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Startup and Operation

4-8

750-392

CBEX-DE

FIGURE 4-1.

Oil gauge glass

To verify air flow and pressure, place the burner run/test switch on the flame safeguard to the “test” position. If
the burner is a combination fuel burner, be sure that the gas/oil selector switch is set to “oil.” Turn the burner
switch on. The burner will cycle to the low-fire pre-purge position and stop there.

Observe the reading on the air pressure gauge. With no oil flow, the pressure should be a minimum of 7 psi.

If there is no pressure, determine the cause and correct it before proceeding. Check for obstructions in the air
inlet line, incorrect rotation (remember, air pump rotation is clockwise), or a loose oil nozzle or other leaks. If the
pressure is much higher without any oil flow, check for obstruction in the discharge line or at the oil nozzle.

The air pressure will increase when an oil flow exists. At low firing rate, the air pressure may rise to 12 psi or
more.

After air flow has been verified, turn the burner switch off and return the run/test switch to the “run” position.

NOTE:

Abnormally high pressure indicated on the nozzle air pressure gauge is an indication that the burner nozzle

has become clogged. In the event of clogging, check the nozzle and clean as necessary.

The air pressure should not exceed 35 psi at high-fire. Greater air pressure causes excessive wear of the air pump,
increases lube oil usage, and can overload the motor, thus causing damage to the equipment.

!

Caution

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Содержание CBEX-DE

Страница 1: ...CBEX DE Dryback Elite Boiler 250 800 HP Operation and Maintenance 750 392 10 2019 ...

Страница 2: ...sual operation will serve as a valuable guide to any necessary investigation Most instances of major boiler damage are the result of operation with low water We cannot emphasize too strongly the need for the operator to periodically check the low water controls and to follow good maintenance and testing practices Cross connecting piping to low water devices must be internally inspected periodicall...

Страница 3: ...oving Switch 3 6 Atomizing Air Proving Switch 3 6 Gas Pilot Flame Adjustment 3 7 Gas Pressure and Flow Information 3 8 Adjusting Combustion 3 12 Linkage Settings optional single point systems 3 12 Low Gas Pressure Switch 3 19 High Gas Pressure Switch 3 20 Burner Drawer Adjustment 3 20 Oil Drawer Switch 3 21 CHAPTER 4 Startup and Operation 4 1 Sequence of Operation 4 1 Flame Loss Sequence 4 4 Gener...

Страница 4: ...nt 5 12 Fan Motor Cassette Replacement 5 13 Safety Valves 5 14 Fuel Oil Metering Valve 5 15 Air Pump and Lubricating System 5 17 Refractory 5 21 Front and Rear Access 5 26 Lubrication 5 28 Combustion Adjustments 5 28 Linkage Systems 5 29 CHAPTER 6 Parts 6 1 Burner Assembly 30 PPM 60 PPM Uncontrolled Emissions 6 2 Arch Brick and Liner Tile 6 5 Front Head 6 6 Blower Cassette 6 8 Modbus Actuators par...

Страница 5: ...el burner burner controls forced draft fan air compressor for oil atomization oil pump refractory and boiler trim supplied according to customer s request Like all CBEX boilers the CBEX DE features spiral tubes for enhanced heat transfer Other features include 30 ppm NOx standard Hinged or davited insulated rear door with sight port FIGURE 1 1 CBEX DE cutaway view ...

Страница 6: ...ell as the FGR damper may differ Installation should conform to state and local codes Prior to installation the proper authorities having jurisdic tion are to be consulted permits obtained etc CBEX DE boilers offer compliance with multiple insurers requirements Equipment provided may vary depending on insurance Steam boilers are built for a specific design pressure which is the pressure used in ca...

Страница 7: ...sembly 2 Feedwater piping 3 Main gas train 4 Burner drawer 5 Oil system 6 Aux low water cutoff 1 2 3 4 5 6 FIGURE 1 3 Boiler side view 67 boiler configurations may vary 1 7 8 9 10 11 12 13 7 Control panel entrance panel 8 Low water cutoff 9 Pressure controls 10 Safety valves 11 Oil supply piping 12 Air compressor 13 Bottom blowdown piping ...

Страница 8: ...ront of the boiler without open ing the front door The front davit arm is used to support the blower cassette during removal 1 2 2 Feedwater piping Feedwater piping configurations can vary A typical configuration is shown below comprising three valve bypass piping with strainer and a modulating feedwater valve FIGURE 1 4 Fan motor cassette FIGURE 1 5 Feedwater piping ...

Страница 9: ...ized The vent valve closes when the gas valves are energized 4 Low Gas Pressure Switch A pressure actuated switch closed whenever main gas line pressure is above a pre selected pressure Should the pressure drop below the setting the switch contacts open a circuit causing the main gas valve s to close or prevent the burner from starting The switch is usually equipped with a device that must be manu...

Страница 10: ... required by insurance regulations 2 Gas Pilot Shutoff Cock For manually opening or closing the gas supply to gas pilot valve 3 Gas Pressure Gauge Indicates gas pressure to pilot 4 Gas Pressure Regulator Reduces incoming gas pressure to suit the pilot 1 2 5 Burner drawer The burner is a nozzle mixing orifice design with interrupted gas pilot Burners equipped for oil use a low pres sure air atomize...

Страница 11: ... The sequence of burner operation from startup through shutdown is governed by the program relay in conjunc tion with the operating limit and interlock devices The devices are wired into the circuitry to provide safe opera tion and protect against incorrect operating techniques All CBEX DE boilers have the burner assembly integral with the front head The burner drawer can be removed as a unit or t...

Страница 12: ...e in accordance with boiler load variances Stem movement is controlled by the oil actuator or in linkage systems by an oil metering cam B Actuator Positions the oil metering valve stem C Oil Burner Pressure Gauge Indicates pressure of the fuel oil at the metering valve D Oil Pressure Regulator For adjustment of the pressure of oil at the metering valve 3 Oil Relief Valve Maintains a constant oil s...

Страница 13: ...partition with a separate hinged door for each section The upper section low voltage houses the boiler control system including the PLC and associated modules the flame safeguard the Hawk HMI touch screen and the LevelMaster panel External switches and indicator lights can vary according to options selected A typ ical configuration will include switches for FSG reset ALWCO reset Burner switch Fuel...

Страница 14: ...the I O modules The remainder of the PLC rack is for the discrete input and output modules and for analog input module optional I O modules are used to send and receive control and communication signals to from other parts of the system A Right End Cap Terminator is required to complete the modular communication bus It attaches to the right side of the last module in the rack An optional analog in...

Страница 15: ...cted pressure setting 3 High Limit Pressure Control Breaks a circuit to stop burner operation on a rise of pres sure above a selected setting It is adjusted to stop the burner at a preselected pressure above the operating limit control setting The high limit pressure control is normally equipped with a manual reset 4 Pressure Transmitter Senses changing boiler pressure and transmits a signal to th...

Страница 16: ...r at the proper operat ing level 2 Water Gauge Glass Drain Valve Provided to flush the gauge glass 3 Vent Valve Allows the boiler to be vented during filling and facilitates routine boiler inspection as required by ASME Code 4 Water Column Drain Valve Provided so that the LWCO and its piping can be flushed regularly to assist in maintaining cross connecting piping and in keeping the float bowl cle...

Страница 17: ...e fuel oil 3 Air Filter The filter cleans the air supply prior to entering air pump 4 Check Valve Prevents lubricating oil and compressed air from surging back through the pump and air filter when the pump stops 5 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 nozzle 6 Lube Oil Level Sight...

Страница 18: ...of back pressure and accumu lation of foreign material around the valve seat Apply only a moderate amount of pipe com pound to male threads and avoid over tighten ing which can distort the 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 by using a p...

Страница 19: ...o remove the accumulations is described later in this chapter 2 1 Water requirements steam boilers Feed Pump Operation Before turning on the pump motor be certain that all valves in the water feed line are open to prevent possible damage to the feed pump mechanism After opening the valves momentarily energize the feed pump motor to establish correct pump rotation With the correct rotation establis...

Страница 20: ...n a boiler of 200 deg F or 240 deg F cannot be completely replaced with 80 deg F water in a few minutes time without causing thermal stress The same fact applies to periods of normal operation as well as during ini tial start up The circulating pumps should be interlocked with the burner so that the burner cannot operate unless the circu lating pump is running in order to avoid damage to the equip...

Страница 21: ... used to preheat No 6 oil Pump Location It is recommended that the system circulating pumps take suction from the outlet connection on the boiler and that they discharge to the system load In order to put the boiler and the expansion tank on the suction side of the pump The suction side is preferred because it decreases air entry into the system and does not impose the system head on the boiler It...

Страница 22: ... to a cold boiler It cannot be overemphasized that rapid changes in temperature within the boiler can cause damage 2 3 Water Treatment Properly treated boiler feed water combined with good engineering and operating practices leads to maximum effectiveness and long life of pressure vessels Contact your local Cleaver Brooks authorized representative for information on how to prevent the presence of ...

Страница 23: ...r steam or hot water and to aid in maintaining proper waterside conditions 2 4 Cleaning 2 4 1 Steam Hot Water Piping Steam piping systems connected to the boiler may contain oil grease or foreign matter The impurities must be removed in order to prevent damage to pressure vessel heating surfaces On a steam system the condensate should be wasted until tests show the elimination of undesirable impur...

Страница 24: ... have oil grease or other protective coatings used in manu facturing Such coatings must be removed because they lower the heat transfer rate and could cause overheating of a tube Before boiling out procedures may begin the burner should be ready for firing The operator must be familiar with the procedure outlined under burner operation A general procedure for cleaning a boiler is 1 Refer to the ta...

Страница 25: ... small amount of fresh water to enter the boiler to create a slight overflow that will carry off surface impurities 9 Continue the boil and overflow process until the water clears Shut the burner down 10 Let the boiler cool to 120º F or less 11 Remove handhole plates and wash the waterside surfaces thoroughly using a high pressure water stream 12 Inspect the surfaces If they are not clean repeat t...

Страница 26: ... water system and boiler that has been initially cleaned filled with raw water and water treated and with no make up water added will require no further cleaning or treatment However since the system new or old can allow entrance of air and unnoticed or undetected leakage of water introductions of raw water make up or air may lead to pitting corrosion and formation of sludge sediment scale etc on ...

Страница 27: ...oiler metal can result in tube failures or other pressure vessel metal damage and lead to boiler downtime and costly repairs Scale is caused primarily by calcium and magnesium salts silica and oil Any calcium and magnesium salts in the boiler water are generally precipitated by the use of sodium phosphate along with organic materials to maintain the precipitates or sludge in a fluid form The solid...

Страница 28: ... terminating slightly below the working water level for the purpose of skimming dissolved solids oil or other impurities from the surface of the pressure vessel water A controlled orifice valve or an auto sensing metering valve is used to allow a continual yet controlled flow of concentrated water to drain or a place of recovery The flow control valve and piping are generally provided by others Al...

Страница 29: ...blowdown since blowdowns are not practiced The need remains to be alert to system water losses and corresponding amount of raw water make up A water meter is recommended for water make up lines 2 7 3 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 Be sure the blowoff piping and separator tank are in ...

Страница 30: ...temperature differentials that can cause expanded tubes to leak Draining the unit too quickly may cause the baking of deposits that may be present on the heating surfaces Some heat however may be desirable to dry out the interior of the boiler If the internal inspection is being made at the request of an authorized inspector it is advisable to ask the inspec tor to observe the conditions prior to ...

Страница 31: ... to deteriorate from corrosion There are two methods of storage wet or dry Your local Cleaver Brooks authorized representative can recom mend the better method depending upon circumstances in the particular installation Although pollution control regulations may continue to limit the permissible sulphur content of fuel oils care must be taken to avoid corrosion problems that sulphur can cause espe...

Страница 32: ...ial grease or tar paint Refractories should be brushed clean and wash coated All openings to the pressure vessel such as manholes and handholes should be shut tightly Feedwater and steam valves should be closed Damper and vents should be closed to pre vent air form reaching fireside surfaces Periodic inspection should be made and absorption materials renewed Wet storage is generally used for a boi...

Страница 33: ...steam or hot water boilers fired with gas and or light oil 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 lockout switch on the flame safe guard and reset if necessary The pressure vessel support legs are welded to mounting skids in front and secured by bo...

Страница 34: ...th the boiler control system 1 Operating Limit Control Senses pressure or temperature and automatically turns the burner on to initiate the startup sequence when required and turns the burner off to initiate the shutdown sequence when the demand is satisfied The control must be set to initiate startup only at the low fire position The operating pressure control of a steam boiler should be set slig...

Страница 35: ...ng controls first be sure all control devices are securely mounted and level With the tem perature sensing control make sure the sensing bulb is properly bottomed in its well and is secured against movement Be sure the connecting tubing is not kinked The dial settings are generally accurate although it is not unusual to have a slight variation between a scale set ting and an actual pressure gauge ...

Страница 36: ...change accordingly This it is referred to as modulated firing Point D represents the maximum firing rate of the burner or high fire In the event pressure or temperature drops while the burner is firing at high fire it indicates that the load exceeds the capacity of the boiler The Firing Graph shows that point B and point C do not coincide Extreme load conditions could require the points be closely...

Страница 37: ...ice or whenever a control is replaced Periodic checks should be made thereafter in accordance with a planned maintenance program The operating limit control may be checked by allowing steam pressure or water temperature to increase until the burner shuts down Depending upon the load it may be necessary to manually increase the firing rate to raise steam pressure to the burner shutoff point If the ...

Страница 38: ...essure against the diaphragm actuates the switch which when closed completes a circuit to prove the presence of atomizing air Since the pressure of the atomizing air is at its minimum value when there is no fuel present at the nozzle adjustment of the switch should be done while the unit is running but not firing The con trol should be set slightly below the minimum pressure but not too close to t...

Страница 39: ...ignal The correct voltage or micro amp readings can be found in the information supplied with the flame safeguard system The program relay used may be of the type that provides message information that includes a constant flame sig nal of DC voltage In this case a separate DC voltmeter is not required To measure and adjust the pilot 1 When making a pilot adjustment turn the manual automatic switch...

Страница 40: ...s elsewhere in the manual 10 The reading of the main flame signal should also be checked Observe the flame signal for pilot alone pilot and main burner flame together and the main burner flame at high low and intermediate firing rate positions Readings should be steady and in the range indicated in step 7 3 8 Gas Pressure and Flow Information Because of variables in both the properties of gas and ...

Страница 41: ...nts For gas fuels other than natural gas please contact the factory Regulated Pressure is the pressure required downstream of the main gas train regulator Manifold pressure is the pressure required downstream of the gas butterfly valve at high fire There is typically a tapping on the elbow for measuring manifold pressure The pressures listed are based on 1000 Btu cu ft natural gas at elevations up...

Страница 42: ...measure gas in cubic feet at line or supply pressure The pressure at which each cubic foot is measured and the correction factor for the pressure must be known in order to convert the quantity indicated by the meter into the quantity which would be measured at base pressure TABLE 3 3 Pressure Altitude Correction Factors Altitude Feet Above Sea Level Correction Factor 1000 1 04 2000 1 07 2500 1 09 ...

Страница 43: ...ents can be determined as follows Pressure Correction for the 2 000 feet altitude must be made since altitude has a bearing on the net regulated gas pres sure The standard gas train requires 55 2 WC gas pressure at sea level Table 3 2 Pressure altitude correc tion Table 3 3 indicates a correction factor of 1 07 for 2 000 feet Multiplying the results in a calculated net regulated gas requirement of...

Страница 44: ...essure specific gravity temperature etc of the gas used 3 9 Adjusting Combustion 3 10 Linkage Settings optional single point systems The linkage consists of various arms connecting rods and swivel ball joints that transmit motion form the mod ulating motor to the metering cam s rotary air damper and gas butterfly valve When properly adjusted a coordinated movement of the damper and metering cams w...

Страница 45: ...e damper motor connecting arm and manipulating the linkage by hand Position the oil and or gas modulating cams on the jackshaft so that the cam follower assembly is opposite the first cam adjusting screw In this position fuel delivery is at low fire rate Tighten the set screws to secure the cams on the jackshaft Initial IFGR linkage settings and adjustments must be established by a qualified Cleav...

Страница 46: ...escribed in the diagrams below Proper settings will ensure that the angular movement of the damper starts slowly increasing in rate as the high fire position is approached 3 10 1 Initial Settings 1 With the air damper in the fully closed position set jack shaft air damper control arm to the settings shown in the table below 2 All angles shown in the table are taken from the horizontal plane 3 When...

Страница 47: ...x x 60 x x x x x x x x x 30 40 1 4 6 2 5 30 70 8 35 60 35 3 16 6 3 4 2 5 45 45 8 20 30 40 1 4 6 2 5 30 70 8 35 60 35 1 4 6 3 4 2 5 25 65 8 20 30 45 1 2 6 1 2 2 4 20 80 8 30 20 60 45 1 4 3 2 4 25 85 8 30 30 45 1 2 6 1 2 2 5 20 80 8 30 20 60 45 1 4 3 2 5 25 85 8 30 30 45 1 1 4 7 2 5 23 92 8 40 44 60 45 3 4 7 2 5 23 92 8 40 30 45 1 7 2 5 23 92 8 40 44 60 45 3 4 7 3 8 2 5 23 92 8 40 700 800 250 300 35...

Страница 48: ...ew 4 Tighten the locknuts on all ball joints BHP Nox A B C D E F G H J K PPM Degrees Degrees Hole Degrees Hole Degrees Hole Degrees Hole Hole 30 X X X X X X X X X X 60 UNC X X X X X X X X X X 30 X X X X X X X X X X 60 UNC X X X X X X X X X X 30 40 37 4 45 4 45 4 40 5 1 60 UNC 40 40 4 45 4 45 4 50 5 1 30 40 37 4 45 4 45 4 40 5 1 60 UNC 43 41 4 45 4 45 4 40 5 1 30 60 52 6 45 4 45 4 45 3 3 60 UNC 60 ...

Страница 49: ...en proper gas flow is obtained take a flue gas reading The O2 should be between 3 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 With the high fire air fuel ratio established the gas pressure regulator needs no further adjusting After being certain that the air control damper and its linkage are correctl...

Страница 50: ...he low fire cam screw 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 fire stopscrew to obtain the proper air fuel ratio at the low fire rate To ensure that the low fire position of the gas butterfly valve is always the same allow one turn of the stop screw for overtravel If the air damper needs to be adjusted in order to provide...

Страница 51: ...fire start switch is set to make the red and yellow leads at approximately 8º on motor closing The high fire purge air proving switch located in the modulating motor is set to make red and blue tracer leads at approximately 60º on motor opening Normally the settings are left as is but job conditions may require readjustment If the cams require adjustment or resetting follow the instructions in the...

Страница 52: ...r fins and gas outlet tubes spuds coming from the burner housing The setting of an oil fired burner is less exacting and the diffuser should be located with the diffuser skirt approximately 1 1 8 in front of the oil nozzle When the proper diffuser location is ascertained the setting of the nozzle in relation to the diffuser should be checked This generally is set at time of manufacture and seldom ...

Страница 53: ...ht tube and the gas pilot tube extend through their respective openings in the dif fuser face 3 14 Oil Drawer Switch The integral contacts of the control are closed by proper posi tioning and latching of the oil nozzle lance in its forward posi tion Adjustment of the switch must be such that its contacts open if the oil nozzle lance is not properly positioned for oil fir ing The switch is electric...

Страница 54: ...Preparations for Startup 3 22 750 392 CBEX DE ...

Страница 55: ...sed All entrance panel switches are closed and power is present at the line terminals corresponding to a Blower motor starter b Air compressor motor starter if provided c Oil pump motor starter if provided The load demand light is on Circuits and Interlocks The burner control circuit is a two wire system designed for 115 VAC 60 Hz single phase power The electrical portion of the boiler is made up ...

Страница 56: ...cutoff LWCO Level Master Gas oil selector switch GOS combination burner only Oil drawer switch ODS oil combination burner Low gas pressure 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 BMS Combustion air proving switch CAPS Atomizing air proving switch AA...

Страница 57: ...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 boiler will go into a safety shutdown At the completion of the high fire purge period the damper actuator will drive the air damper to its low fire posi tion To assure that the system is in low fire position prior to ignition the Low Fire Relay LFR must be...

Страница 58: ...ignal The manual mode is provided for initial adjustment of the burner over the entire fir ing range When a shutdown occurs while operating in the manual mode at other than low fire the damper will not be in a closed position thus allowing more air than desired to flow through the boiler Excess air flow sub jects the pressure vessel metal and refractory to undesirable conditions The burner will fi...

Страница 59: ...tch must be manually reset before operation can be resumed Loss of flame If a flame outage occurs 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 de energize the fuel valve circuit and shut off the fuel flow The reset switch lights and lockout occurs immediately The blower motor continues operation The flame failure li...

Страница 60: ...on of all motors by momentarily closing the motor starter or relay The blower impeller rotation is counterclockwise when viewed from the front of the boiler The air pump rotation is clockwise when viewed from the drive end Before operating the boiler feed pump or oil supply pump be sure all valves in the line are open or properly posi tioned For safety reasons perform a final pre startup inspectio...

Страница 61: ...serve whether the pilot flame is extinguished promptly when the burner switch is opened A lin gering flame indicates a leaking gas pilot valve which is a condition requiring correction before proceeding 4 6 Atomizing Air The supply and pressure of the atomizing air on an oil fired burner should be checked Before starting inspect the oil pump lube oil level Add oil if necessary to bring the level t...

Страница 62: ...mber air pump rotation is clockwise or a loose oil nozzle or other leaks If the pressure is much higher without any oil flow check for obstruction in the discharge line or at the oil nozzle The air pressure will increase when an oil flow exists At low firing rate the air pressure may rise to 12 psi or more After air flow has been verified turn the burner switch off and return the run test switch t...

Страница 63: ...ears Non lubricating fluids such as kerosene should not be used for priming Prior to priming the suction line and the initial start check to make cer tain that all plugs connections etc have been securely tightened to pre vent leaks If the fuel oil supply originates from a pressurized loop it is assumed that the pressure of the loop will be at a minimum of 75 psi Under these con ditions the relief...

Страница 64: ...tain a minimum reading of 75 psi when the burner is firing at maximum rate Adjustment may also be required to the regulator on the fuel oil controller The pressure regulating valve is 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 tenta tive adjustment can be made Without the air supply adjust ...

Страница 65: ...on fuel model set the gas oil switch to gas Withdraw the oil burner gun and latch it in its rearward lockout position On initial startup it is recommended that the main gas shutoff cock downstream of the motorized gas valves remains closed until the pro grammer has cycled through pre purge and pilot sequences When the fuel light on the control panel comes on observe the action of the motorized gas...

Страница 66: ...previous sections in this chapter should be reviewed for preliminary instructions When firing with oil be certain that the burner gun is in its most forward position and latched in place When fir ing with gas the burner gun should be properly withdrawn and latched in place The fuel selector switch should be accordingly set to either oil or gas Set the AUTO MANUAL control to MANUAL Turn the burner ...

Страница 67: ...fire adjustment manually decrease the firing rate stopping at each combustion curve point to analyze combustion gases and adjust as required To properly perform the testing and adjusting it is necessary that the burner be allowed to fire at a maximum rate long enough to achieve desired results 4 9 1 Operating Normal operation of the burner should be with the controls in automatic mode Manual mode ...

Страница 68: ...placed Periodic checks should be made thereafter in accordance with a planned maintenance program The operating limit control may be checked by allowing steam pressure or water temperature to increase until the burner shuts down Depending upon the load it may be necessary to manually increase the firing rate to raise steam pressure to the burner shutoff point If the load is light the header valve ...

Страница 69: ...operation against the normal sequence to determine the stage at which performance deviates from normal Following a routine may possibly eliminate overlooking an obvious condition often one that is relatively simple to correct 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 Mo...

Страница 70: ...to restart Failure to do so may result in serious personal injury or death Do not repeat unsuccessful lighting attempts without rechecking the burner and pilot adjustments Failure to do so may result in serious personal injury or death Do not re light the pilot or attempt to start the main burner either oil or gas if the combustion chamber is hot and or if gas or oil vapor combustion gases are pre...

Страница 71: ...rward position to close oil drawer switch 4 Fuel valve interlock circuit not completed A Fuel valve auxiliary switch not closed B Oil firing FGR linkage proximity switch not met NO IGNITION 1 Lack of spark A Electrode grounded or porcelain cracked B Improper electrode setting C Loose terminal on ignition cable or cable shorted D Inoperative ignition transformer E Insufficient or no voltage at pilo...

Страница 72: ...ating control 5 Binding or loose linkage cams setscrews etc SHUTDOWN OCCURS DURING FIRING 1 Loss or stoppage of fuel supply 2 Defective fuel valve loose electrical connection 3 Flame detector weak or defective 4 Lens dirty or sight tube obstructed 5 If the programmer lockout switch has not tripped check the limit circuit for an opened safety control 6 If the programmer lockout switch has tripped A...

Страница 73: ...rner by turning the burner switch OFF Turn the fuel selector switch to the OFF position Shut off the main manual fuel shutoff valves on the fuel supply line The unit can also be shut down with the main electrical power disconnect Inspect the burner carefully and troubleshoot before restarting the unit ...

Страница 74: ...Startup and Operation 4 20 750 392 CBEX DE ...

Страница 75: ...erial and equipment not necessary to the operation of the boiler or heating system Even though the boiler has electrical and mechanical devices that make it automatic or semi automatic in opera tion the devices require systematic and periodic maintenance Any automatic feature does not relieve the opera tor from responsibility but rather frees the operator from certain repetitive chores providing t...

Страница 76: ...de long life and excellent service Good oper ating practices and conscientious maintenance and care will assure efficiency and economy from their operation and will contribute to many years of performance Daily Monthly Semi Annually Annually Check water level Inspect burner Clean low water cutoff Clean fireside surfaces Check combustion visually Inspect for flue gas leak Clean oil pump strainer fi...

Страница 77: ... the use of untreated or incorrectly treated water Always be sure of the boiler water level On steam boilers the water column should be blown down daily Check samples of boiler water and condensate in accordance with procedures recommended by your local Cleaver Brooks authorized representative Since low water cutoff devices are generally set by the original manufacturer no attempt should be made t...

Страница 78: ...ble to check and clean float ball internal moving parts and the bowl housing Also check the cross con necting piping to be certain that it is clean and free of obstruction 5 4 Water Gauge Glass A broken or discolored glass should be replaced at once Periodic replacement should be a part of the mainte nance program Always use new gaskets when replacing a glass Use a proper size rubber packing Do no...

Страница 79: ...be necessary to determine the cause of excessive current draw at the overloads Power supply to the boiler must be protected with dual element fuses Fusetrons or circuit breakers Similar fuses should be used in branch circuits Standard one shot fuses are not recommended 5 6 Flame Safety Control The flame safeguard itself requires little maintenance Check to see that the retaining screw is securely ...

Страница 80: ...n the burner switch off Reset the safety switch Reopen the gas pilot shutoff cock and re establish main fuel supply 5 6 2 Checking Failure to Light Main Flame Leave the gas pilot shutoff cock open Shut off the main burner fuel supply Turn the burner switch on The pilot will light upon completion of the pre purge period The main fuel valve s will be energized but there should be no main flame The f...

Страница 81: ...d record positions of linkage and remove the linkage arm NOTE Do not remove the actuator unless air damper inspection is scheduled If the damper actuator is removed actuator will need to be re aligned and combustion must be re set by a qualified C B technician before the boiler is returned to operation FIGURE 5 2 Preparations for removing burner drawer 5 8 Oil Burner Maintenance The burner should ...

Страница 82: ...ecision ground surfaces of the swirler and tip Inspect for scratches or signs of wear or erosion which may make the nozzle unfit for further use Take the necessary precautions in working with solvents The tip and swirler are a matched set which are precision lapped at the time of assembly The close fit of the lapped surfaces must be maintained in order to provide optimum performance Additional lap...

Страница 83: ... combustion air which bypasses the diffuser Check to see that the diffuser is properly located in reference to the gas spuds There should be 1 4 between the edge of the diffuser fins and the gas spuds when the burner is installed Check to see that the diffuser fins do not interfere with the gas ports or gas spuds in the burner housing Check the electrode setting for any cracks that might be presen...

Страница 84: ... plunger tube and solenoid are tight when reassembled Take care not to nick dent or damage the plunger tube Coils may be replaced without removing the valve from the line Check coil position and make sure that any insulating washers or retaining springs are reinstalled in proper order 5 12 Air Control Damper The burner air control damper should be checked for free movement as a part of the monthly...

Страница 85: ...and damper Remove the fan motor cassette as follows 1 Disconnect and lock out electric power to the boiler 2 Be sure that the front door is securely bolted to the boiler 3 Release the davit arm by removing the retaining bolt at the top center of the boiler Combustion should be checked and readjusted as required whenever the burner is removed or any control linkage is disturbed Failure to follow th...

Страница 86: ... Adjustment NOx levels should be checked periodically to ensure compliance with all local and federal regulations as well as to ensure that the boiler is operating at maximum efficiency Linkages should be inspected and free movement no binding of the IFGR damper confirmed Increasing or decreasing NOx levels could indicate incorrect damper positioning an improper air to fuel ratio or stack draft ch...

Страница 87: ...ller housing B Adjust the retainers for the correct impeller clearance at two housing attachment points 180º apart C Adjust the retainers for correct clearance at the housing attachment points 90º from those initially adjusted D Adjust for correct 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 ...

Страница 88: ...iler and Pressure Vessel Code FIGURE 5 7 Safety Valves Avoid excessive operation of the safety valve even one opening can provide a means of leakage Safety valves should be operated only often enough to assure that they are in good working order When a pop test is required raise the operat ing pressure to the set pressure of the safety valve allowing it to open and re seat as it would in normal se...

Страница 89: ...bracket so that the bracket can be moved It may also be necessary to loosen the supporting bracket on the far end of the shaft 8 Remove the existing packing and guides Do not re use the packing and guides 9 Lightly coat the stem with the lubricant provided with the packing kit Place the new packing o rings and guides onto the stem in the sequence shown The beveled face of the guides and the Teflon...

Страница 90: ...land after a period of operation if necessary to maintain proper pressure on the pack ing Do not over tighten If there are indications that the oil metering valve has become clogged at its orifice it will be necessary to disas semble the control to remove the obstruction Clean the slotted stem of the oil metering valve with suitable sol vent and blow dry with dry shop air Follow the procedure outl...

Страница 91: ...d are recommended SAE 10 detergent is also permissible When adding oil remove the cover from the fill pipe and add oil through the conical strainer in the pipe with the unit running The oil and its container should be clean Although there is a strainer in the lube oil line its purpose is to remove any unwanted materials rather than to act as a filter for unclean oil 5 18 3 Lubricating Oil Strainer...

Страница 92: ...be oil form the com pressed air The pads play a very important role and should be replaced semi annually It is also important that a proper grade of steel wool be used Only No 3 coarse grade American steel wool or equivalent CB919 124 should be used When replacing the wool insert all but the last pad into the cylinder Alternate the grain of the pads Install the spacer with its stub end toward the ...

Страница 93: ...for angular alignment which is done by checking the gap between coupling halves The coupling should have a minimum gap of 1 16 and a maximum of 3 32 Set the spacing between the halves at one point by using a thickness gauge and then rotate the coupling slowly to be sure that clearance at that point remains the same through 360 degrees of rotation Adjust to obtain proper gap by loosening the hold d...

Страница 94: ... dismantled be sure that the check valve is re installed so that the gate swings toward the pump Reassembly Reassemble in reverse order With the rear pump bracket left in place realignment and spacing between the pump shaft and the motor shaft is greatly simplified There should be approximately 7 8 space between the two shafts Place the coupling insert between the cou pling halves prior to reassem...

Страница 95: ...t wash coating of the refractory surfaces is recommended High temperature bonding air dry type mor tar diluted with water to the consistency of light cream is used for wash coating Re coating intervals will vary with operating loads and are best determined by the operator when the boiler is opened for inspection FIGURE 5 14 Throat Tile and Furnace Liner When doing refractory service or repair work...

Страница 96: ...atch the burner hous ing and be centered in the furnace Since the thickness of the furnace metal varies with the boiler design pres sure a shim of appropriate thickness must be used to compensate for the variance A layer or two of insulating board or equal or a bed of refractory material may be used to center the ring The liner tile can be fitted tightly against the furnace since the finished diam...

Страница 97: ...t tile is needed Figure 5 16 If cut brick is required locate below the 2 o clock and 10 o clock positions see note 1 on Figure 5 18 If brick is cut angle of the cut surface should be the same as original brick If cut brick or tile measures less than 1 2 full width cut two pieces 4 Install bricking tool as shown in Figure 5 15 and continue installing upper half by alternating one arch brick and one...

Страница 98: ... furnace weld seams with insulation Cut a strip of insulation out to rev al weld 5 During installation support upper tiles with wooden supports in a diagonal fashion until row is complete use approx 3 4 x 1 1 2 x 28 Lg boards 6 To insure a tight fit and maximum I D of arch bricks place a 3 square scrap piece of insulation as a shim between bricking tool collar and I D of upper half of arch bricks ...

Страница 99: ...out to expose weld 5 During installation support upper tiles with wooden supports in a diagonal fashion until row is complete 6 To insure a tight fit and maximum I D of arch bricks place a 3 square scrap piece of insulation as a shim between bricking tool collar and I D of upper half of arch bricks as necessary 7 Stagger mortar joints on each row of liner tiles 8 Fill the first two full corrugatio...

Страница 100: ...ps Remove the front clamp ring and the front head capscrews See figure below The door can now be swung open After opening either door check the gaskets and seating surfaces Replace the door gaskets if they are hard or brittle Clean the sealing surfaces of the door and tube sheet If the blanket insulation is torn away the insulation will require replacing FIGURE 5 20 Opening front door 1 REMOVE BUR...

Страница 101: ...d position adjusting the davit bolt to align the door Be sure the gasket is positioned correctly prior to tightening the door Tighten the bolts uniformly starting at the top center and alternating between the top and bottom bolts until both are tight Do not over tighten Tighten alternate bolts until all are secure and the door is gas tight After closing the door loosen the nut on the davit arm stu...

Страница 102: ... clear grease starts to come out of the drain hole Before replacing the drain plug run the motor for 10 to 20 minutes to expel any excess grease The filler and drain plugs should be thoroughly cleaned before they are replaced 5 21 2 Siemens Motors Siemens motors in Cleaver Brooks applications require LUBRIPLATE 730 2 HIGH TEMPERATURE GREASE do not mix with any other type of grease Lubriplate 730 2...

Страница 103: ...ld 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 displacement linkage arms as an aid in subsequent reassembly Inspection of the air damper and linkage bearings should be performed on a more frequent basis if the boiler is operating in a dirty environment ...

Страница 104: ...Inspection and Maintenance 5 30 750 392 CBEX DE ...

Страница 105: ...nly C B authorized replacement parts For Ultra Low NOx applications also see manual 750 220 NTI Burners ITEM PAGE Burner Assembly 30 PPM 60 PPM Uncontrolled Emissions 2 Arch Brick and Liner Tile 5 Front Head 6 Blower Cassette 8 Modbus Actuators parallel positioning 9 Gas Train 12 Light Oil Components 13 Low Water Cutoff 15 Auxiliary Low Water Cutoff 16 Pressure Controls Steam 17 Temperature Contro...

Страница 106: ...E 30 PPM 158 00043 000 429 02220 000 N A 275 01418 000 25 3 8 26 1 2 26 1 2 26 1 2 26 1 2 3 8 3 8 3 8 090 04973 000 090 04973 000 090 01885 000 090 01885 000 090 01885 000 090 01885 000 090 04976 000 090 04976 000 090 01884 000 090 01884 000 090 01884 000 090 01884 000 090 04974 000 090 04974 000 090 01887 000 090 01887 000 090 01887 000 090 01887 000 250 350HP CBEX DE UNCONTROLLED 251 00430 000 2...

Страница 107: ...O DESCRIPTION 20 1 065 00011 000 RETAINER SIGHT HOLE 21 2 860 00201 000 SCREW MACHINE 22 1 032 00497 000 GASKET SCANNER TUBE 23 1 090 01596 000 GUIDE TUBE SCANNER 24 1 134 00053 000 HOLDER ELECTRODE 25 1 860 00244 000 SET SCREW SOCKET HEAD 26 1 134 00050 000 SPIDER DIFFUSER 27 1 SEE TABLE DIFFUSER BURNER 28 1 073 00032 000 SEAL RING GAS PILOT 29 1 022 00132 000 DIFFUSER AIR STABILIZER REAR 30 1 02...

Страница 108: ...R AIR STABILIZER FRONT ITEM QTY PART NO DESCRIPTION 31 1 860 00088 000 MACH SCREW 32 1 022 00132 000 DIFFUSER AIR STABILIZER REAR 33 2 869 00021 000 NUT HEX HD 34 2 868 00208 000 CAPSCREW SOCKET HD 35 1 277 00023 000 BODY NOZZLE W O FITTINGS 36 1 847 00415 000 BUSHING HEX HD 37 1 845 00306 000 ELBOW MALE 38 1 082 00034 000 SPRING BURNER NOZZLE 39 1 251 00007 000 NOZZLE TIP AND SWIRLER SET 40 2 292...

Страница 109: ... B Item 1 Qty Item 1 P N Item 2 Qty Item 5 Qty Item 2 P N 30 60 UC PPM PLAIN 6 3 4 12 Dia 36 094 00746 000 29 0 094 01037 000 400 HP 5 9 PPM PLAIN CORR 6 3 4 16 Dia N A N A 24 0 094 00799 000 30 60 UC PPM CORRUGATED 7 5 8 12 DIA 36 094 00746 000 29 2 094 00643 000 B REF 37 000 3 2 4 1 5 3 DESCRIPTION PART NO QTY ITEM BULK INSULATION 2400 DEG 12 DENSITY 872 00518 000 690 IN 2 1 BULK INSULATION 2400...

Страница 110: ...00 9 CAPSCREW HEX HD 868 00136 000 9 SPACER INNER PLATE 077 00469 000 8 CAPSCREW HEX HD 868 00098 000 8 FRONT HEAD FLANGED 132 01735 000 1 LUG HEAD 103 00107 000 13 SUPPORT DAVIT FRONT HEAD 085 04251 000 1 CAPSCREW HEX HD 868 00176 000 12 COUPLING 858 00057 000 1 COUPLING 858 00311 000 1 NUT OHIO 869 00165 000 4 WELD NUT 869 00166 000 8 971 00078 000 2 GASKET HEAD PLATE 032 00898 000 1 RIVET SPLIT...

Страница 111: ...AT 971 00078 000 2 15 COUPLING 858 00311 000 1 16 COUPLING HALF 858 00057 000 1 17 SUPPORT DAVIT FRONT HEAD 085 04237 000 1 18 LUG HEAD 103 00107 000 13 19 GASKET HEAD PLATE 032 00993 000 1 20 RIVET SPLIT 841 00551 000 8 21 INSULATION FRONT HEAD INTERIOR SEE TABLE 1 22 INSULATED FRONT HEAD BACK PLATE 465 02517 000 1 23 83 APPLICATION ASSEMBLY P N ITEM 1 ITEM 22 RH 30 PPM 132 01741 000 132 01745 00...

Страница 112: ...OTE Impeller size is based on boiler HP ppm emission level boiler operating pressure and altitude To ensure proper selection of impellers and other blower cassette components contact Cleaver Brooks Aftermarket UNCONTROLLED UNCONTROLLED UNCONTROLLED ...

Страница 113: ... 13 WASHER 952 00145 000 2 14 SCREW SELF TAPPING 841 00148 000 2 15 KEY SQUARE DRIVE 841 00739 1 16 4 1 2 CENTER DIST A DAMPER FULL OPEN 2 6 3 6 7 10 12 5 6 WITH QUICK DISCONNECTS WITHOUT QUICK DISCONNECTS MODEL A B ITEM 3 ITEM 4 269 00156 0QC 269 00156 000 250 400 HP 43 4 3 033 00125 000 077 02123 000 269 00157 0QC 269 00157 000 500 600 HP 45 6 8 033 00126 000 077 02124 000 269 00461 0QC 269 0046...

Страница 114: ...5 00259 000 118 04712 000 REMOVAL OF ACTUATOR WILL REQUIRE COMBUSTION TO BE RESET LE REMPLACEMENT DE L ACTUATEUR VA NÉCESSITER UN RÉAJUSTEMENT DE LA COMBUSTION 118 04712 000 DESCRIPTION PART NO QTY ITEM BRACKET SEE TABLE 1 1 CONNECTOR SEE TABLE 1 2 SETSCREW 860 00039 000 4 3 ACTUATOR SEE TABLE 1 4 CAPSCREW 868 00209 000 2 5 LOCK WASHER 952 00117 000 2 6 WASHER 952 00144 000 2 7 1 2 3 4 REMOVE FOOT...

Страница 115: ...000 2 10 CAPSCREW SOCKET HD 10 32 UNF x 5 LG 868 00209 000 2 11 NUT HEX HD 1 4 20 UNC 2B 869 00021 000 2 12 ACTUATOR SERVO MOTOR MODBUS 3 FT LB TORQUE FX04 SEE TABLE 1 13 LOCKWASHER 1 4 952 00092 000 3 14 LOCK WASHER 5 16 DIA CAD PLATED 952 00097 000 2 15 LOCK WASHER 10 PLAIN STEEL 952 00117 000 2 16 WASHER FLAT 3 16 952 00144 000 2 17 WASHER FLAT 1 4 952 00145 000 3 18 OIL VALVE STEM ASSY SEE CHA...

Страница 116: ... and connection sizes pressure requirements and insurance Contact Cleaver Brooks Aftermarket for information regarding your specific application VPS or VENT VALVE ASSEMBLY DOWN STREAM ASSEMBLY TRANSITION ASSEMBLY SSOV ASSY LGPS ASSY HGPS ASSY PILOT GAS TRAIN ELBOW ASSEMBLY PILOT GAS TRAIN ASSEMBLY PILOT TUBING ASSEMBLY MANIFOLD PRESSURE GAUGE ASSEMBLY STARTER TRAIN ASSEMBLY ...

Страница 117: ...STANDARD Description Part No QTY ITEM TUBE ACCUMULATOR OIL 090 01211 000 1 2 VALVE SAFETY SHUTOFF 229 00062 000 2 1 1 1 2 OUTLET PIPING FM NFPA 85 FUEL OIL CONTROLLER FUEL OIL CONTROLLER PART NO MODEL 739 00074 000 739 00073 000 400 700 HP 250 350 HP 739 00079 000 750 800 HP ITEM QTY Part No Description 1 1 106 00012 000 BLOCK OIL TERMINAL 4 1 940 02296 000 VALVE RELIEF 3 1 850 02359 000 GAUGE PRE...

Страница 118: ... Light OIl Pilot 100 Fuel Series only 817 04093 000 LOPS PRESSURE CONTROL OP LIMIT DANFOSS 150 PSI 1 817 04093 000 HOPS PRESSURE CONTROL OP LIMIT DANFOSS 150 PSI IF R E Q U IR E D 2 1 2 ITEM DESCRIPTION PART NO 1 FUEL OIL CONTROLLER 1 3 2 2 STANDARD IRI XL GAPS ...

Страница 119: ... 623 00230 3 1 Ball Valve 941 00055 4 1 Ball Valve 941 01790 3 2 SELECT APPROPRIATE GAUGE GLASS ASSEMBLY 1 4 250 350HP 500 800HP Item Qty Description Part 1 1 LWCO Pump Control 817 02374 2 1 Ball Valve 941 00055 3 1 Gate Valve 941 01886 Item Qty Description Part 1 1 LWCO Pump Control 817 01384 2 1 Ball Valve 941 00055 3 1 Gate Valve 941 01886 2 SELECT APPROPRIATE GAUGE GLASS ASSEMBLY 1 3 ...

Страница 120: ...Part 1 1 ALWCO Control 250 800 817 02372 817 02372 817 02372 2 1 Ball Valve 250 400 941 01790 941 01790 500 800 941 01657 941 01657 Gate Valve 941 01886 Item Qty Description Boiler HP 15 PSI Part 150 PSI Part 1 1 ALWCO Control 250 800 817 02407 817 02407 2 1 Ball Valve 250 350 941 01790 Gate Valve 500 800 941 01886 Gate Valve 250 800 941 01886 1 2 ...

Страница 121: ...000 OPERATING LIMIT 1 4 15 PSI DESIGN PRESSURE 15 PSIG 817 04093 000 OPERATING LIMIT 1 4 150 PSI DESIGN PRESSURE 150 PSIG 817 04883 000 OPERATING LIMIT 1 4 200 PSI DESIGN PRESSURE 200PSIG 817 04147 000 OPERATING LIMIT 1 4 250 PSI DESIGN PRESSURE 250 PSIG 817 04091 000 OPERATING LIMIT 1 4 300 PSI DESIGN PRESSURE 300 PSIG 817 04094 000 HIGH LIMIT 1 4 15 PSI 17 1 817 04092 000 HIGH LIMIT 1 4 150 PSI ...

Страница 122: ...Parts 6 18 750 392 CBEX DE 6 11 Temperature Controls Hot Water ...

Страница 123: ... QTY SEE TABLE SEE TABLE ITEM QTY PART NO DESCRIPTION ITEM QTY DESCRIPTION 7 1 807 00031 000 BALL BEARING DOUBLE ROW 8 1 019 01362 000 COVER BEARING 9 1 287 00094 000 ARM REAR DAVIT 10 1 077 00385 000 SPACER DAVIT 11 1 807 00319 000 BALL BEARING SINGLE ROW 12 2 952 00193 000 WASHER 13 1 914 00158 000 RING RETAINING 14 1 056 00025 000 PIN HINGE DAVIT 8 9 7 10 11 12 13 14 67 78 83 807 00031 000 019 ...

Страница 124: ......

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