1 8 1 4 11 Safety Valve s 1 8 1 5 Hot Water Controls All Fuels 1 9 1 5 1 Water Pressure and Temperature Gauge 1 9 1...

Page 6: ...Oil 2 13 2 7 Controls for Combination Burners Only 2 15 2 8 Combustion Air 2 16 2 9 Automatic Ignition 2 16 2 10 Atomizing Air 2 17 2 11 Oil Fuel Flow Light Oil 2 17 2 12 Oil Fuel Flow Heavy Oil 2 19...

Page 7: ...of a New Unit 3 8 3 7 Washing Out 3 10 3 7 1 Hot Water Boiler 3 10 3 7 2 Steam Boiler 3 10 3 7 3 Flushing of Pressure Vessel Interior 3 10 3 8 Blowdown Steam Boiler 3 10 3 8 1 Intermittent Manual Blow...

Page 8: ...5 3 5 2 4 Low Water Cutoff and Pump Control 5 3 5 2 5 Additional Considerations 5 3 5 3 Gas Pilot 5 3 5 4 Atomizing Air 5 4 5 5 Firing Preparations for No 2 Oil Series 100 200 5 5 5 5 1 Oil Flow 5 5...

Page 9: ...9 Modulating Temperature Control Hot Water 6 8 6 10 Operating Limit Temperature Control Hot Water 6 9 6 11 High Limit Temperature Control Hot Water 6 9 6 12 Low Water Cutoff Devices Steam Hot Water 6...

Page 10: ...3 Oil Drawer Switch 6 26 6 24 Low Oil Temperature Switch 6 27 6 25 High Oil Temperature Switch Optional 6 27 6 26 Low Oil Pressure Switch Optional 6 27 6 27 Electric Oil Heater Thermostat 400 and 600...

Page 11: ...8 7 3 Heavy Oil Strainers 8 8 8 7 4 Cleaning the Oil Nozzle 8 8 8 7 5 Cleaning Air Purge Nozzle No 6 Oil and Back Pressure Orifice Nozzle No 2 Oil 8 9 8 7 6 Ignition System 8 9 8 8 Gas Burner Mainten...

Page 12: ...enance 8 29 8 21 1 Front Head 8 30 8 21 2 Rear Door 8 31 8 21 3 Closing and Sealing 8 33 8 22 Lubrication 8 34 8 22 1 Electric Motors 8 34 8 22 2 Control Linkage 8 34 8 22 3 Solenoid and Motorized Val...

Page 13: ...12 Light Oil Air Piping 9 16 9 2 13 Heavy Oil Air Piping 9 18 9 2 14 Heavy OIl Alstrom Heater 9 20 9 2 15 CB LE IFGR 9 22 9 2 16 IFGR Impeller 9 24 9 2 17 Pressure Controls 9 25 9 2 18 Temperature Con...

Page 14: ...xiv 750 91 revised 2009 Model CB LE Packaged Boiler Manual...

Page 15: ...hrough the various firetube passages The flame originates in the furnace As the combustion gasses travel down the furnace and through the various firetube channels heat from the flame and combustion g...

Page 16: ...reby improving combustion The LE Option is used on Cleaver Brooks Model CB firetube boilers firing either natural gas and or light oil and is compatible with both hot water and steam systems Rated Cap...

Page 17: ...having jurisdiction are to be consulted permits obtained etc All boilers in the above series comply when equipped with optional equipment to Industrial Risk Insurers IRI Factory Mutual FM or other ins...

Page 18: ...dends in the form of longer life less downtime and prevention of costly repairs Care taken in placing the pressure vessel into initial service is vital The waterside of new boilers and new or remodele...

Page 19: ...peration on a rise of boiler pressure at a selected setting It is adjusted to stop or start the burner at a preselected pressure setting 1 4 2 High Limit Pressure Control Breaks a circuit to stop burn...

Page 20: ...ntrol panel and it also causes the low water alarm bell optional equipment to ring Code requirements of some models require a manual reset type of low water cutoff Starts and stops the feedwater pump...

Page 21: ...k Temperature gauge Indicates flue gas outlet temperature 1 4 10 Auxiliary Low Water Cutoff Breaks the circuit to stop burner operation in the event boiler water drops below the master low water cutof...

Page 22: ...seats Use only flat jawed wrenches on the flats provided When installing a flange connected valve use a new gasket and draw the mounting bolts down evenly Do not install or remove side outlet valves...

Page 23: ...perature 1 5 3 High Limit Temperature Control Breaks a circuit to stop burner operation on a rise of temperature at a selected setting It is adjusted to stop burner at a preselected temperature above...

Page 24: ...allows the flue gasses to travel from the exit of the fourth pass tubes to the entrance of the combustion air fan The IFGR damper controls the volume of flue gas induced into the combustion air strea...

Page 25: ...a boiler is equipped to fire either gas or oil dual fuel boilers and the required NOX levels are below 60 ppm on natural gas a dual linkage arrangement is used to provide the different recirculation...

Page 26: ...rawer The spudding pattern for the IFGR system may be different than that of a non IFGR High Turndown CB Burner of the same horsepower HP model designation 1 6 7 Combustion Air Inlet The combustion ai...

Page 27: ...ure and steam nozzle sizing The flame safeguard and program relay include a flame detector to supervise both oil and gas flames and to shut the burner down in the event of loss of flame The programmin...

Page 28: ...ol circuits The function of individual components is outlined in this chapter and the electrical sequence is covered in Chapter 3 2 2 Control and Component Function The term control covers the more im...

Page 29: ...rimarily for ini tial or subsequent setting of fuel input throughout the firing range It has no control over the firing rate when the manual automatic switch is set on automatic Burner Switch A manual...

Page 30: ...must be manually reset following a safety shutdown caused by a loss of flame An internal checking cir cuit effective on every start prevents burner operation in the event anything causes the flame re...

Page 31: ...ream valve is equipped with a proof of closure switch that is connected into the pre ignition interlock circuit Low Gas Pressure Switch A pressure actuated switch that is closed whenever main gas line...

Page 32: ...Burner Operation and Control 2 6 750 91 revised 2009 Model CB LE Packaged Boiler Manual FIGURE 2 1 Gas Train configurations may vary FIGURE 2 2 Gas Modulating Cam...

Page 33: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 2 7 2 4 Controls for Gas Firing FIGURE 2 3 Secondary Air Flow with Gas Train...

Page 34: ...tched in the forward position required for burning oil Atomizing Air Proving Switch Pressure actuated switch whose contacts are closed when sufficient atomizing air pressure from the air pump is prese...

Page 35: ...a contour spring provided for adjustment of oil input at any point in the modulating range Oil Burner Pressure Gauge Indicates pressure of the fuel oil at the metering valve Oil Pressure Regulator Fo...

Page 36: ...p and air filter when the pump stops Air Oil Receiver Tank Holds a supply of oil for lubricating the air pump The receiver tank also separates lube oil from the atomizing air before delivery to the no...

Page 37: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 2 11 2 5 Controls Common to Oil Fired Boilers FIGURE 2 6 Oil Control Valve Assembly Heavy Oil FIGURE 2 7 Air Pump Components...

Page 38: ...ric heater is housed in the steam heater but is housed separately on a hot water heater Steam oil heaters on 15 psi boilers operate at boiler pressure Steam oil heaters furnished on high pressure boil...

Page 39: ...contacts open when fuel oil temperature raises above a selected temperature Switch will interrupt the limit circuit in the event fuel oil temperature rises above the selected point Hot Water Oil Heate...

Page 40: ...controller The valve MUST be closed prior to initial light off Its disc has an orifice to permit a continuous circula tion of hot fuel oil through the controller Air Purge Valve Solenoid valve opens...

Page 41: ...bination burner the gas pilot is used to ignite either the main gas flame or the oil flame At the beginning of the ignition cycle and governed by the program relay the pilot solenoid valve and ignitio...

Page 42: ...the burner is in operation although a positioning switch is often provided so that either continuous or automatic pump operation can be obtained See Figure 2 10 The oil flows through a fuel oil strai...

Page 43: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 2 17 2 11 Oil Fuel Flow Light Oil FIGURE 2 10 Light Oil Flow Diagram...

Page 44: ...fuel oil strainer to prevent any foreign matter from entering the control valves and nozzle The fuel oil controller contains in a single unit the necessary valves regulators and gauges to regulate th...

Page 45: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 2 19 2 12 Oil Fuel Flow Heavy Oil FIGURE 2 11 No 6 Heavy Oil Flow Diagram Steam Electric Heater...

Page 46: ...d the butterfly gas valve or the oil metering valve to maintain a constant air fuel ratio throughout the firing range During burner operation the motor is controlled by a modulating pressure control o...

Page 47: ...ing this time neither the manual flame control nor the modulating control have any control over the damper motor regardless of their setting An optionally equipped boiler uses a second integral switch...

Page 48: ...Burner Operation and Control 2 22 750 91 revised 2009 Model CB LE Packaged Boiler Manual...

Page 49: ...g the pressure vessel into initial service The waterside of new boilers and new or remodeled steam or hot water systems may contain oil grease or other foreign matter A method of boiling out the vesse...

Page 50: ...o periods of normal operation as well as during initial startup When individual zone circulating pumps are used it is recommended that they be kept running even though the hear users do not require ho...

Page 51: ...d point BOILER SIZE BHP BOILER OUT PUT 1000 BTU HR SYSTEM TEMPERATURE DROP DEGREES F 10 20 30 40 50 60 70 80 90 100 MAXIMUM CIRCULATING RATE GPM 15 500 100 50 33 25 20 17 14 12 11 10 20 670 134 67 45...

Page 52: ...he boilers in the boiler room 3 2 2 3 Pump Operation Pumps are normally started and stopped by manual switches It is also desirable to interlock the pump with the burner so that the burner cannot oper...

Page 53: ...boiler It cannot be over emphasized that rapid changes in temperature within the boiler can and sometimes do cause damage 3 3 Water Requirements Steam Boiler 3 3 1 Feed Pump Operation BEFORE turning...

Page 54: ...ment processes depends upon the water source its chemical characteristics amount of makeup water needed plant operating practices etc Treating methods include filtering softening de mineralizing deaer...

Page 55: ...ressure vessel must be kept clean from grease sludge and foreign material Such deposits if present will shorten the life of the pressure vessel will interfere with efficient operation and functioning...

Page 56: ...ry detergent added as a wetting agent The suggested general procedure for cleaning a boiler is refer to Figure 3 4 to determine water capacity 1 Have sufficient cleaning material on hand to complete t...

Page 57: ...ty or relief valves fill the boiler and fire it until the water is heated to at least 180 F to drive off any dissolved gasses which might otherwise corrode the metal The above procedure may be omitted...

Page 58: ...mpletion of the inspection the pressure vessel interior should be flushed out as required with a high pressure hose If deposits are not fully removed by flushing a consultation may be required with yo...

Page 59: ...ployed The blowdown tappings are located at the bottom or lowest part of the boiler in order to lower the dissolved solids in the pressure vessel water and to remove a portion of the sludge that accum...

Page 60: ...mmended for water make up lines 3 8 4 Manual Blowdown Procedure Blowdown is most effective at a point when the generation of steam is at the lowest rate and feedwater input is also low thus providing...

Page 61: ...s available along with any other gaskets or items needed to place the unit back into operation after inspection Have available information on the boiler design dimensions generating capacity operating...

Page 62: ...a boiler is out of service The condition does not generally occur during normal firing operation because the high temperature of operation vaporizes any condensation However proper boiler operation m...

Page 63: ...must again be taken to protect metal surfaces Variables preclude definite recommendations However it is suggested that the pressure vessel be drained thor oughly cleaned internally and re filled to o...

Page 64: ...Waterside Care and Requirements 3 16 750 91 revised 2009 Model CB LE Packaged Boiler Manual...

Page 65: ...t pressure or temperature control are below their cutoff setting All applicable limits are correct for burner operation The load demand light is on All entrance switches should be closed and power sho...

Page 66: ...rating limit control OLC pressure or temperature High limit control HLC pressure or temperature Low water cutoff LWCO Gas oil selector switch GOS combination burner only Oil drawer switch ODS oil burn...

Page 67: ...r The damper begins to open and drives to its full open or high fire position Opening the damper motor allows a flow of purging air through the boiler prior to the ignition cycle On certain boilers th...

Page 68: ...main flame established the program relay releases the modulating damper motor MDM from its low fire position to control by either the manual flame control MFC or the modulating control MC depending u...

Page 69: ...at the end of the post purge cycle and the shutdown cycle is com plete The program relay is now ready for subsequent recycling and when steam pressure or water temperature drops to close the contacts...

Page 70: ...zed The lockout switch must be manually reset before operation can be resumed Refer to the previous caution notice 4 4 3 Loss of Flame If a flame outage occurs during normal operation and or the flame...

Page 71: ...al Following a routine may possibly eliminate overlooking an obvious con dition often one that is relatively simple to correct Remember a safety device for the most part is doing its job when it shuts...

Page 72: ...Sequence of Operation 4 8 750 91 revised 2009 Model CB LE Packaged Boiler Manual...

Page 73: ...ter 4 Verify supply of fuel and proper voltage Check for blown fuses open circuit breakers dropped out overloads etc Check reset of all starters and controls having manual reset features Check the loc...

Page 74: ...m pressure but at least 10 lower than the setting of the safety valve The operating limit temperature control on a hot water boiler should be set slightly above the highest desired water temperature a...

Page 75: ...and the piping are level The CB Level Master is the standard low water cutoff device on CB high pressure steam boilers See CB manual 750 281 for complete operation maintenance and parts information 5...

Page 76: ...e oil level Add oil if necessary to bring the level to the midpoint or slightly higher in the sight glass Use SAE 20 detergent oil of a grade mentioned in Chapter 8 and fill in accordance with instruc...

Page 77: ...line to allow oil to fill the line Venting the suction line can generally be accomplished by cracking a union fitting or by opening the cap of the oil strainer using care to prevent spillage of oil Ti...

Page 78: ...ble firing condition FIGURE 5 3 No 2 Fuel Oil Control 5 5 2 Oil Pressure 1 Oil supply pressure is regulated by adjusting the pressure relief valve at the oil terminal block A pressure gauge should be...

Page 79: ...stablished as outlined in Section 5 4 The schematic flow diagram see Chapter 2 indicates the flow of fuel and atomizing air If the boiler is a combination fuel model be certain that the main gas shuto...

Page 80: ...e relief valves are equipped with tubing that directs and adds atomizing air pressure to the adjustable spring pressure Since the air pump is not running at this time only tentative adjustments can be...

Page 81: ...4 Starting When all the conditions covered in Sections 5 1 5 2 5 3 and 5 4 are assured the burner is ready for firing Refer to Section 5 8 for further starting and operating information 5 7 Firing Pre...

Page 82: ...cock Main flame should ignite unless there is air pres ent in the line 12 If the flame is not established within about 5 seconds turn the burner switch OFF and allow the programmer to recycle normall...

Page 83: ...eller and motor rotation Correct rotation is counterclockwise when viewed from the front of the boiler 3 Verify that all the IFGR components are set to the settings recorded on the Startup Report as n...

Page 84: ...Starting and Operating Instructions 5 12 750 91 revised 2009 Model CB LE Packaged Boiler Manual FIGURE 5 6 Jackshaft Linkage Settings FIGURE 5 7 Overtravel Linkage Settings...

Page 85: ...r gun should be properly withdrawn and latched in place The fuel selector switch should be accordingly set to either oil or gas 2 Set the manual automatic switch to manual and turn the manual flame co...

Page 86: ...the firing rate stopping at each cam screw to analyze combustion gasses and adjust as required To properly perform the testing and adjusting it is necessary that the burner be allowed to fire at a ma...

Page 87: ...purge period the blower motor is turned off The air pump motor of an oil fired burner is also turned off The timer has returned to its original starting position and stops The unit is ready to restar...

Page 88: ...e thermometer to verify the desired settings at the point of cut out and again when the burner restarts Return the manual automatic switch to automatic and check the modulating control for the desired...

Page 89: ...djustment procedures in Chapter 6 apply to standard components furnished on steam or hot water boilers fired with gas and or the various grades of oil 6 1 1 High Turndown Burner In order to reduce str...

Page 90: ...ravel the closer the connector is to the driven shaft the farther that arm will travel Over travel linkage where used should not be required in order to extend its spring to the fullest stretch With t...

Page 91: ...one third of maximum for a standard burner or one sixth for a HTB The amount of angular movement controlling the rate of air flow is determine by the location of the ends of the rotary air damper rod...

Page 92: ...rives to an open position FIGURE 6 3 Modulating Motor 6 4 Modulating Motor Switches Low Fire and High Fire The modulating motor contains either one or two internal switches depending upon application...

Page 93: ...position before the operating limit control either starts or stops the burner When adjusting or setting controls first be sure all control devices are securely mounted and level With the tem perature...

Page 94: ...ol closes and the burner will restart The modulating control will signal the modulating motor to be in a low fire position If the load demands exceed the low fire input potential the modulating contro...

Page 95: ...assuming that air fuel combustion ratios have been set make the required adjustments to the controls to bring the boiler pressure or temperature up to meet the load requirements To properly set the m...

Page 96: ...desired difference between cut out and cut in pressures The cut in burner on pressure is the cut out pressure minus the differential The cut out pressure should not exceed 90 of the safety valve sett...

Page 97: ...ut out burner off temperature on scale using the adjusting screw The control will break the circuit and lock out on a rise in water temperature above the setting The setting should be sufficiently abo...

Page 98: ...manually reset before it can be restarted Add a half turn or so to the adjust ing screw to remake its circuit Recycle the program relay to be sure that normal operation is obtained Replace the wire on...

Page 99: ...provides message information that includes a constant flame signal of DC voltage In this case a separate DC voltmeter is not required 6 15 1 Measure and Adjust Pilot 1 When making a pilot adjustment t...

Page 100: ...main burner flame at high low and intermediate firing rate positions Readings should be steady and in the range indicated in Step 8 If there are any deviations refer to the trouble shooting section in...

Page 101: ...size altitude and type of gas train The pressures listed are based on 1000 Btu cu ft natural gas at elevations up to 700 feet above sea level For installation at higher altitudes multiply the selecte...

Page 102: ...00 1 464 500 Boiler HP High Fire Input Btu hr OIL Low Fire Input Btu hr OIL 250 10 461 000 1 307 625 300 12 553 000 1 569 125 350 14 645 000 1 830 625 Boiler HP High Fire Input Btu hr Low Fire Input B...

Page 103: ...dex reading by the proper pressure factor obtained from Figure 6 10 Conversely to determine what the meter index reading should be in order to provide the volume of gas required for input divide the d...

Page 104: ...gas fuel is carried out be means of the adjusting screws in the gas modulating cam while performing a combustion efficiency analysis See Section 6 17 for details 6 17 Gas Fuel Combustion Adjustment Af...

Page 105: ...ent blue to translucent yellow FIGURE 6 11 Flue Gas Analysis for Natural Gas Most flue gas analyzers in use today measure the content by percentage of oxygen O2 and carbon monoxide CO either by percen...

Page 106: ...less than 400 ppm CO at high fire Using information from section 6 16 determine the standard conditions of gas pressure and flow for the boiler size and attached gas train Calculate the actual pressur...

Page 107: ...and 4 at high fire If the fuel input is correct but the O2 values do not fall within this range the air damper travel may need to be adjusted Adjustment of the air damper linkage is described in Sect...

Page 108: ...g the low fire cam screw to approximately 25 of that at high fire see Fig ure 6 8 At low fire the O2 flue gas reading should be between 6 and 7 It may be necessary to readjust the setting of the low f...

Page 109: ...o maintain a smooth cam profile If all screws are properly adjusted none will deviate from the general overall contour of the cam face 6 18 Low Gas Pressure Switch Adjust the scale setting to slightly...

Page 110: ...in the adjusting of the controls in the following paragraphs will vary and thus may be regarded as tentative and to be changed to provide best firing conditions Figure 6 15 is an oil viscosity tempera...

Page 111: ...always be excess air in the combustion process to account for changes in boiler room conditions and to ensure the combustion is on the proper side of the combustion curve Proper setting of the air fu...

Page 112: ...han to extend the adjusting screws to an extreme position in an effort to cut back flow After being certain that the air control damper and its linkage are operating properly final adjustment can be m...

Page 113: ...adjustments that can be made to the burner however a check should be made to assure that all components are properly located and that all holding screws are properly tightened The diffuser location on...

Page 114: ...eating spring in place See Section 8 7 for additional nozzle tip information Check to see that the flame detector sight tube and the gas pilot tube extend through their respective openings in the diff...

Page 115: ...mperature The con trols generally have a set differential and will close 5 F below the setpoint 6 26 Low Oil Pressure Switch Optional The LOPS prevents burner ignition or stops its operation when the...

Page 116: ...nd equipped with a hot water oil heater has a built in adjustable thermostat The maximum temperature setting is stamped on its dial The desired temperature can be obtained by turning the adjusting scr...

Page 117: ...properly the troubleshooting chapter should be referred to for assistance in pinpointing problems that may not be readily apparent Troubleshooting should be performed only by personnel who are famili...

Page 118: ...ted and corrected Most circuitry checking can be done between appropriate terminals on the terminal boards in the control cabinet or the entrance box Refer to the schematic wiring diagram for terminal...

Page 119: ...tion or atomizing air proving switches defective or not properly set B Motor starter interlock contact not closed 5 Flame detector defective sight tube obstructed or lens dirty PILOT FLAME BUT NO MAIN...

Page 120: ...me signal or open control in the running interlock circuit 7 Improper air fuel ratio lean fire A Slipping linkage B Damper stuck open C Fluctuating fuel supply 1 Temporary obstruction in fuel line 2 T...

Page 121: ...air the boiler and its related equipment The boiler room should be kept free of all material and equipment not necessary to the operation of the boiler or heating system Even though the boiler has ele...

Page 122: ...boiler shutdown Replacement spare parts if not on hand should be ordered sufficiently prior to shutdown Cleaver Brooks boilers are designed engineered and built to provide long life and excellent ser...

Page 123: ...o the operator that a water column blowdown is required A switch on the Level Master control panel optional external switch allows blowdown to be performed while the boiler is running Upon completion...

Page 124: ...e mounted in exact alignment If they are not the glass will be strained and may fail prematurely 8 5 Electrical Controls The operating controls should be inspected monthly Examine tightness of electri...

Page 125: ...the overloads trip out repeatedly when the motor current is normal replace them with new overloads If the condition continues after replacement it will be necessary to determine the cause of excessive...

Page 126: ...the complete safeguard system at least once a month or more often Tests should verify safety shutdown and a safety lockout upon failure to ignite the pilot upon failure to ignite the main flame and u...

Page 127: ...The blower motor will run through the post purge and stop 2 Turn the burner switch off 3 Reset the safety switch 4 Re establish main fuel supply 5 The flame detector lens should be cleaned as often as...

Page 128: ...e care not to damage the cartridge discs or the cleaner blades Wash the cartridge in solvents Do not attempt to disassemble the cartridge 8 7 4 Cleaning the Oil Nozzle The design of the burner togethe...

Page 129: ...tip and internal core 1 Clean all internal surfaces of the tip and the slotted parts of the core using a wood splinter to avoid damage from scratching 2 Replace the core setting it tightly but not exc...

Page 130: ...y accumulated lint or other foreign material Check the ignition cables for cracks in the insulation Verify that all connections between the transformer and the electrode are tight 8 9 Motorized Gas Va...

Page 131: ...d be tight but should not bind If the linkage assembly is binding determine the cause of the binding and correct as necessary Linkage rod end attachment points should be marked on the variable displac...

Page 132: ...essary to align the housing with the impeller 7 Slide the impeller toward the motor Use a feeler gauge to obtain a 030 050 clearance between the impeller and the housing 8 Secure the key and then tigh...

Page 133: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 8 13 8 12 Forced Draft Fan FIGURE 8 3 Forced Draft Fan Mounting...

Page 134: ...he side and secure it to the boiler using high strength cord Do not over extend the motor wires Disconnect and lock out electrical power to the boiler before removing the fan motor cassette Failure to...

Page 135: ...ired or if problems persist contact your local Cleaver Brooks authorized representative for further assistance As ash and products of combustion pass through the IFGR damper there will be some accumul...

Page 136: ...ect impeller clearance at the remaining attachment points 5 Check and replace any gaskets that have been damaged Gaskets that have been in use for one year or more should be replaced In particular ins...

Page 137: ...he inlet gasket then measure the clearance between the cassette flange and the front door mounting face There must be clearance of at least 1 4 to provide adequate gasket compression when the cassette...

Page 138: ...t would in nor mal service Do not hand operate the valve with less than 75 of the stamped set pressure exerted on the underside of the disc When hand operating be sure to hold the valve in an open pos...

Page 139: ...at the pin holding the metering portion is not protruding Back off the packing gland 6 Remove the capscrews holding the jackshaft support bracket so that the bracket can be moved It may also be necess...

Page 140: ...stem of the oil metering valve with suitable solvent and blow dry with an air line Follow the procedure outlined above when removing or reinstalling the metering valve stem Also check all fuel line st...

Page 141: ...A spare strainer basket can be obtained if desired and used on a rotating basis while the other is serviced 8 19 4 Air Cleaner Never operate the air pump without the air cleaner in place The cleaner i...

Page 142: ...upling alignment semi annually and replace the coupling insert as required Keep the coupling guard in place The most commonly used tools for checking alignment are a small straightedge and a thickness...

Page 143: ...st to obtain proper gap by loosening the hold down bolts and shifting either the pump or the motor as required Generally a slight tapping on either the front or rear legs is all that is needed to obta...

Page 144: ...6 Remove the fan from the air pump 7 Disconnect the flexible air line from the lube tank 8 Remove the coupling guard by pushing in on both sides until it clears the clamp 9 Loosen the clamp at the rea...

Page 145: ...may be fitted into place Be sure that all piping connections are tight If the motor was replaced or if motor leads were disconnected be sure that pump rotation is proper before starting operation The...

Page 146: ...d order proper replacement materials Remove existing refractory Thoroughly clean the furnace to remove all old refractory cement or other foreign material to ensure the new liner seats firmly against...

Page 147: ...r and be centered in the furnace Since the thickness of the furnace metal varies with the boiler design pressure a shim of appropriate thickness must be used to compensate for the variance A layer or...

Page 148: ...te use is required fire intermittently at a low rate for sev eral hours to thoroughly dry the refractory For detailed information request Bulletin C10 5921 from your local Cleaver Brooks representativ...

Page 149: ...ntenance Disconnect and lock out electrical power and fuel to the boiler before opening either the front or rear head Failure to follow these instructions can result in electrical shock and serious pe...

Page 150: ...remove the supply and return oil lines and the oil pilot line if necessary Remove the head bolts and swing the head The opened head should be supported by blocking or jacking to eliminate possible de...

Page 151: ...tightening in a star pattern After all bolts are secured tighten the upper and lower hinge nuts evenly to pull the door securely against the vessel Repeat the star tightening sequence on the head bolt...

Page 152: ...nges in temperature they should be expected to show minor cracks due to contraction when examined at low temperatures Cracks to approximately 1 8 across may be expected to close at high temperature If...

Page 153: ...n the baffle and attach a new length of 1 1 2 diameter fiberglass rope P N 853 1036 to the groove Be certain that the rope is properly positioned Wash coat the lower half of the rear door refractory p...

Page 154: ...od commercial grades of grease locally available Some lubricants that are distributed nationally are 8 22 2 Control Linkage Apply a non gumming dripless high temperature lubricant such as graphite or...

Page 155: ...reaking any of the electrical connections to the electric heating elements mark all wires and terminals to assure rapid and correct replacement of wires Finish the cleaning process with a cleaning sol...

Page 156: ...f there is no danger of freezing plain water may be used as a replenishment if necessary to refill Evidence of oil in either the steam heater condensate or in the water heater indicator demands prompt...

Page 157: ...ure Inspect burner Inspect for flue gas leak Inspect for hot spots Check cams Check for tight closing of fuel valve Check fuel and air link age Check indicating lights and alarms Check operating and l...

Page 158: ...Inspection and Maintenance 8 38 750 91 revised 2009 Model CB LE Packaged Boiler Manual...

Page 159: ...y giving the item number description and the quantity of parts desired together with the complete nameplate data including all electrical requirements Repair and replacement parts should be ordered fr...

Page 160: ...G AIR OIL TANK TO MANIFOLD V BELT SHEAVE SHEAVE AIR PUMP ASSEMBLY BELT GUARD ASSEMBLY AIR COMPRESSOR BRACKET NOTE 4 AIR OIL TANK ASSEMBLY AIR CLEANER 3 4 STRAINER ASSEMBLY AIR INLET ASSEMBLY AIR INLET...

Page 161: ...OMPRESSOR ASSEMBLY PART NO USED ON DESCRIPTION QTY ITEM 1 1 505 113 2 2 008 01159 868 00431 4 3 952 114 4 4 952 133 4 5 78 847 469 1 6 7 1 SEE TABLE 8 1 SEE TABLE 8 7 ITEM 819 158 894 3431 200 460V 60...

Page 162: ...CONDUIT BRACKET 1 3 BULK CONDUIT 1 2 THINWALL EMT X A LG APPROX 1 2 BULK CONDUIT 1 2 THINWALL EMT X B LG APPROX 1 1 DESCRIPTION PART NO QTY ITEM 827 8 868 136 5 CAPSREW HEX HD 1 4 20 X 3 4 LG 7 COUPL...

Page 163: ...BINATION 20 22 21 BAFFLE ATTACHMENT STUD BAFFLE SEAL BAFFLE TUBE SHEET INNER DOOR 27 25 26 28 28 5 429 D 1270 429 1271 429 1272 400 600 429 820 429 819 429 819 700 429 1274 429 D 1273 429 D 1273 101 2...

Page 164: ...3 8 BRASS FLANGE RING 10 1 15 B 121 869 29 8 15 NUT HEX 1 2 13 BRASS 85 C 444 1 14 SUPPORT BURNER HOUSING GASKET BURNER HOUSING SUPPORT 13 2 32 A 928 869 15 8 18 NUT HEX 1 2 13 15 B 39 1 FLANGE RING...

Page 165: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 7 9 2 Parts Lists and Drawings 9 2 5 Control Panel...

Page 166: ...Parts 9 8 750 91 revised 2009 Model CB LE Packaged Boiler Manual Control Panel...

Page 167: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 9 9 2 Parts Lists and Drawings 9 2 6 Entrance Box...

Page 168: ...Parts 9 10 750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 2 7 Front Head Electrical...

Page 169: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 11 9 2 Parts Lists and Drawings 9 2 8 Front Davit...

Page 170: ...Parts 9 12 750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 2 9 Front Head Insulation...

Page 171: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 13 9 2 Parts Lists and Drawings 9 2 10 Front Head Linkage...

Page 172: ...IPPLE ALL HP HAWK 2 157 1039 S O NIPPLE 1 2 3 GTS STD HIGH GAS PRESS SWITCH ALL HP HAWK 1 817 752 HIGH GAS PRESS SWITCH 300 350 HP STD 1 507 6785 GAS PRESS SENSOR 200 350 HP HAWK 2 941 130 LUBRICATED...

Page 173: ...4 GTS 33 2 952 92 LOCKWASHER QTY 3 ON 4 GTS 32 2 928 44 STRAP QTY 3 ON 4 GTS 31 4 869 36 HEX NUT QTY 6 ON 4 GTS 30 4 952 133 WASHER QTY 6 ON 4 GTS 29 4 952 114 LOCKWASHER QTY 6 ON 4 GTS 2 7 77 U BOLT...

Page 174: ...Parts 9 16 750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 2 12 Light Oil Air Piping...

Page 175: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 17 9 2 Parts Lists and Drawings Light Oil Air Piping...

Page 176: ...Parts 9 18 750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 2 13 Heavy Oil Air Piping...

Page 177: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 19 9 2 Parts Lists and Drawings Heavy Oil Air Piping...

Page 178: ...Parts 9 20 750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 2 14 Heavy OIl Alstrom Heater...

Page 179: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 21 9 2 Parts Lists and Drawings Heavy OIl Alstrom Heater...

Page 180: ...50 300 250 ITEM 4 P N 350 300 7 30 25 PPM 132 1721 RH 132 1723 RH 132 1724 LH 132 1722 LH 20 PPM 132 1720 LH 132D1688 RH 60 PPM ITEM 1 P N PRESS ASSY 270 02244 270 02245 270 02246 270D02241 270D02247...

Page 181: ...093 PART NO DESCRIPTION QTY ITEM 1 1 SEE TABLE 2 1 146 D 13 146 D 120 1 3 SEE TABLE 1 4 465 D 625 1 5 146 D 102 1 6 7 32 C 2532 1 8 9 32 C 2543 1 10 11 12 13 14 2 32 B 899 15 16 1 146 C 38 1 465 C 163...

Page 182: ...Parts 9 24 750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 2 16 IFGR Impeller...

Page 183: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 25 9 2 Parts Lists and Drawings 9 2 17 Pressure Controls...

Page 184: ...Parts 9 26 750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 2 18 Temperature Controls...

Page 185: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 27 9 2 Parts Lists and Drawings 9 2 19 W C Main Aux...

Page 186: ...Parts 9 28 750 91 revised 2009 Model CB LE Packaged Boiler Manual W C Main Aux...

Page 187: ...SSY 78 96 317 60 GASKET MANHOLE 12 X 16 853 00939 COVER MANHOLE SA 285 GR C PVQ 821 00207 YOKE HANDHOLE 2 PRONG FORGED 953 00048 GASKET HANDHOLE 3 1 4 X 4 1 2 853 00935 YOKE MANHOLE PRESSED STEEL 953...

Page 188: ...Parts 9 30 750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 2 21 Rear Head Sealing Davit...

Page 189: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 31 9 2 Parts Lists and Drawings 9 2 22 Throat Tile and Furnace Liner Plain furnace Standard corrugated furnace...

Page 190: ...Parts 9 32 750 91 revised 2009 Model CB LE Packaged Boiler Manual Throat Tile and Furnace Liner Plain furnace Standard corrugated furnace...

Page 191: ...750 91 revised 2009 Model CB LE Packaged Boiler Manual 9 33 9 2 Parts Lists and Drawings Throat Tile and Furnace Liner cont d Optional corrugated furnace...

Page 192: ...Parts 9 34 750 91 revised 2009 Model CB LE Packaged Boiler Manual Throat Tile and Furnace Liner cont d Optional corrugated furnace...

Page 193: ......

Page 194: ...e mail info cleaverbrooks com Web Address http www cleaverbrooks com...

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CleaverBrooks CBLE, Operation And Maintenance Manual

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