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Manual Part No. 750-364

MODEL

FLX

PACKAGED BOILER

12,500,000 to 25,000,000 BTU/hr

Hot Water

Fuel: Light Oil, Gas or Combination

09/2013

Содержание FLX 1250

Страница 1: ...Manual Part No 750 364 MODEL FLX PACKAGED BOILER 12 500 000 to 25 000 000 BTU hr Hot Water Fuel Light Oil Gas or Combination 09 2013...

Страница 2: ...anual 12 500 000 to 25 000 000 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...

Страница 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...

Страница 4: ...stem 2 4 F Installation 2 5 G FGR System Low NOx Applications 2 6 H Burner Maintenance 2 7 Chapter 3 Pressure Vessel Care A General 3 1 B Water Requirements 3 1 C Water Treatment 3 3 D Using Glycol 3...

Страница 5: ...6 J High Gas Pressure Switch 5 6 K Fuel Oil Pressure And Temperature 5 7 L Fuel Oil Combustion Adjustment 5 7 M Low Oil Pressure Switch 5 7 Chapter 6 Troubleshooting 6 1 Chapter 7 Inspection And Main...

Страница 6: ...iv...

Страница 7: ...Gas No 2 Oil Design Pressure 30 60 125 or 160 psig hot water DANGER CAUTION The care taken in placing the boiler into initial service is vital to continuous reliable operation If the boiler is to be...

Страница 8: ...CAUTION Waterside care is of prime importance For specific information or assistance with your water treatment requirements contact your Cleaver Brooks service and parts represen tative Failure to fo...

Страница 9: ...ical 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 only a m...

Страница 10: ...Chapter 1 GENERAL DESCRIPTION 1 4 750 364...

Страница 11: ...tes the combustion air volume and is positioned by a modulating motor The damper is normally almost closed in the low fire position and opens as the burner drives toward a high fire position Motor dri...

Страница 12: ...es through grooves and out of the nozzle orifice in a cone of atomized oil Proper velocity and angle of the fine spray ensures good mixing with the combustion air providing quiet starts and excellent...

Страница 13: ...il from the tank to the compressor to lubricate bearings and vanes A sight glass indicates the level of lubricating oil in the air oil reservoir Lubricating oil must be visible in the gauge glass at a...

Страница 14: ...he requirements of the regulating authority the gas control system and gas train may consist of some or all of the following items Operation Metered gas flows through the main gas shutoff cock through...

Страница 15: ...rculating Loop Operation An oil circulating pump provides continuous oil circulation to the circulation loop A back pressure valve holds 10 to 15 psi on the loop system With the oil supply line connec...

Страница 16: ...burner operation be sure all motors are rotating in the correct direction Before firing make sure that the refractory flame cone is properly sealed to the burner mounting flange and the boiler front...

Страница 17: ...impeller Inserting a bar through the impeller blade and using it as a lever will only damage the blade and also void the impeller warranty Firing Head Inspection Remove the bolts that secure the burn...

Страница 18: ...t the nozzle spring is not properly in place or the nozzle is clogged This problem is usually indicated by an abnormally high reading on the atomizing air pressure gauge on the air oil tank To remove...

Страница 19: ...l strainer clogged line strainer or burner strainer Suction line piping too small see Chapter 2 Pump rotating in wrong direction Three phase pump motor operating on single phase because of fuse failur...

Страница 20: ...is obtained Follow previous instructions for oil replacement Air Oil Tank Air Cleaner Never operate the air pump without the air cleaner in place The cleaner itself must be periodically checked and it...

Страница 21: ...e 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...

Страница 22: ...ing exceeds the nameplate rating plus service factor determine the cause and correct it immediately In dusty locations clean the motor regularly to assure adequate cooling Lubricate in accordance with...

Страница 23: ...ces the possibility of released air which is trapped at the top of the drum from entering the system Any air or oxygen that may be released in the boiler will collect at the top of the upper drum wher...

Страница 24: ...rough the boiler when the burner is oper ating may result in damage to the equip ment System Pressure The design of the system and the usage requirements often will dictate the pressure exerted upon t...

Страница 25: ...re used they should be set so that the boiler is not by passed thus impairing circulation within the boiler when the burner is firing This could lead to over temperature and nuisance shutdowns as the...

Страница 26: ...used 8 It is the end user s responsibility to routinely monitor the condition of the system fluid Frequent analyses during the first six months of operation and semi annual checks thereafter are reco...

Страница 27: ...s purpose The overflow connection to the boiler should incorporate a tee fitting for adding cleaning solution to the boiler 6 Fill the unit with clean water to a point just below the access port in th...

Страница 28: ...layup procedures in this chapter G 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 theory a ho...

Страница 29: ...for inspection of the firing chamber or furnace is gained through the hinged burner door Inspection of the upper pass requires removal of the side casing panels and second and fourth pass cover plate...

Страница 30: ...sing that the air inlet has been blocked Failure to remove the air inlet block when at tempting to operate the burner may result in damage to the equipment Dry Storage Dry storage generally is used fo...

Страница 31: ...ater than atmospheric pressure Nitrogen often is used to pressurize the vessel The boiler water should be tested weekly as long as the unit is in storage Additional chemicals may be required to preven...

Страница 32: ...Chapter 3 Pressure Vessel Care 3 10 750 364...

Страница 33: ...le limits are correct for burner operation The load demand indicator is on All entrance switches are closed and power is present at the line terminals of Blower motor starter Oil pump motor starter if...

Страница 34: ...als the PLC to drive the air damper actuator to its full open or high fire position Opening the damper allows a flow of purging air through the boiler prior to the ignition cycle The controls wired in...

Страница 35: ...e MGV or OV to close The flame is extinguished The control panel lights LDL and FVL are turned off The blower motor continues to run to force air through the boiler for the post purge period The blowe...

Страница 36: ...ce in pinpointing problems that may not be readily apparent The program relay has the capability to self diagnose and to display a code or message that indicates the failure condition Refer to the con...

Страница 37: ...er Operation and Maintenance manual for specific information on boiler startup and operation The term controls is used in this manual to refer to The Operating Limit and High Limit controls hard ware...

Страница 38: ...al the actuators to be in a low fire position If the load demands exceed the low fire input potential the controls will increase the firing rate proportionately as pressure or temperature falls toward...

Страница 39: ...ing on a temperature increase To reset allow the water temperature to drop below the cut out setting less differential and then press the manual reset button D LOW WATER CUTOFF DEVICES No adjustment i...

Страница 40: ...ed G GAS PRESSURE AND FLOW INFORMATION Because of variables in both the properties of gas and the supply system it will be necessary to regulate the pressure of the gas to a level that produces a stea...

Страница 41: ...CFH at line pressure that must pass through the meter so that the equivalent full input requirement of 5 000 CFH at base pressure will be delivered Checking Gas Flow Your gas supplier can generally fu...

Страница 42: ...ndicated by the slot on the end of the shaft Determine the actual gas flow from a meter reading See Section G With the butterfly valve open and with regulated gas pressure set at the calculated pressu...

Страница 43: ...ng approximate settings Combustion settings should be done so that there is a bright sharp flame with no visible haze Most flue gas analyzers in use today measure the content by percentage of oxygen O...

Страница 44: ...4 PER CENT O2 IN FLUE GAS PER CENT CO PER CENT EXCESS AIR 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 O2 and products of combustion FIRST VISIBLE TRA...

Страница 45: ...y the trouble shooting chapter should be referred to for assistance in pinpointing problems that may not be readily apparent The boiler control system has the capability to self diagnose and to displa...

Страница 46: ...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...

Страница 47: ...main fuel valve circuit terminal BURNER STAYS IN LOW FIRE 1 Manual automatic switch in wrong position SHUTDOWN OCCURS DURING FIRING 1 Loss or stoppage of fuel supply 2 Defective fuel valve loose elect...

Страница 48: ...r casing to heat up above the condensation temperature of the flue gasses A Increase temperature of the cold boiler room if possible B Verify insulation is in place between inner and outer casing and...

Страница 49: ...Troubleshooting Chapter 6 750 364 6 5...

Страница 50: ...Chapter 6 Troubleshooting 6 6 750 364...

Страница 51: ...rator from responsibility Automatic features do free the operator of certain repetitive chores thus providing more time to devote to upkeep and maintenance Alertness in recognizing an unusual noise im...

Страница 52: ...ns Refractory surfaces should be cleaned if necessary with a soft bristle brush Loose material should be vacuumed from the bottom of the furnace D UPPER PASS CLEANING Upper pass access is gained throu...

Страница 53: ...the top of the rear panel and working down tighten the bolts Repeat this on the front panel After finishing this return to the rear panel and tighten to the bottom repeat this on the front panel Inst...

Страница 54: ...odels of the low water cutoff devices on a hot water boiler Hot water systems are fully closed Daily or monthly maintenance on some models of the low water cutoff devices would involve draining the en...

Страница 55: ...control programmer Note NOTE Be sure that the connecting contacts on the control and the base are not bent out of position DANGER WARNING When replacing a control be sure to lock out the main power s...

Страница 56: ...nger tube thoroughly Do not use any oil Make sure that the plunger tube and solenoid are tight when assembled Take care not to nick dent or damage the plunger tube Solenoid coils can be replaced witho...

Страница 57: ...ht port is caused by either a poor seal between the sight port insulator and the wall a cracked insulator or a flue gas leak at the sight port cap Check the threads of the cap and sight tube If necess...

Страница 58: ...Chapter 7 Inspection and Maintenance 7 8 750 364...

Страница 59: ...CHAPTER 8 Parts FLX 1250 2500 Hot Water Recommended Spare Parts List 8 2 Outer Casing 8 3 Inner Casing 8 4 Temperature Controls 8 7 Level Controls 8 8 EV Burner 8 9...

Страница 60: ...asket P N 853 00996 1250 1450 1650 1850 2100 2500 Qty inches 186 186 202 202 228 228 Inner Casing Gasket P N 032 02560 1250 1450 1650 1850 2100 2500 Qty feet 175 180 220 225 260 290 Blower Motor Fuse...

Страница 61: ...1 1 2 CASING PANEL OUTER SIDE MIDDLE 105 12217 8 105 12217 6 105 12360 10 105 12360 10 105 12252 10 105 12252 10 3 OUTER CASING SIDE CORNER 315 01187 4 315 01187 4 105 12362 4 105 12362 4 105 12254 4...

Страница 62: ...L SEAMS 4 APPLY SILICONE AT GAPS TO SEAL 5 APPLY GASKET TO BOILER IN SINGLE PIECE NO SEAMS ALLOWED ON BASE OR END WALLS 6 APPLY SILICONE AT POINTS WHERE VERTICAL GASKETS OVERLAP WITH HORIZONTAL GASKET...

Страница 63: ...ILICONE CAULK PRIOR TO INSTALLING COLLAR PLATE 5 FIT INSULATION UNDER BOILER TUBING ITEM 29 6 PACK INSULATION UNDER VENT TUBE TO FILL VOIDS BETWEEN REAR WALL AND NEXT TUBE 7 SPRAY ADHESIVE ON TUBES AB...

Страница 64: ...S 853 00996 5 FT 853 00996 5 FT 853 00996 5 FT 853 00996 5 FT 853 00996 5 FT 853 00996 5 FT 17 CAPSCREW 3 8 16 UNC 868 00056 112 868 00056 112 868 00056 160 868 00056 160 868 00056 228 868 00056 228 1...

Страница 65: ...Parts FLX 750 364 8 7 Temperature Controls 2 2 3354 817 3354...

Страница 66: ...FLX Parts 8 8 750 364 Level Controls...

Страница 67: ...1 16 THK X 8 5 8 ID X 11 OD 853 00610 000 A 11 SCREW CAP 3 4 10 X 2 LG 868 00197 000 8 12 CAP SCREW 3 8 16 x 1 1 4 LG HEX HEAD 868 00232 B 13 A A B B 4 1 2 3 11 13 18 20 12 22 14 22 10 17 17 16 21 7 1...

Страница 68: ...00 040 01022 000 194 00107 279 00628 000 656 09949 000 185 01178 000 040 01001 000 040 01021 000 279 00628 000 656 10044 000 185 01178 000 040 01010 000 040 01022 000 194 00241 000 279 00628 000 656 0...

Страница 69: ......

Страница 70: ...e mail info cleaverbrooks com Web Address http www cleaverbrooks com...

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