CleaverBrooks CBW Guide
CLEAVER-BROOKS
MODELCBW
PACKAGED BOILERS
Operation, Service, and Part Manual
100 thru 400 HP
Fuel: Gas, Light Oil, Heavy Oil or Gas Combination
Cleave
Please direct purchase orders for replacement manuals
to your local Cleaver-Brooks representative
Manual
Part
No.
750-150
Printed
in
U.S.A.
WARNING
DO NOT OPERATE, SERVICE,
OR
REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND
ALL
APPLICABLE SECTIONS
OF
THIS MANUAL.
DO NOT
ALLOW
OTHERS TO OPERATE, SERVICE,
OR
REPAIR THIS EQUIPMENT UNLESS
THEY
FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.
FA.ll..URE
TO
FOLLOW
ALL APPLICABLE WARNINGS
AND
INSTRUCTIONS MAY RESULT IN SE-
VERE PERSONAL INJURY
OR
DEATH.
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
followed.
No
attempt should be made to operate the tmit until the principles
of
operation and all
of
the components are
thoroughly understood. Failure to follow all applicable instructions and warning 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 contractor's personnel who are
servicing, 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
mechanical devices supplied as part
of
the unit were chosen because
of
their know ability to perform; however, proper operating
techniques and maintenance procedures must be followed at all times. Although these componesnts afford a high degree
of
protection 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/her
of
certain repetitive chores and give him/her more time tot 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,
maintain, 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 consider-
ably from one boiler to another. This manual contains information designed to show how a basic boiler operates.
Operating controls will normally fi.mction
for
long periods
of
~e
and we have found that some operators become lax in their
daily or monthly tesing, assuming that normal operation will continue indefinitely. Malfi.mctions
of
controls lead to uneconomi-
cal operation
and
damage and, in most cases, these conditions ca nbe 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, nonthly 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/her low water controls and to follow good maintenance and testing practices. Cross·
connecting piping to low water devices must be internally inspected periodically to guard against any stoppages which could
obstruct 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/her operating personnel must comply with all requirements or regulations
of
his/her 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.
Safety precautions and Abbreviations
1.
Safety Precautions
It
is
essential to read and understand the following
safe.ty precautions before attempting to operate the
eqmpmenL
Failure to heed these precautions may result in damage
to equipment, serious personal injury
or
death!
A complete understanding
of
this manual
is
required-
_bef<:;~re
attempting to- startup, operate
or
maintam the
equtpmenL
The equipment should be
o~rated
only by personnel
who have a working knowledge and understanding
of
the equipment.
!WARNING
This symbol indicates a potentially
hazardous situation which,
if
not
avoided, could result in serious per-
sonal in· or death.
CAUTION!
This symbol indicates a
~tentially
haz-
ardous
situation which,
if
not avoided,
could result in damage to the equip
..
ment.
Note: This symbol indicates information that
is
vital to the operation
of
this equip-
ment.
2.
Abbreviations
Following
is
an exP.lanation
of
the abbreviations,
acronyms, and symbols
used
in this manual.
AC
AR
ASME
ASThfD
BHP
Alternating Current
Automatic Reset
American Society
of
Mechanical
Engineers
American Society
of
Tables, Measures,
Dimensions
Boiler Horsepower
ii
BTU
·c
CFH
Cu.
Ft.
DC
OF
FM
FT
GPM
Hd
'HT
HTB
HZ
IRI
Lb
LWCO
:MFD
MR
NO
pH
PIN
PPM
PR
PSI
SAE
T
TC
11
v
we
WSI
British Thermal Unit
Degrees Celsius
Cubic Feet per Hour
· Cubic Feet
Direct Current
Degrees Fahrenheit
Factory Mutual
Feet
Gallons per Minute
Head
Height
High Turndown Burner
Hertz
Industrial Risk Insurance
Pound
Low Water
Cutoff
Micro Farad
Manual Reset
Number
Measure
of
the degree
of
acid
or
base
of
a soluti
on
Part Number
Parts Per Million
Program Relay
Pounds Per Square Inch (Gauge)
Society
of
Automotive Engineers
Ternperature
Temperature Control
Temperature Gauge
Volt
Water Column
Watts Per Square Inch
THE
THREE
PASS
CONSTRUCTION
OF
A TYPICAL
CBW
BOILER
(CBWlOO
through
200
Boiler Horsepower
Shown)
Combustion air enters through the air inlet. The forced draft fan forces air through the rotary air
damper and diffuser into the combustion chamber. The main combustion chamber or main
firetube constitutes pass one. A combustion turnaround section directs the gases into the second
pass tubes. The turnaround section
is
contained within the pressure vessel, completely covered
with water, giving the design name "WETBACK." Gases are directed from the second to the
third pass at the front
of
the boiler and finally exit out the vent at the rear
of
the boiler.
iii
Table
of
Contents
CHAPTER 1
1-1
GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION •
.1·1
A
The
Boiler
1-2
B.
The
Burner
and
Control System
1·2
C.
Control
and
Component Function
1-3
D.
Controls Common to
aJI
Boilers
1-4
E.
Steam Controls
(AJI
Fuels)
1-6
F.
Hot Water Controls
(AJI
Fuels)
1-8
G.
Controls for Gas Firing
1-8
H.
Controls Common to Oil Fired Boilers
(lncfuding combination) ·
1-10
I.
Additional Controls For Heavy Oil
1-13
J. Controls for Combination Burners Only
1-16
K CombustionAir
1-16
L . Automatic Ignition
1-16
M.
Atomizing Air
1-16
N.
Oil Fuel Flow -Ught Oil
1-18
0.
Oil Fuel Flow -Heavy
Oil
1-18
P.
Gas Fuel Flow
1-21
Q. Modulating Firing
1-22
CHAPTER 2
2-1
THE PRESSURE VESSEL • • • •
II
e • • • • a • • • • • • e • • 2·1
A General
2-1
B.
Construction 2-2
C.
Water Requirements 2-2
D.
WaterTreatment 2-6
E.
Cleaning 2-7
F.
Boil-out
of
a New Unit 2-8
G.
Washing Out 2-10
H.
Slowdown-
Steam Boiler 2-10
I.
Periodic Inspection 2-13
J.
Preparation for Extended Lay-up 2-14
CHAPTER
3
3-1
SEQUENCE OF OPERATION • • • • • • • • • • • • • • • • • • •
3-1
CHAPTER
4
A General
3--1
B.
c.
D.
Circuit and Interlock Controls
3--6
Sequence
of
Operation -Oil
Or
Gas 3-7
Flame Loss Sequence 3-9
STARTING
AND
OPERATING INSTRUCTIONS • • • • • • • • •
4-1
CHAPTER
5
A General Preparation
For Start-Up -
AJI
Fuels
B.
ControiSe~ngs-
Steam And
Hot
Water
C.
Gas Pilot
4-1
4-2
4-3
D.
Atomizing Air 4-4
E.
Firing Preparations for No. 2 Oil
(Sseries 100-200) 4-5
F.
Firing
Preparati~n
For No. 6 Oil
(Series 400-600) 4-6
G. Firing Preparations For
gas
(Series 200-400-700) 4-8
H. Start-up, Operating and Shutdown
-
AJI
Fuels 4-9
I.
Control Operational Test and Checks
4-11
5-1
ADJUSTMENT PROCEDURES • • • • • • • • • • • • • • • • • .
5-1
A Gene
raJ
5-2
B.
Unkage-Modulating
Motor
and Air Damper 5-3
c.
Modulating Motor
5-4
D.
Modulating Motor Switches -
Low Fire and High Fire 5-5
E.
Burner Operating Controls -General 5-5
F.
Modulating Pressure Control (Steam) 5-7
G. Operating
Umit
Pressure Control
(Steam) 5-8
H.
High
Umit
Pressure Control (Steam) 5-8
I.
Modulating Temperature Control
(Hot
Water)
5-8
J.
Operating Umit Temperature Control
(Hot
Water)
5·8
K
High
Umit Temperature Control
(Hot
Water)
5-9
L
Low
Water Cutoff Devices
(Steam
and
Hot
Water)
5-9
M.
Combustion Air Proving Switch
5-9
N.
Atomizing Air Proving switch
5-9
0.
Gas
Pilot Flame Adjustment
5-10
P.
Gas
Pressure
and
Flow Information 5-12
a.
Gas
Fuel
Combustion Adjustment
5-15
R.
Low
Gas
Pressure Switch 5-17
s.
High
Gas
Pressure Switch
5-18
T.
Fuel
Oil
Pressure
And
Temperature -
General
5-18
u.
Fuel
Oil
Combustion Adjustment 5-19
v.
Burner DrawerAdjustment
5-23
w.
Oil
Drawer Switch
5-23
X.
Low
Oil
Temperature Switch
5-23
Y.
High
Oil
Temperature Switch (Optional) 5-24
z.
Low
Oii_Pressure
Switch (Optional) 5-24
AA.
Electric
Oil
Heater Thermostat
(400
and
600
Series -Steam) 5-24
88.
Steam
Oil
Heater Thermostat
(No.6
Oil)
(400
and
600
Series -
Steam)
5-24
cc.
Hot
Water
Oil
Heater Thermostat
(
400
and
600
Series) 5-24
DO.
Steam
Heater Pressure Regulator
(400
and
600
Series-
Steam)
5-25
CHAPTER 6
6-1
TROUBLE SHOOTING • • • • • • • • • • • • • • • • • • • • • •
8-1
A Burner
Does
Not
Start
6-2
B.
No Ignition 6-2
c.
Pilot
Flame,
But
No
Main
Flame
6·3
D.
Burner Stays
In
Low
Fire 6-4
E.
Shutdown Occurs During Firing
6-4
F.
Modulating Motor
Does
Not
Operate
6-5
CHAPTER 7
7·1
INSPECTION AND MAINTENANCE • a • • a a e • e e • G • e e
7•1
A General
7-2
B.
Fireside Cleaning
7-3
G.
Water
Level
Controls
7-3
D.
Water
Gauge
Glass
7-4
E.
EJectriccU
Controls 7-4
F.
Flame
Safeguard Control
7-6
G.
Oil
Bumer Maintenance
7-7
H.
Gas
Bumer Maintenance
7-9
I.
Motorized
Gas
Valve(s)
7-9
J.
Sole~oid
Valves
7-9
K Air
Control
Damper,
Unkage
and
Cam
Spring
7-12
L
Forced
Draft
Fan
7w12
M.
Safety
Valves
7-13
N.
Fuel
Oil
Metering
Valve,
Adjusting
and
Relief
Valves
7-13
0.
The
Air
Pump
and
Lubricating
System
7-15
P.
Refractory
7-16
a.
Opening
And
Closing Doors
7-20
A.
Lubrication 7·20
s.
Oil
Heaters -
Electric,
Steam,
Hot
Water
7-22
T.
Combustion
7-22
CHAPTER 8
8-·1
PARTS ORDER/UST INSTRUCTIONS
•.•.•.•••••.••
8-1
CHAPTERl
GENERAL
DESCRIPTION
AND J?RINCIPLES
OF
OPERATION
CHAPTER 1
GENERAL
DESCRIPTION
AND
PRINCIPLES
OF
OPERATION
A The Boiler
B.
The Burner And Control System
C.
Control And Component Function
D.
Controls Common To All Boilers
E. Steam Controls (All Fuels)
F.
Hot Water Controls (All Fuels)
G.
Controls For Gas Firing (Including Combination)
H. Controls For Oil Fired Boilers
I.
Co~trols
For Heavy Oil
J. Controls For Combination Burners
K. Combustion Air
L. Automatic Ignition
M. Atomizing Air
N.
Oil Fuel Flow -Light Oil
0.
Oil Fuel Flow -Heavy Oil
P. Gas Fuel Flow
Q. Modulating Firing
NOTE:
If
your boiler
is
equipped with a
CB-HA
WK™
boiler
manage·
ment control system, refer to CB-
Hawk. Installation, Operating,
and Servicing Manual No. 750-
133 for information regarding
controls discussed in this section.
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
The general information
in
this manual applies
directly
to
Cleaver-Brooks
"CBW''
Boiler
Models in sizes ranging from 100 through 400
boiler horsepower for the following fuels:
750-150
NOTE:
Although the Series 400
or
600
burner
is
designed and designated
to bum No. 6 oil, the burner will
handle grades 4 and 5 equally
well
with
some
possible
modifications. While this manual
contains peninent infonnation on
CHAPTER 1
..
1
CHAPTER!
GENERAL
DESCRIPTION
AND
PRINCIPLES
OF
OPERATION
No. 6 fuel oil, all references
to
this fuel should
be
considered ap-
plicable
to
all grades
of
heavy oil.
The boiler and related equipment installation, by
others,
is
to
be
in compliance with the standards
of
the National Board
of
Fire Underwriters. In-
stallation also should conform
to
state and local
codes governing such equipment. Prior to instal-
lation, 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 (I.R.I.), Factory Mutual (FM), or
other insuring underwriters requirements.
A.
THE
BOILER
The "CBW" 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 ap-
propriate boiler trim.
Rated Capacity . . .100 through 400)-IP
Operating Pressure .Steam 15-250 psig,
or higher if.specified
Hot Water . . . . . . . .30-250 psig
or
higher ifspecified
Fuel . . ; . . . . . . . .Oil
or
Gas
or Combination
Ignition .Automatic
Firing . . . . . . . . . .Full Modulation
Through Operating
Ranges
CHAPTER 1-2
Burner (Oil)
.......
(Low Pressure)
Air Atomizing
Burner (Gas)
......
Non-premix
Otificed Type
Air Damper . . . . . . . Rotary Type
(Electrically
Modulated)
Steam Trim . . . . . . . ASME Code
Water Trim . . . . . . . ASME Code
The horsepower rating
of
the boiler
is
indicated
by
the numbers following the fuel series. Thus,
CBW700-200 indicatesa gas fired 200 HP boiler.
B.
THE
BURNER
AND
CONTROL
SYSTEM
The oil burner
is
of
the low pressure, air
atomiz~
ing (nozzle) type. The gas burner
is
of
the non-
premix orifice type. The burners are ignited
by
spark ignited gas pilot. The pilot
is
of
the inter-
rupted type and
is
extinguished after the main
flame
is
established.
NOTE:
A Series 100 boiler
is
usually
equipped with a light oil pilot al-
though a gas pilot frequently
is
used.
The burners equipped to burn oil and gas include
equipmentfor each distinct fuel. Since the burner
uses only one type
of
fuel at a time, a gas/oil
selector switch is incorporated in a combination
burner.
It
is
important that the burner model and serial
number, shown on the nameplate,
be
included
in
any correspondence
or
parts order.
750-150
CHAPTER I GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION
Regardless
of
which fuel is used, the burner
operates with full modulation (within
its
rated
operating range) through potentiometer-type
positioning controls, and the burner returns to
minimum firing position for ignition. High pres-
sure boilers (above 15 psi) can be wired for both
low pressure and high pressure modulation
as
optional equipment. This enables the boiler to
operate at lower pressure during off-load hours,
but at asomewhat reduced steam output depend-
ent upon lower steam pressure and steam nozzle
sizing.
The flame safeguard and program relay include
a flame detector to supervise both oil·and gas
flames and to shut the burner down
in
the event
ofloss
of
flame signal. Theprogramming portion
of
the control provides a .pre-purging period,
proving
of
the pilot and main flame, and a period
of
continued blower operation to postpurge the
boiler
of
all unburned fuel vapors. Other safety
controls shut down the burner under low water
conditions, excess steam pressure or high water
tern
perature.
The safety interlockcontrols includecombustion
and atomizing air proving switches and, depend-·
ing upon the fuel and insurance carrier require-
ments, controls that prove the presence
of
adequate fuel pressure plus temperature proving
controls when heated fuel oil
is
used.
The sequence
of
burner operatiop from start-up
through shut-down
is
governed
by
the program
relay
in
conjunction with the operating, limit and
interlock devices, which are wired into the cir-
cuitry to provide safe operation and help to
protect against incorrect operating techniques.
All "CBW" model boilers ·have the burner as-
sembly attached
to
the front head. Theentirehead
may be swung open for inspection and main-
tenance.
Combustion air
is
provided
by
a centrifugal
blower located
in
the front head. Combustion air
delivery
to
the burner
is
under the control
of
the
damper motor. This same motor regulates the
flow
of
gas fuel through a linkage system con-
nected to the gas butterfly valve and the flow
of
750-150
fuel oil through a cam operated metering valve.
Fuel input and air are thus properly proportioned
for most efficient combustion.
Filtered primary air for atomizing fuel oil
is
furnished independently
of
combustion air
by
an
air pump. The burner control circuit operates on
115 volt, single phase 60 hertz (or
SO
hertz when
so equipped) alternating current.Theforced draft
fan motor
is
generally operated on 3 phase ser-
vice at the available main power supply voltage.
Indicator lights signaling load demand, fuel
valve, low water, and flame failure conditions are
standard equipment.
In addition to the standard basic controls sup-
plied, other devices may be required to meet
specific requirements
of
an insurance carrier or
local code. Refer to the Wiring Wiagram (WD)
prepared by Cleaver-Brooks for your specific
installation to determine the specific controls
in
the burnerand limitcontrol circuits. The function
of
individualcomponents
is
outlined
in
this chap-
ter and the electrical sequence
is
covered
in
Chapter
3.
C.
CONTROL
AND
COMPONENT
FUNCTION
The term "control" covers the more important
valves and components, includingbut not limited
to electrical controls or those monitored by the
program relay.
The
operator
must become
familiar with the individual functioning
of
all
controls before he can understand the boiler's
operation and procedures outlined
in
the manual.
Identify and locate each item using the figure
callout.
The actual controls furnished with any given
boilerwill depend upon the type
of
fuel forwhich
it
is
equipped and whether
it
is
a hot water or
steam boiler. Refer to the applicable group or
groups listed which apply to the particular boiler.
CHAPTER
1--3
CHAPTER!
GENERAL DESCRIPTION
AND
PRINCIPLES OF OPERATION
GAS
CONTROL
VALVE FUEL OIL
CONTROLLER OIL RELIEF VALVE
ERATING, HIGH
LIMIT
AND
LATING PRESSURE CONTROLS
WATER
COLUMN
AND PUMP CONTROLS
[FIGURE
1-1
I TYPICAL STEAM
BOILER-
LIGHT OIL FIRED]
Boilers having optionally ordered features may
have control components not listed here.
D.
CONTROLS COMMON
TO
ALL
BOILERS
(1) Forced Draft Fan Motor (Fig. 1-1): Drives the
forced draft fan directly
to
provide combustion
air. Also referred
to
as a blower motor.
(2) Forced Draft Fan Motor Starter (Fig. 1-7):
Energizes the forced draft fan (blower) motor.
CHAPTER 1-4
(3) Forced Draft Fan (Fig. 1-10): Furnishes all
air, under pressure, for combustion
of
pilot fuel
and main fuel, and for purging.
(4) Ignition Transfonner (Fig.
1-1
): Provides a
high voltage spark for ignition
of
the gas pilot or
the light oil pilot.
(5) Modulating Motor (Fig. 1-1): Operates the
rotary air damper and fuel valves through a cam
and linkage system to provide proper air fuel
ratios under all boiler load conditions.
750-150
CHAPTER!
GENERAL DESCRIPTIONAND PRINCIPLES OF OPERATION
OIL
STRAINEfl
OIL
SUPPLY
PFESSUAE
GAUGe
WATER
FIEUEF
VALVES
HOTWA~
OILHEATER
.
BVP..a&VAL\IE
EI009"1"EF!
WATER
PUMP
0Pe=IA11NG
TEMPeRATURE.
HIGHUMIT
•
T'EJIIFIEAA
TURE
AND
MOOULA11NG
'T"EMP'ERA
TUAE
CONTROLS
HOT
WATER
OIL
HEATER
COIL
WATER
'T"EMPERA
TUAE
GAUGE
NOTE:
FOR
STREAM
COMPONENTS
~TO
FIGURE 1-8
[FIGURE 1-2I TYPICAL HOT WATER BOILER WITH HEAVY
OIL
HEATER]
(6) Low Fire Switch (Not Shown): An internal
auxiliary switch, camactuated by the modulating
motorshaft, which mustbeclosed
to
indicate that
the air damper and fuel metering valve are
in
the
low fire position before an ignition cycle can
occur.
(7)
Burner
Switch
(Fig.
1·7):
A
manually
operated start·stop switch for directly starting
and stopping operation
of
burner.
(8) Manual*Automatic Switch (Fig. 1-7): When
set at "automatic," subsequent operation
is
at the
command
of
the
modulating
control, which
governs the position
of
the modulating motor
in
accordance with load demand.
When
set at
750-150
"manual," the modulating motor, through the
manual flame control, can be positioned at a
desired burner firing rate.
The
primary purpose
of
the manual position
is
for testing and setting
the air-fuel ratio through the entire firing range.
(9) Manual FlameControl (Fig. 1-7): A manually
operated potentiometerthat permits the position-
ing
of
the modulating motor to a desired burner
firing rate when the manual·automatic switch
is
set on manual.
It
is
used primarily for initial or
subsequent setting
of
fuel input throughout the
frring range. It has no control over the firing rate
when the manual-automatic switch
is
set on
"automatic."
CHAPTER
1..5
CHAPTER!
GENERAL DESCRIPTIONAND PRINCIPLES OF OPERATION
(10) Modulating Motor Transformer (located in
the mod motor): Reduces control circuit voltage
(115V
Aq
to required voltage (24V
Aq
for
operation
of
the modulating motor.
(11) Indicator Lights (Fig. 1-7): Provide visual
information onoperation
of
the boiler
as
follows:
Flame Failure
Load Demand
Fuel Valve (valve open)
Low Water
(12) Program Relay and Flame Safe Guard Con-
trol (Fig.
1~
7): Automatically programs each
starting, operating and shutdown period
in
con-
junction
with
operating limit and interloc,k
devices. This includes,
in
a timed and proper
sequence, the operation
of
the blower motor,
ignition system, fuel valve(s), and the damper
motor. The sequence includes air purge periods
prior to ignition and upon burner shutdown.
The flame
detector
portion
of
this control
monitors both oil and gas flames and provides
protection
in
the event
of
the loss
of
a flame
signal.
The control
re~ycles
automatically during nor-
mal operation
or
following a power interruption.
It
must be manually reset following a safety
shut~own
caused by a loss
of
flame. lncor·
porated
is
an internal checking circuit, effective
on every start that will prevent burner operation
in
the event anything causes the flame relay to
h~ld
in during this period.
(13) Flame Detector (Fig. 1-1): Monitors gas
or
oil pilot and energizes the programmer's flame
relay in response
to
a flame signal. It continues
to monitormainflame (oil
or
gas) afterexpiration
CHAPTER 1-6
of
pilot proving period. A standard equipped
boiler has a ·lead sulfide (infrared sensitive)
detector.
(14) Combustion Air Proving Switch (Fig. 1-1):
A pressure sensitive switch actuated
by
air pres-
sure from the forced draft fan. Its contacts close
to
prove the presence
of
combustion air. The fuel
valves cannot be energized unless this switch is
satisfied.
(15) Alarm (Not Shown): Sounds
to
notify the
operator
of
a condition requiring attention. The
alarm
is
available
as
optional equipment.
(16) StackThennometer(Fig. 1-1): Indicates the
temperature
of
the vented flue gases.
(17) Diffuser (Figs. 1-4 and 1-10): This
is
a
circular plate located at the furnace end
of
the
burner drawer, which imparts a rotary swirling
motion to combustion air immediately prior to its
entering·the furnace, thus providing for thorough
and efficient mixing with the fuel.
(18) Rotary Air Damper (Figs. 1-4 and 1-10):
This damper provides accurate control
of
com-
bustion air
in
proportion to fuel input for various
load demands.
It
consists
of
two concentric
cylinders with openings. The outer
is
stationary.
The
inner is rotated,
under
control
of
the
modulating motor, to vary the effective size
of
the openings where they overlap.
E.
STEAM
CONTROLS
(ALL
FUELS)
(1) Steam Pressure Gauge (Fig. 1-1): Indicates
the pressure
in
the boiler.
(2) Operating Limit Pressure Control (Fig. 1-1):
Breaks a circuit
to
stop the burner operation on a
rise
of
boiler pressure above a selected setting.
It
is
adjusted to stop
or
start the burner at a
preselected pressure setting.
750-150
CHAPTER I GENERAL DESCRIPTIONAND PRINCIPLES OF OPERATION
(3)
High
Limit
Pressure
Control (Fig. 1-1):
Breaks a circuit to stop the burneroperation
on
a
rise
of
pressure above a selected setting. It is
adjusted
to
stop the burner at a preselected pres-
sure above the operating limit control setting.
This control
is
normally equipped with a manual
reset.
(4)Modulating Pressure Control (Fig. 1-1):
Sen-
ses the changing boiler pressures and transmits
this information to the
modulating
motor to
change the
burner's
firing rate
when
the manual-
automatic switch is
set
on
automatic.
(5)
Low
Water
Cutoff
and Pump Control (Fig.
1-1): This float-operated control responds to the
water level in the boiler. It performs two distinct
functions:
(a) Stops the
fuing
of
the burner
if
the
water level drops below a safe operating
level and energizes the low water light in
the control panel; it also causes the low
water alarm bell
(optiOI~al
equipment) to
ring. Code requirements
of
some
models
require a manual reset.type.
of
low water
cutoff. This type requires manual re8et-·
ting to start the burner after a low water
shutdown. ·
(b) Starts and stops the feedwater pump
(if
used) to maintain water at the proper
operating level.
CAUTION!
Determine
that
·the
main
and
auxiliary
low
water
cutoffs
and
pump
control
are level
after
in-
stallation
and
throughout
the
equipment's
operating
life
to
avoid
damage
to
the
equipment.
(6) Auxiliary Low Water
Cutoff
(Not Shown)
(Optional Equipment): This control breaks the
circuit to stop the burner operation in the event
the boiler water drops below the master low
750-150
water
cutoff
point. Manual reset type (optional
equipment) requires manual resetting in order
to
start the burner after a
low
water condition.
(7)
Low
Water Pump Control Instruction Plate
(Fig. 7-1): Gives instructions and information for
operation
of
low water devices.
(8) Water Column (Fig. 1-1): This assembly
houses the low water
cutoff
and pump control
and includes the water gauge glass, gauge
gl~
shutoff
cocks, and trycocks.
(9) Water Column Drain Valve (Fig. 1-1): The
water column drain valve is provided so that the
water
column
and its
piping
can
be flushed
regularly to assist in maintaining cross-connect-
ing piping and to keep the float bowl clean and
free
of
sediment. A similar drain valve is fur-
nished with the auxiliary low water cutoff (
op-
tional equipment) for the
same
purpose.
(10) Water Gauge Glass Drain Valve (Fig. 1-1):
This valve
is
provided to flush the gauge glass.
(11) Test Valve (Fig. 1-1): This valve allows the
boiler to be vented during filling, and facilitates
routine boiler inspection.
(12) Safety Valve (Fig. 1-1):
The
purpose
of
the
valve(s) is to prevent pressure buildup
over
the
design pressure
of
the pressure vessel.
The
size
rating and number
of
valves
on
a boiler is deter-
mined by the
ASME
Boiler Code.
The
safety
valves and their escape piping
shown
in (Fig.
1-9) are to be installed to conform to the
ASME
code requirements.
The
installation
of
a valve
is
of
primary importance to its service life. A valve
must
be
mounted in a vertical position
so
that
discharge piping and code-required drains can be
properly piped to prevent build up
of
back
pres-
sure an accumulation
of
foreign material around
the
valve
seat
area.
Apply
only
a moderate
amount
of
pipe compound to male threads and
avoid overtightening as this
can
dis
toft
the seats.
Use
only
flatwjawed
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 pipe
or
wrench
in
the
outlet
CHAPTER 1·7
CHAPTER!
GENERAL
DESCRIPTION
AND
PRINCIPLES
OF
OPERATION
A drip pan elbow
or
a flexible connection be-
tween the valve and the escape pipe
is
recom-
mened (see Fig. 1-9). The discharge piping must
be
properly arranged and supported so that its
weight does not bear upon
~e
valve.
Do
notpaint, oil,
or
otherwisecovery any interior
orworkingparts
of
thesafetyvalve. A valve does
not require any lubrication
or
protective coating
to work properly.
!WARNING
Only properly certified personnel
such
as
the
safety
valve
manufacturer's
certified
repre-
sentative
should
adj~st
or
repair
the boilersafetyvalves. Failure
to
heed
this
warning could result in
serious personal
injury
or
death.
F.
HOT
WATER
CONTROLS
(ALL
i=UELS)
(1) Water Temperature Gauge (Fig. 1-2): Indi-
cates water temperature in the boiler.
(2) Water Pressure Gauge (Fig. 1-2): Indicates
water pressure in the boiler.
(3) Operating Limit Temperature Control (Fig.
1-2): Breaks a circuit
to
stop the burneroperation
on a rise
of
boiler temperature above a selected
setting.
It
is adjusted to stop
or
start the burner at
a preselected operating temperature.
(4) High Limit Temperature Control (Fig. 1-2):
Breaks a circuit
to
stop the burner operation on a
rise
of
temperature above a selected setting. It
is
adjusted
to
stop the burner at a preselected
temperature above the operating control setting.
The high limit temperature control normally
is
equipped with a manual reset.
CHAPTER
1...S
(5) Modulating Temperature Control (Fig. 1-2):
Senses changing boiler temperature and trans-
mits this information
to
the modulating motor to
change the burner's frring rate when the manual-
automatic switch
is
set on automatic.
(6)
low
Water Cutoff (Fig. 1-2): Breaks the
circuit to stop the burner operation
if
the water
level in the boiler drops below a safe operating
level, activating the low water light and optional
alarm bell
if
the boiler
is
so equipped.
(7) Auxiliary
low
Water Cutoff (Not Shown)
(Optional): Breaks the circuit
to
stop the burner
operation
if
the water level in the boiler drops
below the master low water cutoffpoint.
(8) Relief Valve(s) (Fig. 1-2): Relief valve(s)
relieve the boiler
of
pressure higher than the
design pressure (or a lower pressure, if desig-
nated). Relief valves and their discharge piping
are
to
be installed
to
conform
to
ASME code
requirements.
!WARNING
.Only properly certified personnel
such as
the
relief valve manufac··
turer's
certified
representative
should adjust
or
repair
the
boiler
relief valves. Failure to heed
this
warning
could
result In serious
personal
injury
or
death.
G.
CONTROLS
FOR
GAS
FIRING
Depending upon the requirements
of
the in·
surance carrier
or
other governing agencies, the
gas
flow control system,
or
gas train, may consist
of
some,
or
all,
of
the following items. Refer
to
the Dimension Diagram (DD) prepared by
Cleaver-Brooks for your specific installation. A
typical gas train
is
shown
in
Fig. 1-3.
750-150
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