CleaverBrooks FLX 1000 Page 125 Operation, Service And Parts Manual Download

Page: 125 / 136

50-

17
7

8-5

Part List, LP Steam

250

350

500

800

1100

ITEM

DESCRIPTION

PART #

REQ

PART #

REQ

PART #

REQ

PART NO.

REQ

PART #

REQ

Base

315-1124

315-1169

315-1180

315-1194

315-1203

Roof 315-1215

315-1230

315-1239

315-1250

315-1260

3.a

Front wall, w/o Hinge

315-1263

315-1264

n/a

3.b

Front wall w Hinge

315-1216

315-1229

315-1138

315-1249

Rear wall-large piece

315-1217

315-1228

315-1237

315-1248

Outer casing panel

315-1218

315-1227

315-1236

315-1247

315-1257

Outer casing strips-top

315-1131

315-1163

315-1174

315-1188

315-1197

Plate, base to wall

315-1132

Outer casing strips corner strip

315-1219

315-1226

315-1235

315-1246

Burner plate

Note 5

10.

Inner side panel Left Hand

315-1220

315-1225

315-1234

315-1245

315-1256

11.

Inner side panel Right Hand

315-1221

315-1224

315-1233

315-1244

315-1255

12.

Mounting Plate

315-1143

13.

Plate, Collar, Lower Outer

315-694

315-695

14.

Plate, Collar, Upper Outer

315-1222

315-1243

15.

Plate, Cover, Lug, Lifting

315-1100

315-1099

16.

Cap, sight

550-42

17.

Capscrew, hex hd. 3/8”-16x 3/4”lg

868-1506

108

868-1506

144

18.

Capscrew, hex hd. 1/2”-13x 1-1/2”lg

868-102

19.

Capscrew, hex hd. 5/8”-11x 1-1/2”lg

868-188

20.

Screw, self tapping, ¼” x 1”lg

841-423

21.

Locknut, hex hd., 3/8”

869-510

128

869-510

130

869-510

188

869-510

252

869-510

308

22.

Nut, hex hd., ½” brass

869-27

23.

Nut, hex hd., ½”

869-144

24.

Capscrew, Hex hd ¾”-10 x 6” LG

868-600

25.

Washer, flat, ½”

952-286

26.

Washer, flat, 5/8”

952-321

27.

Never-Seez

797-1816

28.

nner Casing Spacer Block

315-1336

29.

Inner Side Panel Mid Left

n/a

315-1295

30.

Inner Side Panel Mid Right

n/a

315-1253

31.

Inner Side Panel Mid

n/a

315-1242

n/a

315-1261

32.

Retaining Plates, Lower, Inner, Small

315-1278

315-1280

33.

Retaining Plates, Lower, Inner, Large

315-1158

315-1282

315-1182

34.

Plate, collar, upper, inner

315-1223

351-1254

315-1254

35.

Ring Seal, Outlet Steam #15

315-219

315-220

315-221

315-1057

315-1058

36.

Assembly, rear wall corner piece

315-1286

315-1287

315-1289

315-1291

37.

Assembly, front wall corner piece

315-1285

315-1288

315-1290

315-1292

38.

Gasket, Expanded PTFE 3/8” x 3/16”

32-2560

79 ft

32-2560

86 ft

32-2560

110 ft

32-2560

144ft

32-2560

168ft

39.

Handle, Flush Mount, Snap In

865-68

Summary of Contents for FLX 1000

Page 1: ...Manual Part No 750 177 R6 MODEL FLX PACKAGED BOILER 1 500 000 to 12 000 000 Btu hr Hot Water and Steam Fuel Light Oil Gas or Combination 5 2014...

Page 2: ...nual 1 500 000 to 12 000 000 Btu hr Fuel Light Oil Gas or Combination Please direct purchase orders for replacement manuals to your local Cleaver Brooks authorized representative Manual Part No 750 17...

Page 3: ...to show 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...

Page 4: ...up and Operation 2 19 G Adjustments 2 26 H Gas System 2 34 I Oil System 2 37 J Combination Gas Oil System 2 39 K Modulation Control 2 40 L Air and Fuel Controls 2 42 M Maintenance 2 43 N Troubleshooti...

Page 5: ...mit Pressure Control Steam 5 5 H High Limit Pressure Control Steam 5 5 I Modulating Temperature Control Hot Water 5 6 J Operating Limit Temperature Control Hot Water 5 6 K High Limit Temperature Contr...

Page 6: ...F Oil Burner Maintenance 7 6 G Gas Burner Maintenance 7 7 H Refractory 7 7 I Casing Seals 7 7 Chapter 8 Parts Casing HW 8 2 Casing Low Pressure Steam 8 4 Casing High Pressure Steam 8 6 Steam Pressure...

Page 7: ...inuous reliable operation If the boiler is to be used for temporary heat for example in new con struction properly treated water must be used Fail ure to do so can be detrimental to the boiler This ma...

Page 8: ...20 F The operating pressure for hot water heating systems usually is 30 psig to 125 psig Steam and hot water boilers are defined according to design pressure and operating pressure Design pressure is...

Page 9: ...al automatic switch is set on automatic 4 Low Water Cutoff and Pump Control Float operated control responds to the water level in the boiler It performs two distinct functions Stops firing of the burn...

Page 10: ...F SAFETY VALVE SETTING TO STEAM 1 1 2 MIN Figure 2 3 Recommended piping for steam relief valve not furnished by Cleaver Brooks DANGER WARNING Only properly certified personnel such as the safety valve...

Page 11: ...a vertical position so that discharge piping and code required drains can be properly piped to prevent buildup of back pressure and accumulation of foreign material around the valve seat area Apply on...

Page 12: ...Chapter 1 General Description 1 6 750 177...

Page 13: ...e the Canadian Gas Association CGA B149 and the Canadian Standards Association CSA B140 codes shall prevail Other regulatory agency control options are available DANGER CAUTION ONLY FACTORY AUTHORIZED...

Page 14: ...hutdown This safety control also includes flame detection system to confirm proper operation or cause a manual reset lockout in the event of a pilot or main flame failure External controls connected t...

Page 15: ...enings in boiler room Two 2 permanent air supply openings in the outer walls of the boiler room are rec ommended Locate one 1 at each end of the boiler room preferably 7 foot or lower This allows air...

Page 16: ...to provide the burner s high fire rate rated gallons per hour gph Smaller gph nozzles may be used to match burner output to a heat exchanger s required input Models V13 34 are supplied with simplex no...

Page 17: ...oil spray contacts the established gas pilot flame On full modulation units the modulating actuator varies the oil metering valve setting The metering valve located in the return oil loop reduces the...

Page 18: ...r 2 Profire V Burner 2 6 750 177 Figure 2 3 Full Modulation Oil System with Integral Pump Return Flow Nozzle V13 55 OIL NOZZLE OIL PRESSURE SWITCH N C VALVES FUEL UNIT PRESSURE TAP MODULATING MOTOR OI...

Page 19: ...ssure to specified pressure required at the burner manifold Input is set by main gas pressure regulator adjustment Main Gas Cocks Used for manual shutoff of the gas supply upstream of the pressure reg...

Page 20: ...Chapter 2 Profire V Burner 2 8 750 177 Figure 2 5 Typical Gas Train for Full Modulation System V13 34 Figure 2 6 Typical Gas Train for LHO LHL Systems V35 63 Full Modulation Systems V35 168...

Page 21: ...air is supplied by the burner forced draft blower providing adequate air for any normal combustion condition Since draft control is essential to maximum efficiency a draft regulator maybe required whe...

Page 22: ...l and vertical 3 Read up from line total feet of copper tube to the intersection line of the specific suction capacity in gph 4 Read left to column inches of vacuum at fuel unit This is vacuum require...

Page 23: ...Profire V Burner Chapter 2 750 177 2 11 Figure 2 8 Typical No 2 Oil Loop Single Burner Figure 2 9 Multiple Burners with Separate Suction Lines...

Page 24: ...Chapter 2 Profire V Burner 2 12 750 177 Figure 2 10 Typical Oil Loop for Multiple Burners with Transfer Pump Figure 2 11 Typical Installation Using Day Tank...

Page 25: ...rain components upstream of the butterfly valve are shipped loose These components should be mounted by the installer as close to the butterfly valve as practical If a pre piped and wired gas train is...

Page 26: ...otected with refractory The burner mounting flange must be properly sealed against the vessel front plate 6 Make certain that the operator in charge is properly instructed in operation and maintenance...

Page 27: ...open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valves low fire setting Safety shut off valves open allowing oil to flow...

Page 28: ...up Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valves low fire setting Safety shut off valves open allowing o...

Page 29: ...butterfly valve low fire setting Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s pressure setting less the volume of oil returnin...

Page 30: ...RUN MODULATE Damper is driven by its parallel positioning actuator to a firing rate position as determined by the parallel positioning control The actuator and parallel positioning control will then c...

Page 31: ...he wiring diagram and local codes The control cabinet components are 120 volt If a control transformer is supplied ensure that the supply voltage matches its primary voltage Check motor rotation by mo...

Page 32: ...the suction line a closed valved kinked copper tubing plugged filter sticking check valve frozen oil line undersized oil line or excessive lift When there is a positive head of oil at the fuel unit ei...

Page 33: ...ll in Upon completion of successful test disconnect power supply Reconnect oil safety shutoff valve and turn on manual pilot gas valve Reconnect power supply and proceed with startup procedures BURNER...

Page 34: ...e manual oil valves 3 When firing on gas open the main manual gas valve 4 When firing on gas manually reset the high and low gas pressure switches if applicable 5 Place the gas oil selector switch if...

Page 35: ...prior to putting the equipment back into service DANGER WARNING FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN EXPLOSION FIRE PROPERTY DAMAGE AND PERSONAL INJURY THIS PROCEDURE MUST BE PERFORMED ONLY...

Page 36: ...Do not disturb established low fire adjustment Allow the burner to return to low fire position before adjusting high or intermediate setting CO levels should be less than 400 ppm on an air free basis...

Page 37: ...CULATION AT ALL TIMES TO AVOID DAMAGE AND SEIZURE OF THE PUMP NORMAL OPERATION Normal operation must be with the MANUAL AUTO switch selector on AUTO In automatic operation the operating cycle always p...

Page 38: ...t may help in making preliminary settings The proper settings of air fuel ratios must be determined by flue gas analysis Combustion gas analysis indicates the air to fuel ratio and the degree of compl...

Page 39: ...usting the pressure setting of the pilot regulator Normal setting is 4 to 6 W C when the pilot is burning The flame must be sufficient to be proven by the flame detector and ignite the main flame To a...

Page 40: ...djustment 1 Lock out and tag the electrical power supply to the burner to prevent inadvertent operation during checkout or maintenance activities 2 Disconnect the high voltage power supply from the oi...

Page 41: ...Carefully install the drawer assembly into the burner 5 Re connect the oil line and high voltage power cable to the assembly Measure the position of the diffuser to the air baffle and compare to the f...

Page 42: ...LE TIP TO BOTTOM EDGE OF ELECTRODE WIRES 5 32 BETWEEN INNER EDGES OF ELECTRODE WIRES 656 10215 000 Chapter 2 Profire V Burner 2 30 750 177 Figure 2 16 Drawer Assembly for VL Oil Only V13 34 Watertube...

Page 43: ...F DIFFUSER 1 89 REAR FACE OF DIFFUSER TO FRONT FACE OF 25 NOZZLE TIP TO OUTER EDGE OF ELECTRODE WIRES 7 16 FROM CENTER OF OIL NOZZLE TIP TO BOTTOM EDGE OF ELECTRODE WIRES 5 32 BETWEEN INNER EDGES OF E...

Page 44: ...REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 Figure 2 21 Drawer Assembly for VG Gas Only V60 110 Watertube 1 83 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 00 FROM NOZZLE TIP...

Page 45: ...re V Burner Chapter 2 750 177 2 33 Figure 2 23 Drawer Assembly for VG Gas Only V120 168 Watertube 1 92 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 65...

Page 46: ...is the pressure that is required to fire the burner at its rated capacity The gas pressure regulator must be adjusted to achieve this pressure to assure full input LOW GAS PRESSURE SWITCH Turn adjusti...

Page 47: ...gas butterfly valve low and high gas pressure switches and an air damper assembly The auxiliary switch inside the M436 Mod motor makes or breaks the high fire gas The Low High Low boiler control energ...

Page 48: ...e in the low fire position 6 After a few seconds the O2 analyzer should have an accurate reading of the O2 present in the flue gas Normally O2 levels are set between 4 to 6 at low fire for standard tu...

Page 49: ...ing is complete continue with the instructions above adjusting the cam at each screw to obtain the proper NOx values Verify the values modulating back to low fire and adjust accordingly I Oil System A...

Page 50: ...r for a clean fire Record the combustion reading from the flue gas analyzer normally 3 5 to 4 5 O2 and less than No 1 smoke Bacharach To adjust the oil pressure regulating valve remove the lockscrew a...

Page 51: ...ttings Complete the Startup Report 10 Turn the MANUAL AUTO switch to AUTO The burner will now modulate according to the load demand to the boiler J Combination Gas Oil System In general the combinatio...

Page 52: ...oil metering unit When properly adjusted coordinated movement of the air and fuel control devices provide proper fuel air ratios through the firing range In linkage adjustments several important facto...

Page 53: ...en operate the automatic modulating cycle to assure satisfactory results Tighten the locking setscrews NOTE It is essential that the cam spring cam follower bearing wheel and cam follower arm at the p...

Page 54: ...djustments also vary with specific system applications Turndown capability for oil is less than that of natural gas On combination fueled burners gas turndown performance may be restricted by the exce...

Page 55: ...TEM Most operating controls require very little maintenance beyond regular inspection Examine electrical connections Keep the controls clean Remove any dust from the interior of the control Covers sho...

Page 56: ...ler blade and using it as a lever will only damage the blade FIRING HEAD INSPECTION Open side access panels to view the drawer assembly Inspect the lead wire to the ignition electrode It must be firml...

Page 57: ...st if necessary For burners equipped with a gas pilot the pilot is located on the side opposite to the main gas entrance 1 Close the gas pilot cock 2 Disconnect the pilot gas supply line 3 Remove the...

Page 58: ...with a scribed or pencil line where the three mounting screws are located to insure that the diffuser is placed back in the same position 3 Remove the screws holding the diffuser to the blast tube an...

Page 59: ...actuator if valve fails to operate After replacement cycle the valve with the fuel shut off to determine that it opens and closes If the valve has a visual indicator observe its position for correct o...

Page 60: ...ner fuel supply to extinguish main flame 2 The fuel valves will be de energized and the relay will signal the condition within four seconds Thecontrol will then lock out on a safety shutdown 3 The fla...

Page 61: ...or fluctuating Linkages Operator Check all burner linkages for tightness Tighten if required MONTHLY Low Fan Pressure Interlock Operator Manually adjust until switch opens High and Low Gas Pressure In...

Page 62: ...3 Limit circuit not completed no voltage at end of limit circuit program relay termi nal a Pressure or temperature is above setting of operation control b Water below required level Low water light an...

Page 63: ...med or linkage binding 4 Running interlock circuit not completed a Combustion proving switches defective or not properly set b Motor starter interlock contact not closed 5 Flame detector defective sig...

Page 64: ...ogrammer lockout switch has not tripped check the limit circuit for an opened safety control 6 If the programmer lockout switch has tripped a Check fuel lines and valves b Check flame detector c Check...

Page 65: ...LX Burner Characteristics Model No Burner Maximum Input MBH Burner Model Fan Motor 3450 RPM Voltage FLX 150 1500 PFVLG 15 115 230 1 60 FLX 200 2000 PFVLG 20 115 230 1 60 FLX 250 2500 PFVLG 25 115 230...

Page 66: ...4 21 7 PFVG 20 FLX 250 1 5 12 4 15 7 PFVG 25 FLX 300 1 5 15 9 20 7 PFVG 30 FLX 350 1 5 15 5 22 0 PFVG 35 FLX 400 1 5 18 7 27 2 PFVG 40 FLX 450 2 16 0 26 7 PFVG 45 FLX 500 2 17 6 21 0 PFVG 50 FLX 550 2...

Page 67: ...High Water Cut Off Operating Limit High Limit Operating Control Stack Temp Interlock Flame Failure Combustion Air Switch High Purge Switch Low Fire Interlock Oil Pressure Switch Oil Valve with P O C I...

Page 68: ...Chapter 2 Profire V Burner 2 56 750 177...

Page 69: ...severe stress to the pressure vessel Figure 3 1 Upper Drum Hot Water A B C C A HOT WATER OUTLET B AIR VENT TAPPING C PRESSURE TEMPERATURE GAUGES Although it is of prime importance the subject of wate...

Page 70: ...7 111 5 0 11 89 2 FLX 600 2 99 486 8 0 77 243 4 0 35 162 3 0 20 121 7 0 13 97 4 FLX 700 1 75 567 9 0 45 284 0 0 21 189 3 0 12 142 0 0 08 113 6 FLX 800 2 27 649 1 0 59 324 5 0 27 216 4 0 15 162 3 0 10...

Page 71: ...The recommended minimum system return water temperature shall be 140 F 60 C when firing natural gas or 150 F 66 C when firing oil And for special burner applications firing digester gas minimum return...

Page 72: ...en changes in firing rate or operating pressure of the boiler will initiate a call for water from the make up controller which will require that the feed water be delivered to the boiler in sufficient...

Page 73: ...column Figure 3 4 Blowdown is the removal of some of the concentrated water from the boiler and the water level control system in order to lower the concentration of solids in the water Solids are int...

Page 74: ...pen the downstream valve slightly to release the water trapped between the valves then close the valve again The water column and gauge glass should be blown down by draining until the water in the ga...

Page 75: ...erformed 3 months after the initial start up then at regular 6 9 or 12 month intervals thereafter The frequency of periodic inspections will depend upon the internal conditions found the particular in...

Page 76: ...m It is important that the water used for the filling process is at a temperature of 70 F or above 7 Add the boilout solution using a chemical pump DANGER WARNING The chemicals used in this procedure...

Page 77: ...oiler layup procedures in this chapter H Washing Out Depending on system integrity feedwater quality or operating conditions the water side of the boiler may need to be washed out on occasion In theor...

Page 78: ...or internal or external corrosion or leakage Fireside surfaces also should be cleaned so that metal surfaces welds joints tube fittings and any previous repairs can be readily checked DANGER WARNING T...

Page 79: ...orage wet or dry Your local Cleaver Brooks authorized representative can recommend the better method based on the circumstances of your particular installation Regardless of the method employed the bo...

Page 80: ...er will be out of service for shorter periods of time when a boiler is held in standby conditions or in cases where dry storage is not practical The boiler held in wet storage can be brought back into...

Page 81: ...nclature to aid in applying the text to the wiring diagram The burner and control system are in starting condition when the following conditions exist Boiler water is up to the correct level closing t...

Page 82: ...ssures switch LGPS High gas pressure switch HGPS Fuel valve interlock circuit Main gas valve auxiliary switch MGVAS Oil valve auxiliary switch OVAS Blower Motor Starter Circuit Blower motor starter BM...

Page 83: ...nto the running interlock circuit must be closed within 10 seconds after the start sequence In the event any of the controls are not closed at this time or if they subsequently open the program relay...

Page 84: ...ire firing range When a shutdown occurs while operating in the manual position at other than low fire the damper will not be in a closed position thus allowing more air than desired to flow through th...

Page 85: ...curs during normal operation and or the flame is no longer sensed by the detector the flame relay will trip within 2 to 4 seconds to deenergize the fuel valve circuit and shut off the fuel flow The re...

Page 86: ...R Blower Motor Power Relay BMPS Blower Motor Purge Switch BMR Blower Motor Relay BMS Blower Motor Starter BMSI Blower Motor Starter Interlock BMSS Boiler Master Selector Switch BS Burner Switch BSS Bo...

Page 87: ...e Light HFOV High Fire Oil Valve HFPS High Furnace Pressure Switch HFS High Fire Switch Table 4 1 Electrical Nomenclature Continued MNEMONIC DESCRIPTION HFS A High Fire Switch Air HGPL High Gas Pressu...

Page 88: ...lve Auxiliary Switch MOVEL Main Oil Valve Energized Light MPC Modulating Pressure Control MPCB Main Power Circuit Breaker MPP Manual Positioning Potentiometer Table 4 1 Electrical Nomenclature Continu...

Page 89: ...wer Pressure Switch SBR Sootblower Relay SC Scanner SCTS Supervisory Cock Test Switch SDL Steam Demand Light SHT Steam Heater Thermostat SHV Steam Heater Valve SLCL Safety Limits Complete Light SPIR S...

Page 90: ...Chapter 4 Sequence of Operation 4 10 750 177...

Page 91: ...10 T Fuel Oil Combustion Adjustment 5 12 U Low Oil Pressure Switch 5 12 A GENERAL Each Cleaver Brooks boiler is tested for correct operation before shipment from the factory However variable conditio...

Page 92: ...ver Brooks Service or Parts representative it may have an incorrect stroke To prevent damage verify the 90 stroke prior to installing a replacement The stroke may be determined by powering the motor a...

Page 93: ...imit control modulating control and the high limit control The burner will be on whenever the pressure or temperature is less than point B and off whenever pressure or temperature is greater than poin...

Page 94: ...r in low fire The modulating control will be calling for high fire and the burner will move to that position as rapidly as the damper motor can complete its travel Note Rapid heat input can subject th...

Page 95: ...he fixed time required for proving the pilot and main flame In addition approximately one half minute is required for the damper motor to travel from low to high fire The time lag may allow pressure o...

Page 96: ...ciently above the operating limit temperature to avoid unnecessary shutdowns The control requires manual resetting after tripping on a temperature increase To reset allow the water temperature to drop...

Page 97: ...ot only the quantity of gas demanded by the unit but must also be at a pressure high enough to overcome the pressure loss due to the frictional resistance imposed by the burner system and the control...

Page 98: ...e a warm boiler adjustments should be made to obtain efficient combustion Burner efficiency is measured by the amount or percentage of O2 present in the flue gas O2 readings determine the total amount...

Page 99: ...the shaft Determine the actual gas flow from a meter reading See Section O With the butterfly valve open and with regulated gas pressure set at the calculated pressure the actual flow rate should be...

Page 100: ...casionally require adjustments to assure highest combustion efficiency The handling and burning characteristics may vary from one delivery of oil to another Therefore it is recommended that the oil sy...

Page 101: ...FVG 45 FLX 500 2 17 6 21 0 PFVG 50 FLX 550 2 22 9 27 1 PFVG 55 FLX 600 2 20 0 24 9 PFVG 60 FLX 700 2 25 2 31 9 PFVG 70 FLX 800 2 5 19 9 22 2 PFVG 80 FLX 900 2 5 24 7 27 7 PFVG 90 FLX 1000 2 5 31 6 31...

Page 102: ...nalyzers but may be displayed as a calculation The O2 levels through the entire firing range of the burner low fire to high fire should be tested Cleaver Brooks recommendations on turndown should also...

Page 103: ...IR 10 20 30 40 50 60 5 6 7 8 9 10 11 12 1 1 2 2 3 3 4 4 5 5 6 6 7 8 9 0 PER CENT CO 2 IN FLUE GAS FIRST VISIBLE TRACE OF STACK HAZE 1 10 of 1 CO 1 000 PPM 15 Figure 5 4 Flue Gas Analysis Chart for Nat...

Page 104: ...Chapter 5 Adjustment Procedures 5 14 750 177...

Page 105: ...perly the trouble shooting chapter should be referred to for assistance in pinpointing problems that may not be readily apparent The program relay has the capability to self diagnose and to display a...

Page 106: ...ches 4 Fuel valve interlock circuit not completed A Fuel valve auxiliary switch not enclosed NO IGNITION 1 Lack of spark A Electrode grounded or porcelain cracked B Improper electrode setting C Loose...

Page 107: ...re above modulating control setting 2 Manual automatic switch in wrong position 3 Inoperative modulating motor 4 Defective modulating control 5 Binding or loose linkage setscrews etc SHUTDOWN OCCURS D...

Page 108: ...wn A Motor defective B Loose electrical connection C Damper motor transformer defective 4 Motor does not operate on demand A Manual automatic switch in wrong position B Modulating control improperly s...

Page 109: ...ld system startup A Any time a boiler is started with a cold system it will produce condensate until internal surface temperatures exceed 130 F Internal condensation will not be produced once a boiler...

Page 110: ...Chapter 6 Troubleshooting 6 6 750 177...

Page 111: ...uld result in electrical shock serious personal injury or death Good housekeeping practices help maintain a professional appearing boiler room Only trained and authorized personnel should be permitted...

Page 112: ...te to many years of reliable performance from the equipment Cleaver Brooks offers a Planned Maintenance Program that covers many of the items included on this chapter For more information on the Plann...

Page 113: ...3rd pass is only open on the ends cleaning is done by pushing a wire brush mounted on a long handle through from each end Since the arc of movement is restricted cleaning the 3rd pass must be done fr...

Page 114: ...bottom section into the boiler and allowing it to slide down to catch the bottom clamp angle Then slide the end panels under the corner frames and install any remaining center panels The fireside shou...

Page 115: ...tional feedwater treatment that might not otherwise be necessary To verify the proper operation of float style low water cutoff devices the system must be drained Remove the operating mechanism from t...

Page 116: ...of the feedwater controller and the low water cutoffs DANGER CAUTION If a control does not break the circuit to stop the burner at the proper point then shut down the burn er immediately Failure to do...

Page 117: ...ntrol be kept on hand and service be rotated between the active and the spare control programmer Note Be sure that the connecting contacts on the control and the base are not bent out of position DANG...

Page 118: ...y or death Reassemble the strainer taking care to seal the canister properly to avoid air infiltration and resulting loss of suction Open the fuel supply and the return line valves G Gas Burner Mainte...

Page 119: ...igh temperature bonding air dry mortar such as Cleaver Brooks Corline DANGER WARNING Disconnect main power to the boiler and the pilot fuel supply to the burner before the burner door is opened Electr...

Page 120: ...o set up and apply a thick bead of high temperature silicone around the drum and install the cover plates Sight Port Inspect the area around the sight port for paint discoloration A hot spot around th...

Page 121: ...er 8 2 Flextube Casing Low Pressure Steam 8 4 Flextube Casing High Pressure Steam 8 6 Steam Pressure Controls 8 8 Water Level Controls 8 9 Water Column Main and Aux 15 Steam 8 11 Water Column Main and...

Page 122: ...8 2 750 177 Figure 8 1 Typical Hot Water Flextube Casing...

Page 123: ...6 26 868 1506 28 868 1506 60 868 1506 96 868 1506 128 18 Capscrew hex hd 1 2 13x 1 1 2 lg 868 102 8 868 102 8 868 102 8 868 102 8 868 102 8 19 Capscrew hex hd 5 8 11x 1 1 2 lg 868 188 8 868 188 8 868...

Page 124: ...8 4 750 177 Figure 8 2 Typical Low Pressure Steam Flextube Casing...

Page 125: ...868 102 8 868 102 8 868 102 8 868 102 8 868 102 8 19 Capscrew hex hd 5 8 11x 1 1 2 lg 868 188 8 868 188 8 868 188 8 868 188 8 868 188 8 20 Screw self tapping x 1 lg 841 423 56 841 423 56 841 423 56 8...

Page 126: ...8 6 750 177 Figure 8 3 Typical High Pressure Steam Flextube Casing...

Page 127: ...8 102 8 868 102 8 868 102 8 868 102 8 868 102 8 19 Capscrew hex hd 5 8 11x 1 1 2 lg 868 188 8 868 188 8 868 188 8 868 188 8 868 188 8 20 Screw self tapping x 1 lg 841 423 50 841 423 56 841 423 56 841...

Page 128: ...Parts Chapter 8 8 8 750 177 Steam Pressure Controls...

Page 129: ...Chapter 8 Parts 750 177 8 9 Water Level Controls...

Page 130: ...Parts Chapter 8 8 10 750 177 Water Level Controls continued...

Page 131: ...Chapter 8 Parts 750 177 8 11 Water Column Main and Aux 15 Steam...

Page 132: ...Parts Chapter 8 8 12 750 177 Water Column Main and Aux 150 Steam...

Page 133: ...Chapter 8 Parts 750 177 8 13 Safety Valves...

Page 134: ...Parts Chapter 8 8 14 750 177...

Page 135: ......

Page 136: ...e mail info cleaverbrooks com Web Address http www cleaverbrooks com...

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