Aqua-Chem Cleaver-Brooks CB Series Guide

$25.00 U.S.
Manual Part No. 750-184
8/98
CLEAVER-BROOKS
MODEL CB, CB-LE
PACKAGED BOILER
125 through 200 HP
Fuel: Light Oil, Heavy Oil, Gas or Combination
Operation, Service, and Parts Manual
Compliments of Power Mechanical, Inc.
Used Boilers
Rental Boilers

SAFETY PRECAUTIONS AND
ABBREVIATIONS
Safety Precautions
It is essential to read and understand the following safety
precautions before attempting to operate the equipment.
Failure to follow these precautions may result in damage to
equipment, serious personal injury, or death. A complete
understanding of this manual is required before attempting to
start-up, operate or maintain the equipment. The equipment
should be operated only by personnel who have a working
knowledge and understanding of the equipment.
The following symbols are used throughout this manual:
!DANGER
WARNING
This symbol indicates a potentially
hazardous situation which, if not
avoided, could result in serious
personal injury, or death.
!DANGER
CAUTION
This symbol indicates a potentially hazard-
ous situation which, if not avoided, could re-
sult in damage to the equipment.
Note: This symbol indicates information
that is vital to the operation of this
equipment.
Abbreviations
Following is an explanation of the abbreviations, acronyms,
and symbols used in this manual.
AC Alternating Current
AR Automatic Reset
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
BHP Boiler Horsepower
BTU British Thermal Unit
° C Degrees Celsius
CFH Cubic Feet per Hour
Cu Ft Cubic Feet
DC Direct Current
° F Degrees Fahrenheit
FM Factory Mutual
FS Flame Safeguard
ft Feet
GPM Gallons per Minute
Hd Head
HT Height
HTB High Turndown Burner
HZ Hertz
In H
2
O Inches of Water
IRI Industrial Risk Insurance
Lb Pound
LWCO Low-Water Cut-Off
M Million
MFD Micro-Farad
MR Manual Reset
NEC National Electric Code
No. Number
pH Measure of the degree of acid or base of a
solution
P/N Part Number
PPM Parts Per Million
PR Program Relay
psi Pounds Per Square Inch
SAE Society of Automotive Engineers
scfh Standard Cubic Feet per Hour
T Temperature
TC Temperature Control
TI Temperature Gauge

MODEL CB, CB-LE
PACKAGED BOILER
Operation, Service, and Parts Manual
125 through 200 HP
Fuel: Light Oil, Heavy Oil Gas or Combination
Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative
Manual Part No. 750-184
8/98 Printed in U.S.A.
 Cleaver-Brooks 1998
NOTE: If you have a CB-HAWK  Boiler Management Control
System, refer to CB-HAWK Installation, Operating and Service
Manual No. 750-133 during initial start up, and when referenc-
ing Chapters 5, 6, and 7 in this manual.

i
TO: Owners, Operators and/or Maintenance Personnel
This operating manual presents information that will help to properly operate and care for the equipment. Study its contents
carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are fol-
lowed. No attempt should be made to operate the unit until the principles of operation and all of the components are thoroughly
understood. Failure to follow all applicable instructions and warnings may result in severe personal injury or death.
It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who are ser-
vicing, repairing or operating the equipment, in all safety aspects.
Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and me-
chanical devices supplied as part of the unit were chosen because of their known ability to perform; however, proper operating
techniques and maintenance procedures must be followed at all times. Although these components afford a high degree of pro-
tection and safety, operation of equipment is not to be considered free from all dangers and hazards inherent in handling and
firing of fuel.
Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely free
him of certain repetitive chores and give him more time to devote to the proper upkeep of equipment.
It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instructions can
replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the responsibility
for proper operation. On the other hand, a thorough understanding of this manual is required before attempting to operate, main-
tain, service, or repair this equipment.
Because of state, local, or other applicable codes, there are a variety of electric controls and safety devices which vary consid-
erably from one boiler to another. This manual contains information designed 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 normal operation will continue indefinitely. Malfunctions of controls lead to uneconom-
ical operation and damage and, in most cases, these conditions can be traced directly to carelessness and deficiencies in testing
and maintenance.
It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly and yearly maintenance
activities and recording of any unusual 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 his low water controls and to follow good maintenance and testing practices. Cross-con-
necting piping to low water devices must be internally inspected periodically to guard against any stoppages which could ob-
struct the free flow of water to the low water devices. Float bowls of these controls must be inspected frequently to check for
the presence of foreign substances that would impede float ball movement.
The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be inspected frequently to
check for the presence of any mud, sludge, scale or corrosion.
The services of a qualified water treating company or a water consultant to recommend the proper boiler water treating practices
are essential.
The operation of this equipment by the owner and his or her operating personnel must comply with all requirements or regula-
tions of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency between
such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.
DO NOT OPERATE, SERVICE, OR REPAIRTHIS EQUIPMENT UNLESSYOU FULLY UNDERSTAND ALL
APPLICABLE SECTIONS OFTHIS MANUAL.
DO NOT ALLOW OTHERSTO OPERATE, SERVICE, OR REPAIRTHIS EQUIPMENT UNLESSTHEY FULLY
UNDERSTAND ALL APPLICABLE SECTIONS OFTHIS MANUAL.
FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
!
DANGER
WARNING

TABLE OF CONTENTS
Chapter 1
Basics of Firetube Operation
A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
B. The Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
C. Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
D. Steam Controls (All Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
E. Hot Water Controls (All Fuels). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
F. Induced Flue Gas Recirculation Components (CB-LE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Chapter 2
Burner Operation and Control
A. The Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
B. Control And Component Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
C. Components Common To All Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
D. Controls For Gas Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
E. Controls Common To Oil-Fired Boiler
(Including Combination). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
F. Additional Controls For Heavy Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
G. Controls For Combination Burners Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
H. CombustionAir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
I. Automatic Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
J. Atomizing Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
K. Oil Fuel Flow - Light Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
L. Oil Fuel Flow - Heavy Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
M. Gas Fuel Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
N. Modulating Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Chapter 3
Waterside Care And Requirements
A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
B. Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
C. Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
D. Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
E. Boil-out Of A New Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
F. Washing Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
G. Blowdown Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
H. Periodic Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
I. Preparation For Extended Lay-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
ii

TABLE OF CONTENTS(continued)
Chapter 4
Sequence Of Operation
A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
B. Circuit And Interlock Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
C. Sequence Of Operation - Oil Or Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
D. Flame Loss Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Chapter 5
Starting And Operating Instructions
A. General Preparation for Start-up - All Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
B. Control Settings-Steam and Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
C. Gas Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
D. Atomizing Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
E. Firing Preparations for No. 2 Oil (Series 100-200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
F. Firing Preparations for No. 6 Oil (Series 400-600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
G. Firing Preparations for Gas (Series 200-400-700). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
H. Induced Flue Gas Recirculation Set Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
I. Start-up, Operating and Shutdown - All Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
J. Control Operational Tests and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Chapter 6
Adjustment Procedures
A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
B. Linkage - Modulating Motor & Air Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
C. Modulating Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
D. Modulating Motor Switches Low Fire and High Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
E. Burner Operating Controls General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
F. Modulating Pressure Controls (Steam). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
G. Operating Limit Pressure Control (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
H. High Limit Pressure Control - (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
I. Modulating Temperature Control - (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
J. Operating Limit Temperature Control - (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
K. High Limit Temperature Control - (Hot Water). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
L. Low-Water Cutoff Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
M. CombustionAir Proving Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
N. Atomizing Air Proving Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
O. Gas Pilot Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
P. Gas Pressure and Flow Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Q. Gas Fuel CombustionAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
R. Low-Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
S. High-Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
T. Fuel Oil Pressure and Temperature - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
U. Fuel Oil CombustionAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
iii

TABLE OF CONTENTS (continued)
Chapter 6 (continued)
Adjustment Procedures
V. Burner Drawer Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
W. Oil Drawer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
X. Low-Oil-Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Y. High-Oil-Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Z. Low-Oil-Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
AA. Electric Oil Heater Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
BB. Steam Oil Heater Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
CC. Hot Water Oil Heater Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
DD. Steam Heater Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Chapter 7
Trouble Shooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Chapter 8
Inspection And Maintenance
A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
B. Fireside Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
C. Water Level Controls and Waterside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
D. Water Gauge Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
E. Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
F. Flame Safety Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
G. Oil Burner Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
H. Gas Burner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
I. Motorized Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
J. Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
K. Air Control Damper, Linkage and Cam Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
L. Forced Draft Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
M. CB-LE Fan/Motor Cassette Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
N. CB-LE Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
O. CB-LE Airbox Gasket Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
P. CB-LE Fan/Motor Cassette Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Q. Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
R. Fuel Oil Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
S. Air Pump and Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
T. Head Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
U. Refractory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
V. Sealing and Closing Inner Door and Front Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
W. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
X. Oil Heaters—Electric, Steam, Hot Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Y. Combustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Z. Air Pump Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
iv

Chapter 9
Customer Service And Parts
Front Door, Inner Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Rear Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dry Oven & Liner Tile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 8
Impellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9,10
Jackshafts, Mod Motor, Air Damper Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Burner Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17
Burner Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
Flame Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 21
Entrance Box & Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23
Front Head Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25
Electric Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 27
Oil Emission Steam Electric Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-30
Air Compressor /Air Line Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-34
Light Oil / Air Piping Front Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 36
Gas Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 38
Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Temperature Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 41
Water Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 43
v
Notes

750-184 1-1
CHAPTER 1
Basics of Firetube Operation
A. GENERAL
Firetube boilers are available for low or high pressure steam,
or for hot water applications. Firetube boilers are typically
used for applications ranging from 15 to 800 horsepower. A
firetube boiler is a cylindrical vessel, with horizontal tubes
passing through and connected to the front and rear tube
sheets. The vessel contains the water and absorbs the energy
generated from the flame. The front door and rear door
provide the seal to contain the hot combustion gasses. Baffles
designed into the doors serve to redirect the combustion
gasses through the various firetube passages. The flame
originates in the furnace. As the combustion gasses travel
down the furnace and through the various firetube channels,
heat from the flame and combustion gasses is transferred to
the water. Transferred energy develops into the required
steam or hot water. The primary purpose of the boiler is to
supply energy to the facility’s operations - for heat,
manufacturing process, laundry, kitchen, etc. The nature of
the facility’s operation will dictate whether a steam or hot
water boiler should be used.
Note: If your boiler is equipped with a CB-
HAWK  boiler management control
system, refer to CB-HAWK Installation,
Operating and Servicing Manual No. 750-
133 for information regarding controls
discussed in Chapter 1.
Figure: 1-1 Firetube Cut Away(Typical)
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
B. The Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
C. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
D. Steam Controls (All Fuels). . . . . . . . . . . . . . . . . . . 1-5
E. Hot Water Controls (All Fuels). . . . . . . . . . . . . . . . 1-7
F. Induced Flue Gas Recirculation Components. . . . . 1-9

Chapter 1 Basics of Firetube Operation
1-2 750-184
The general information in this manual applies directly to
Cleaver-Brooks Model CB Boilers in sizes ranging from 125
through 200 boiler horsepower for the following fuels:
Series 100 Light Oil (No. 2)
Series 200 Light Oil (No. 2) Or Gas
Series 400 Heavy Oil (No. 6) Or Gas
Series 600 Heavy Oil (No. 6) Only
Series 700 Gas Only
Note: Although the Series 400 or 600 burner
is designed and designated to burn No. 6
oil, the burner will handle grades 4 and 5
equally well, with some possible
adjustments. While the manual contains
pertinent information on No. 6 fuel oil, all
references to No. 6 fuel should be
considered applicable to all grades of heavy
oil.
The LE Option, available on Cleaver-Brooks Firetube
Boilers, reduces Nitrogen Oxide (NOx) emissions, a major
precursor to ozone pollution (smog). Carbon Monoxide (CO)
emissions also tend to be lower, due to increased turbulence
caused by the addition of the flue gases into the combustion
air stream, thereby improving combustion.
Note: For information on IFGR when firing
heavy oil, review the Operation and
Maintenance manual for Heavy Oil Isolation
750-171
The LE Option is used on Cleaver-Brooks Model CB Firetube
boilers firing either natural gas and/or light oil, and is
compatible with both hot water and steam systems.
The IFGR system mixes a portion of the relatively cool flue
gas from the exit of the fourth-pass tubes with the incoming
combustion air to reduce the furnace flame temperature,
thereby reducing NOx emissions. In this approach, the
combustion air fan handles both the combustion air and the
recirculated flue gases. Accordingly, this method is called
Induced Flue Gas Recirculation (IFGR), because the flue gas
is “induced” into the fan inlet.
The LE Option, with its various levels of IFGR systems, can
affect the selection of the combustion air fan, motor, burner,
and other components. Several different system
configurations are available, depending on the requirements
for NOx emissions and the fuels used. All systems use
similar primary components, but may have different linkage
controls, IFGR damper, fan, and motor sizes.
Always order genuine Cleaver-Brooks parts from your local
Cleaver-Brooks authorized representative.
The boiler and related equipment installation are to be in
compliance with the standards of the National Board of Fire
Underwriters. Installation should also conform to state and
local codes governing such equipment. Prior to installation,
the proper authorities having jurisdiction are to be consulted,
permits obtained, etc. All boilers in the above series comply,
when equipped with optional equipment, to Industrial Risk
Insurers (IRI), Factory Mutual (FM), or other insuring
underwriters requirements.
B.THE BOILER
The Model CB boiler is a packaged firetube boiler of welded
steel construction and consists of a pressure vessel, burner,
burner controls, forced draft fan, damper, air pump,
refractory, and appropriate boiler trim.
The horsepower rating of the boiler is indicated by the
numbers following the fuel series. Thus, CB700-200
indicates a gas-fired 200 hp boiler.
The firetube construction provides some characteristics that
differentiate it from other boiler types. Because of its vessel
size, the firetube contains a large amount of water, allowing
it to respond to load changes with minimum variation in
steam pressure.
Firetube boilers are rated in boiler horsepower (BHP), which
should not be confused with other horsepower measure-
ments.
Hot water is commonly used in heating applications with the
boiler supplying water to the system at 180 ° F to 220 ° F. The
operating pressure for hot water heating systems usually is
30 psig to 125 psig.
Rated Capacity 125 through 200hp
Operating Pressure Steam15-250 psig, orhigherif
specified
Hot Water 30-250 psig or
higher if specified
Fuel Oil or Gas or Combination
Ignition Automatic
Firing Full Modulation Through
Operating Ranges
Burner (Oil) (Low Pressure) Air Atomizing
Burner (Gas) Non-premix – Orificed Type
Air Damper Rotary Type
(Electrically Modulated)
Steam Trim ASME Code
Water Trim ASME Code