CleaverBrooks Model 4 User manual

Model 4 1,500
–
6,000 MBTU
Rev. 03-08
Section B2-1
MODEL 4 BOILER
1,500 - 6,000 MBTU &
Watertube Boiler
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 -3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2- 4
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 - 4
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 -7
Insurance/Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 -7
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 -8
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 - 15
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B2 -15
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 -16
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2- 16
Feedwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 -16
Blowdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B2 -17
BoilerStacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B2 -17
Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B2 -20
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 -20
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 -27

Model 4 1,500
–
6,000 MBTU
Rev. 03-08
Section B2-2
ILLUSTRATIONS
Figure B2-1. Model 4 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-9
Figure B2-2. Model 4 Standard Pilot andMain Gas Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-2
Figure B2-3. Boiler room air supply - “ E ngineered Design” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-1 9
Figure B2-4. Typical gas header piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2- 26
TA B L E S
Table B2-1. Model 4 BoilerSizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-5
Table B2-2. Model 4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2- 10
Table B2-3. Model 4 Steam Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-1 1
Table B2-4. Recommended Steam Nozzle Size (to maintain4000 to 5000 fpm nozzle velocity) . . . B 2-1 1
Table B2-5. Min. req. NATURAL GAS pressure STANDARD UL, FM, & XL GAP gas trains . . . . . . . B 2-1 3
Table B2-6. Min. req. NATURAL GAS pressure OVERSIZED UL, FM, & XL GAP gas trains . . . . . . . B 2-1 3
Table B2-7. Min. req. PROPANE GAS pressure STANDARD UL, FM, & XL GAP gas trains . . . . . . . B 2-1 4
Table B2-8. Min. req. PROPANE GAS pressure OVERSIZED UL, FM, & XL GAP gas trains . . . . . . . B 2-1 4
Table B2-9. Safety valve outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2- 15
Table B2-10. Predicted efficiency, 10 psig operating (includes radiation and convection losses) . . . B 2-1 5
Table B2-11. Model 4 emission data- NaturalGas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-1 6
Table B2-12. Model 4 emission data- No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-1 6
Table B2-13. Feedwater makeup rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-1 7
Table B2-14. Water quality parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-1 7
Table B2-15. Model 4 fuel, combustion air, andflue gas flow rates . . . . . . . . . . . . . . . . . . . . . . . B 2-1 9
Table B2-16. Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-2 2
Table B2-17. Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-2 2
Table B2-18. Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-2 3
Table B2-19. Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-2 4
Table B2-20. Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 2-2 5
This
section contains information on the Model 4 Commercial Watertube Boiler product line for low and high
pressure steam applications. Sizes range from 1.5 to 6 MMBtu/hr. The Model 4 Boiler is an excellent choice
where high outputs are
needed but space limitations exist. The model number designation is 1500 through
6000,
representing MBtu/hr input (1,500,000 to 6,000,000 Btu/hr).
Fuel series designation is asfollows:
• Series 100: No. 2 oil firing.
• Series 700: Natural gas firing.
• Series 200: No. 2 oil/natural gas firing.
Design pressure designation is stated as 15 psig, 150 psig, and 250 psig for steam. For example, an M4P-
700-2500-150ST boiler
designates a gas-fired, 2,500,000 Btu/hr, 150 psig, steam boiler.

Model 4 1,500
–
6,000 MBTU
Rev. 03-08
Section B2-3
FEATURES AND BENEFITS
The following features and benefits applyto the Model 4 Boilerproductline.
33" Cased Width:
• Boilerfits through most standard doorways.
• Reduced installationcosts.
Direct Driven, Vibration-Free Centrifugal Impeller:
• Quiet operation.
• Sound levels below79 dBA.
• Idealfor noise critical areas such as hospitals, churches, etc.
Minimum Refractory:
• Membrane waterwalls reduce the need for refractory by 95%.
• Reduced maintenance costs and refractory repair requirements.
Membrane Waterwalls:
• Enhanced heat transfer area in compact design.
• Full waterwall furnace improves heat transfer for high efficiency.
Small Boiler Footprint:
• Savings of up to 50% in floor space.
Weighs up to 40% less than Comparable Boilers:
• Lower freight and rigging costs.
• Reduced structural requirements.
Standard Built-in Soot Washers:
• Boiler fireside cleaning without shutdown.
• Maintains peak boilerperformance.
Packaged Forced Draft Burner:
• High pressure dropdesign.
• Optimumfuel and air mixing.
• Improved combustion efficiency.
Burner/Windbox Davit:
• Easy access to furnace with swing-open windbox.
• Reduced maintenance costs.
Steam Design Pressures to 500 psig (optional):
• High performance in a compact design.
• Proven vessel design for high design pressure applications.

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-4
PRODUCT OFFERING
The Model 4 (M4) Boiler is a compact carbon steel, extended fin, watertube boiler.
Heat transfer design is
configured in a "3-pass"gas travel acrossthe watertube
surfaces. The pressure vessel is constructed to conform to the A.S.M.E. Code, either
Section IV for low pressure steam @ 15 PSIGMAWP (maximum allowable working
pressure) or Section I for MAWP greater than 15 PSIG.
The vessel(boiler) consists of two rows on each side of the vessel, of formed
seamless tubes with extended fin surfaces and downcomers connected to the steam
drum and lower drum. To reduce standby losses,the
vessel is insulated with a
fiberglass blanket and removable steel jacket.
Complete with an integral burner for either No.2 fuel oil or Natural Gas, the
complete burner/boiler package is UL Approved, listed, and labeled.
Standard Equipment The standard boiler/burner package is described below. Optional controls, trim, and
devices may be added to meet project requirements. Someof those options are
noted following this standards li st.
1. Boiler
A. Designed, constructed, and hydrostatically tested in accordance with the
A.S.M.E. Boiler and
Pressure Vessel Code. The complete vessel is mounted on a
structural steel frame.
B. Steam drum includes a hand hole in the rear head for drum water side
inspection.
Connections are included for the following:
• Feedwater Makeup w/internal dispersion tube.
• Surface Blowoff.
• Steam Supply.
• Safety Relief Valve.
C. Lower Drum includes hand holes at each endfor waterside inspection. A drain/
blowoff tapping is
provided at the front, bottom
centerline.
D. Soot washer lancesare provided on each side of the
vessel betweenthe two
rowsof
tubes for fireside cleaning. Soot washer drains are located at the bottom of
the boiler, with
connections to drain located on each side of the lower drum at the
rear.
E.
Refractory is limited to the furnace floor, lower drum, and burner throat tile.
High temperature insulation is installed on the front water wall and furnace access
door.
F. Two lifting
eyes are provided on the top centerline of the upperdrum for ease of
installation.
G.
Furnace inspection/access door is provided in the furnace front wall.
H. The
exhaust gas vent is located at the top rear centerline of the boiler. A stack
thermometer is shipped loose for field installation by the installing contractor into
the stack.
I. The
complete vessel is fully insulated (2" fiberglass blanket) under a preformed,
sectional steel jacket.

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-5
Table B2-1. Model 4 Boiler Sizes
MODEL
NO.
INPUT
MBH
HEAT
OUTPUT
MBH
EQUIV
HP
STEAM
OUTPUT
LB
/ HR
SHIPPING
WEIGHT
LBS
1500 1500 1200 35 1237 3100
2000 2000 1600 47 1649 3100
2500 2500 2000 59 2062 3700
3000 3000 2400 71 2474 3700
3500 3500 2800 83 2887 4100
4000 4000 3200 95 3299 4100
4500 4500 3600 107 3711 4700
5000 5000 4000 119 4124 4700
6000 6000 4800 143 4949 5400
NOTE: Steam output from and at 212 °F.
J.
Factory painted using hard-finish enamel.
2.
Forced Draft Burner
A. The
burner is a high radiant multi-port type approved for operation on natural gas
and a
pressure atomizing type approved for operation with commercial grade No. 2
fuel oi l.
B.
Consisting of the fan which is direct connected to the fan motor, wind box, air
damper that is linkage connected to a damper drive motor, the complete assembly is
factory mounted andtested.
C. To ensure proper air for pre purge and combustion is provided by the fan, a
combustion air proving switch is provided.
D. The
complete burner/wind box swings open via a davit arm attached to the upper
drum. Thispermits
fireside inspection of the furnace and burner internals.
E.
Responding to steam demand from the drum mounted pressure control,the burner
operatesin the low-high-low-off firing mode. Ultra-violet (UV) flame scanner is
provided for flame presence during firing.
F. AnIgnition
transformer is provided.
G. Ignition is direct
spark on straightoil fired burners, and gas pilot on straight gas or
combination gas/oil burners.
H. Oil Train
consists of the following:
• 4 Solenoid Shutoff Valves providing low fire, intermediate transitional firing from low
to high and high fire.
• An oil pump is mounted (belt driven from the fan motor) for pressure atomization of
the fuel
oil.
• Oil Pressure Gauge.
• Suction andreturntubing connected to an oil connection block.

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-6
Gas Train consists of the following:
• Primary gas shutoff valve with integral proof of closure switch.
• A manual shutoff valve located ahead of the primary gas valve.
• A plugged leakage test connection anda second manual shutoff valve for tightness
checking of the primary shutoff valve.
• Separate Gas Pressure Regulators for the pilot train andmain gas train.
• Low Gas Pressure andHigh Gas Pressure Switches for units at 3000 and greater.
• A second motorized gas valve is provided in additionto the primary valve on size
6000
un its.
• The pilot gas train includes a manual shutoff valve and solenoid shutoff valve.
3. BoilerTrim and Controls
A. 15 psigor 150 psigset
A.S.M.E. safety relief valves.
B.
Steam pressure gauge with inspectors test cock andconnection.
C.
Primary Water Column complete with gauge glass and columndrain valve.
D. Low Water cutoff switch and pump control switch, integrally mounted in the
primarywatercolumn.
E.
Auxiliary Low Water Cutoff, manual reset type.
F.
Steam Pressure Controls:
• Operating Limit.
• Excess Steam Pressure (High Limit), manual reset.
• Burner firing rate, low high low.
4. Burner Control Panel and Controls
A. Thecontrol panelis
enclosed within a NEMA1A Rated enclosure, mounted on
the
burner wind box at approximately eye level height.
B. Mounted within or on the control panel box are the following controls. Panel
wiring is
factory tested.
• Combustion Flame Safeguard Control, Model CB120 that provides pre purge, post
purge, trial for ignition, main flame/burner operation, and safety shutdown.
• Fan Motor Starter wiredinto the non recycling circuit of theflamesafeguard
control.
• Indicating Lights for low water, flamefailure,load demand, andfuel valve on.
• Burner On/Off Switch.
• Damper Positioning Switch.
• Fuel Selector Switch for combination fuel fired burners.
• Control Circuit Step-down Transformer with primary fuse protection.
• Terminals for interface wiring connection of controls.
• Oil, heat, and moisture resistant wire used. Each wire is number coded relative to
the wiring diagram.
5. Electric Service Panel
An electric
service panel (entrance box) is provided on the sideof the boiler for all
external wiring connections to remotecontrol devices and the main power for the
boiler. Wiring to this panel
eliminates the need to disconnect wiring when the front
burner wind box is opened for burner or boilerservicing.

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-7
Optional Equipment For more detailed information on optional equipment, contact your local Cleaver-
Brooks authorized representative. In summary, options includethe following:
1. Boiler
• Larger pressure gauges or specific manufacturer type.
• BottomDrain Valves for low pressure applications.
• BottomBlowoff Valves for high pressure applications.
• Surface Blowoff Valve with internal collector pipe.
• Feedwater Stop and Check Valves.
• Steam Stop Valve.
• ASME Hydro Test of Valves and Valve Piping.
• Design pressures above 150 P S IG.
2.
Burner/Control Optio n s
• Full Modulation Firing on Gas.
• Lead/Lag C o n t r o l .
• Day-Night Controls.
• Low Fire Hold Control.
• Elapsed TimeMeter.
• Alarmwith silence switch.
• Additional Indicator Lights.
• Main Power Disconnect.
• Remote Oil Pump.
• Optional NEMA Enclosures.
• Special Fan Motor requirements (TEFC).
3.
Fuel Options
• Automatic Fuel Changeover (combination burner).
• Propane Fuel Firing.
• Special Gas Pressure Regulators.
• Special fuel shut-off valves.
• DualPilots (gas and oi l) .
• Gas strainer.
Insurance/Codes The boiler package can be equipped to meet various insurance or code
requirements.
Some of these insurance/code requirements are:
• Factory Mutual (FM)
• XL GAP (Formerly GE GAP/IRI).
• A.S.M.E. CS D - 1.
A. Factory Mutual (FM Global) - Recommended guidelinesas describedby FM
pertain to boilers rated at greater than 2.5 MMBtu/hr input on gas and 2.8 MMBtu/
hr input on oil. Boilers that are labeled and tested in accordance with an
independent testinglab such as UL or CSA and are below these inputs areexempt
from
these recommendations.
The Model 4 boiler is UL listed and labeled. In addition to the standard UL
requirements the following are needed to comply with FM whenrequired.
• AlarmBell with silence switch for low waterand safety shutdowns.
• Low Oil Pressure Switch if the oil pump is not direct driven from the fan motor.
B. XL GAP
(Formerly GE GAP/IRI) Recommended guidelines as described by XL
GAP pertainto boilers ratedat 400,000 Btu/hr input to 12.0 MMBtu/hr input. For

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-8
these boilers, the requirements are the same as for A.S.M.E CSD-1 requir emen ts.
Above 12.0 MMBtu/hr input, the requirements defer to the NFPA 85 standards for
single burner boilers.
C.
A.S.M.E. CSD-1 - Recommended guidelines as described by this Code pertain to
boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. Above
12.0
MMBtu/hr input, the
requirements defer to the NFPA 85 standards for single burner
boilers.For the
sizes this Code covers, the requirements are as follows, in addition
to the
standard UL package:
• Low Oil Pressure Switch for oil firing
• ¾ " Pressure Control Piping
• If gas supply is > 5 psig, a relief valve is required after the gas pressure regulator in
the main andpilot
gas trains.
• Lever Handled shutoff cock for the pilot gas train.
• Non-fused disconnect to remove boilerfrom all sources of power.
DIMENSIONS AND RATINGS
For layout purposes,the nominal dimensionsand connections for the Model 4
Standard Package Boiler are shown in Figure B2-1 and Table B2-2. Ratings of each
boiler
size are noted in Table B2-3. Additional information is shown in the following
figures, tables, andillustrations.
Table B2-4: Recommended steam nozzle sizes for high pressure boilers operating at
lowerand
higher pressures.
Figure B2-2: Standard gas train dimensions and components.
Table B2-5: Natural Gas Pressure Requirements, standard gas train size.
Table B2-6: Natural Gas Pressure Requirements, oversized gas train .
Ta ble B2-7: Propane Gas Pressure Requirements, standard gas train size.
Table B2-8: Propane Gas Pressure Requirements, oversized gas train.
Table B2-9: Safety Valve Outlet Sizes.

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-9
Figure B
2
-
1. Mode
l
4
Dimension
D
rawing

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-10
Table B2-2. Model 4 Dimensions
Boile
r
Size
Note 1
1500 2000 2500 3000 3500 4000 4500 5000 6000
A
Lengths
Overall
All D imensions are in inches
84.25 84.25 100.25 100.25 117.375 117.375 136.75 136.75 152.375
B Pressure Vessel w/casing 61 61 77 77 92.375 92.375 109 109 124.625
C Base Fram e 54 54 69.625 69.625 85.25 85.25 101 101 116.5
C
1
Base to Burner/W
indbox 9.625 9.625 9.625 9.625 9.625 9.625 10 10 10
C
2
Base Fram e Anchor
Holes 51.5 51.5 67.125 67.125 82.75 82.75 98.375 98.375 114
CC Rear Casing to Stack Connec tion 25.8 25.8 26.25 26.25 26.25 26.25 30.375 30.375 30.375
D Burner/W indbox Ex tension 20.1 20.1 20.1 20.1 21.9 21.9 24.6 24.6 24.6
DD Front Casing to Steam Nozzle 17.25 17.25 25.25 25.25 30.75 30.75 37.375 37.375 45.25
HH Steam Nozzle to Safety Valve
15# 8 8 12 12 11.5 11.5 13 13 17
Steam Nozzle to Safety Valve 150# 8 8 12 12 17 17 17 17 17
E
Widths
Overall 53.25 53.25 53.25 53.25 53.25 53.25 53.25 53.25 53.25
F Center to Water Column 32.4 32.4 32.4 32.4 32.4 32.4 32.4 32.4 32.4
G Center to Opt. Aux. W ater C olum n 26.6 26.6 26.5 26.6 26.6 26.6 26.6 26.6 26.6
H Center to Outside Casing 16.375 16.375 17.375 16.375 16.375 16.375 16.375 16.375 16.375
I Base Fram e Inside 20 20 20 20 20 20 20 20 20
J Base Fram e Outside 28 28 28 28 28 28 28 28 28
K Soot Washers, Center to Center 21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4
L Boiler Centerline to Soot Washer 10.7 10.7 10.7 10.7 10.7 10.7 10.7 10.7 10.7
M Boiler Centerline to Base Centerli ne 12 12 12 12 12 12 12 12 12
N Boiler Centerline to Soot Drain 5.25 5.25 5.25 5.25 5.25 5.25 5.25 5.25 5.25
OO
Heights
Overall [Base to Stack Connection] 78.75 78.75 78.75 78.75 78.75 78.75 78.75 78.75 78.75
O Base to Steam Nozzle 150# 74.75 75.75 74.75 74.75 74.75 74.75 78 78 78
O Base to Steam Nozzle 15# 75 75 75 75 78.25 78.25 78.25 78.25 78.25
O
1
Base to Stack
Box. 77.8 77.8 77.8 77.8 77.8 77.8 77.8 77.8 77.8
O
2
Base to Top of Control
Panel 83.25 83.25 83.25 83.25 83.25 83.25 83.25 83.25 83.25
P Base to Surface Blowoff 59.25 59.25 59.25 59.25 59.25 59.25 59.25 59.25 59.25
Q Base to Feedwater Inlet 57.25 57.25 57.25 57.25 57.25 57.25 57.25 57.25 57.25
R Base to Soot Washer Lance 55.5 55.5 55.5 55.5 55.5 55.5 55.5 55.5 55.5
S Height of Base 4 4 4 4 4 4 4 4 4
OS Base to Oil Supply Connection 27.75 27.75 27.75 27.75 27.75 27.75 27.75 27.75 27.75
OR Base to Oil Return C onnection 25.75 25.75 25.75 25.75 25.75 25.75 25.75 25.75 25.75
BB.
Connections
OD Stack - Sleeve
C onnection 12 12 12 12 12 12 16 16 16
T Bottom Drum Blow Down, 15# [one] 1.25 1.25 1.25 1.25 1.5 1.5 1.5 1.5 1.5
T
1
Bottom Drum Blow Down, 150#
[one] 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
U Steam Nozzle, 15#
4
A
4
A
4
A
4
A
6
B
6
B
6
B
6
B
6
B
V Steam Nozzle, 150#
2.5
A
2.5
A
3
A
3
A
3
A
3
A
4
B
4
B
4
B
W Soot Washer D rains [Two] 2 2 2 2 2 2 2 2 2
X Surface Blow off [One] 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
Y Feedwater Inlet [One] 1 1 1 1 1 1 1 1 1
Z Soot Washer [Two] 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25
GG Oil Supply and Return 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
JJ Relief Valve,
15# 2 2 2 2 2 2.5 2.5 2.5 3
Relief Valve, 150# 11.25 1.25 1.25 1.5 1.5 1.5 1.5 2
EE
Clearances
Burner/W indbox
Sw ing
33 33 33 33 33 33 33 33 33
FF Tube removal each s ide 30 30 30 30 30 30 30 30 30
RF Allowance for
Burner/Windbox Swing
and 30" Rear Aisle Space.
124 124 140 140 155 155 172 172 187
RD Allowance for Tube Removal
Each
Side and
Burner/Windbox Swing.
93 93 93 93 93 93 93 93 93
NOTES: 1. The above dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction via certified
prints.
For 200 PSIG design pressure and greater, contact Milwaukee Sales for certified prints.
2. Allow
sufficient space at rear of boilerfor removal of soot washer lance.
3.
For access to the furnace, a 13" x 21" access door is provided behind the front door.
4.
Control Panel maybe larger (up to 4" in height) if certain control options are provided.
A.
Connection is a Female Pipe Thread.
B.
Connection is a 150# Flange, Flat Face.

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-11
Table
B2-3. Model 4 Steam Ratings
Boiler SIZE
1500 2000 2500 3000 3500 4000 4500 5000 6000
Ratings [Note A]
Rated Capaci ty - Steam (lbs . s team/hr
from & at 212o F.)
1,237 1,649 2,062 2,474 2,887 3,299 3,711 4,124 4,949
Rated Steam Capaci ty [kg/hr from and at
100 C ]
461.7 615.5 769.6 923.4 1,077.5 1,231.3 1,385.0 1,539.2 1,847.2
Output Btu/hr [1,000 Btu/h] 1,200 1,600 2,000 2,400 2,800 3,200 3,600 4,000 4,800
Output Kcal/Hr [1,000 Kcal/h] 302 403 504 605 706 806 907 1,007 1,210
Output KW 348 464 580 696 812 928 1,044 1,160 1,392
Approximate Fuel C onsumption At Rated C apacity [ Input - N ote B]
Natural Gas [ft3/hr] - 15# Steam
1,511 1,538 2,500 3,038 3,487 4,025 4,494 5,050 6,052
Natural Gas [ft3/hr] - 150# Steam
1,572 2,133 2,597 3,117 3,590 4,155 4,657 5,194 6,233
Natural Gas [m3/hr] - 15# Steam
42.8 43.5 70.8 86 98.7 114.0 127.0 143.0 171.4
Natural Gas [m3/hr] - 150# Steam
44.5 60.4 73.5 88.3 101.6 117.6 131.8 147.0 176.5
Propane Gas [ft3/hr] - 15# Steam
604 615 1,000 1,215 1,395 1,610 1,798 2,020 2,421
Propane Gas [ft3/hr] - 150# Steam
629 853 1,039 1,247 1,436 1,662 1,863 2,078 2,493
Propane Gas [m3/hr] - 15# Steam
17 17.4 28.3 34.4 39.5 45.6 51 57.2 68.5
Propane Gas [m3/hr] - 150# Steam
17.8 24.1 29.4 35.3 40.7 47 52.7 58.8 70.6
No.2 Oil Fuel - 15# Steam, gph 10 14 17 21 24 28 31 35 42
No.2 Oil Fuel - 150# Steam, gph 11 15 18 22 25 28.9 32 36 43
No.2 Oil Fuel - 15# Steam, liters/hour 38 53 64 79 91 106 117 132 159
No.2 Oil Fuel - 150# Steam, liters/hour 41 56 68 82 95 109 121 136 163
Pow er Requirements - 3 Phase 60 Hz Standard [Note C]
Blower Motor HP - Gas Firing 3/4 11-1/2 2 2 3 3 3 5
Blower Motor HP - Oil or Combinati on 1-1/2 1-1/2 2 2 3 5 3 3 5
Oil Pump for Oil or C ombination Belt Driven from the Blower
Motor
Minimum Ampacity
Blower Motor - Gas Firing Only, 230V 1.53 3.3 4.7 6 6 9 9 9 15
Blower Motor - Gas Firing Only, 460V 0.77 1.7 2.4 3 3 4.5 4.5 4.5 7.5
Blower Motor - Oil or Combination, 230V 4.7 4.7 6 6 9 15 9 9 15
Blower Motor - Oil or Combination, 460V 2.4 2.4 3 3 4.5 7.5 4.5 4.5 7.5
Control C irc ui t 1.7 1.7 1.7 1.9 1.9 1.9 2.4 2.4 2.4
Weights
Operating W eight, lbs . 3,758 3,758 4,566 4,566 5,175 5,175 5,991 5,991 6,900
Operating W eight, k g 1,399 1,399 1,704 1,704 1,932 1,932 2,236 2,236 2,575
Water C ontent Normal, gallons 79 79 104 104 130 130 156 156 181
Water C ontent Normal, l iters 299 299 394 394 492 492 591 591 685
Water C ontent Flooded, gallons 109 109 145 145 177 177 213 213 245
Water C ontent Flooded, liters 413 413 549 549 670 670 806 806 927
Shipping Weight, approximate lbs. 3,100 3,100 3,700 3,700 4,100 4,100 4,700 4,700 5,400
Shipping Weight, approximate kg 1,157 1,157 1,381 1,381 1,530 1,530 1,754 1,754 2,015
Notes:
A. Ratings shown for elevation to 1000 Feet. For ratings above 1000 Feet,
c ontact your local Cleaver-Brooks Representative.
B. Input calculated w ith N at. Gas @ 1000 Btu/ft3, Propane @ 2500 Btu/f t3, and Oil @ 140,000Btu/gal.
C . For altitudes above 1000 Feet, contact your loc al C leaver-Brooks authorized representative for verifi cation of capacity rating.
Table B2-4. Recommended Steam Nozzle Size (to maintain 4000 to5000 fpm nozzle velocity)
Operating
Pressure
(PSIG)
BO ILER
SIZE
1500 2000 2500 3000 3500 4000 4500 5000 6000
15 4 4 6 6 6 6 8 8 8
20 3 4 4 6 6 6 8 8 8
30 3 4 4 4 4 6 6 6 6
40 2-1/2 3 3 4 4 4 6 6 6
50 2-1/2 3 3 4 4 4 4 4 6
65 2-1/2 2-1/2 3 3 3 4 4 4 4
75 2-1/2 2-1/2 3 3 3 4 4 4 4
95 - 125
A
2-1/2 2-1/2 3 3 3 3 4 4 4
150 1-1/2 2 2 2-1/2 2-1/2 2-1/2 3 3 3
200 1-1/2 1-1/2 1-1/2 2 2 2-1/2 2-1/2 2-1/2 3
250 - 400 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2-1/2
A. Standard nozzle size for 150 PSIG MAWP Boiler
Design
Example 1: Size 3500, 150# boiler to operate @ 30 PSIG requires 4" steam nozzle in lieu
of
standard 3" nozzle.
Example 2: Size 3500, 150# boiler to operate @ 200 PSIG requires 2" steam nozzle in lieu
of
standard 3" nozzle.

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-12
ITEM PART DESCRIPTION SIZES
INCHES
Sizes 1500 TO 2500
1 Butterfly Valve 1-1/2
2 Pilot Shutoff Cock 1/2
3 Pilot Gas Regulator 1/2
4 Pilot Solenoid Valve 1/2
5 Manual Shutoff Valve 1-1/2
6 Main Gas Regulator 1-1/2
7 Motorized Valve with P.O.C. 1-1/2
Size 3000
1 Butterfly Valve 1-1/2
2 Pilot Shutoff Cock 1/2
3 Pilot Gas Regulator 1/2
4 Pilot Solenoid Valve 1/2
5 Manual Shutoff Valve 1-1/2
6 Main Gas Regulator 1-1/2
7 Low Gas Pressure Switch 1/4
8 Motorized Valve with P.O.C. 1-1/2
9 High Gas Pressure Switch 1/4
Sizes 3500 to 5000
1 Butterfly Valve 2
2 Pilot Shutoff Cock 1/2
3 Pilot Gas Regulator 1/2
4 Pilot Solenoid Valve 1/2
5 Manual Shutoff Valve 2
6 Main Gas Regulator 2
7 Low Gas Pressure Switch 1/4
8 Motorized Valve with P.O.C. 2
9 High Gas Pressure Switch 1/4
Size 6000
1 Butterfly Valve 2
2 Pilot Shutoff Cock 1/2
3 Pilot Gas Regulator 1/2
4 Pilot Solenoid Valve 1/2
5 Manual Shutoff Valve 2
6 Main Gas Regulator 2-1/2
7 Low Gas Pressure Switch 1/4
8 Motorized Valve (std) 2
9 Motorized Valve with P.O.C. 2
10 High Gas Pressure Switch 1/4
Figure B2-2. Model 4 Standard Pilot and Main Gas T r ains
Pilot
Main
1
3 4
2
6
5 5
7
9
6
55
7
8
6
55
7 9
8
6
5 5
7 10
8 9

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-13
Table
B2-5. Minimum required NATURAL GAS pressure at entrance to STANDARD UL,FM, & XL GAP gas
trains (upstream of gas pressure regulator)
BOILER
SIZE INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
PRESSURE REQUIRED REQUIRED FUEL
FLOW (SCFH)
MIN ("W.C.) MAX ("W.C.)
1500 1.5 1.5 4.4 28.0 1500
2000 1.5 1.5 8.4 28.0 2000
2500 1.5 1.5 12.9 28.0 2500
3000 1.5 1.5 17.1 28.0 3000
3500 2.0 2.0 11.3 28.0 3500
4000 2.0 2.0 13.6 28.0 4000
4500 2.0 2.0 12.2 28.0 4500
5000 2.0 2.0 16.8 28.0 5000
6000 2.0 2.0 21.5 28.0 6000
Note: For altitude above 1000 feet, contact your local Cleaver-Brooks representative.
Natural Gas @ 1000Btu/cu-ft, specific gravity@ 0.65
Table B2-6. Minimum required NATURAL GAS pressure at entrance to OVERSIZED UL,FM, & XL GAP gas
trains (upstream of gas pressure regulator)
BOILER
SIZE INLET
PIPE
SIZE
(inches)
HONEYW ELL
VALVE SIZE
(inches)
PRESSUR E REQ UIRED
REQUIRED FUEL
FLOW (SC FH)
MIN ("W.C.) MAX ("W .C.)
1500
2.0 2.0 2.3 28.0 1500
2000
2.0 2.0 4.8 28.0 2000
2500
2.0 2.0 6.5 28.0
2500
2.5 2.5 5.7
3000
2.0 2.0 9.0 28.0
3000
2.5 2.5 6.8
3.0 3.0 6.0
3500
2.5 2.5 9.7
3500
3.0 3.0 7.1
4000
2.5 2.5 11.8
4000
3.0 3.0 8.5
4500
2.5 2.5 9.8
4500
3.0 3.0 5.6
5000
2.5 2.5 12.9 28.0
5000
3.0 3.0 7.1
4.0 4.0 5.6
6000
2.5 2.5 17.5 28.0
6000
3.0 3.0 10.0
4.0 4.0 7.9
N ote: For altitude above 1000 feet, contact your local Cl eaver-Brook s representati ve.
N atural Gas @ 1000 Btu/cu-ft, specific gravity @ 0.65

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-14
BOILER
SIZE INLET
PIPE
SIZE
(inches)
HONEYW ELL
VALVE SIZE
(inches)
PRESSUR E REQ UIRED
REQUIRED FUEL
FLOW (SC FH)
MIN ("W.C.) MAX ("W .C.)
1500
2.0 2.0 5.9 28.0 600
2000
2.0 2.0 9.0 28.0 800
2500
2.0 2.0 10.8 28.0
1000
2.5 2.5 10.5
3000
2.0 2.0 13.8 28.0
1200
2.5 2.5 12.9
3.0 3.0 12.6
3500
2.5 2.5 13.6
1400
3.0 3.0 12.6
4000
2.5 2.5 15.8
1600
3.0 3.0 14.5
4500
2.5 2.5 13.8
1800
3.0 3.0 12.1
5000
2.5 2.5 14.8 28.0
2000
3.0 3.0 12.5
4.0 4.0 12.0
6000
2.5 2.5 18.0 28.0
2400
3.0 3.0 15.0
4.0 4.0 14.1
Table B2-7. Minimum required PROPANE GAS pressure at entrance to STANDARD UL,FM, & XL GAP gas
trains (upstream of gas pressure reg u la tor)
BOILER
SIZE
INLET
PIPE
SIZE
(
inches
)
HONEYW ELL
VALVE SIZE
(
inches
)
PRESSUR E REQ UIRED
REQUIRED FUEL
FLOW (SC FH)
MIN ("W.C.) MAX ("W .C.)
1500
1.5 1.5 6.7 28.0 600
2000
1.5 1.5 10.5 28.0 800
2500
1.5 1.5 13.3 28.0 1000
3000
1.5 1.5 17.0 28.0 1200
3500
2.0 2.0 14.3 28.0 1400
4000
2.0 2.0 16.5 28.0 1600
4500
2.0 2.0 14.8 28.0 1800
5000
2.0 2.0 16.4 28.0 2000
6000
2.0 2.0 19.6 28.0 2400
N ote: For altitude above 1000 feet, contact your local Cl eaver-Brook s representati ve.
Propane @ 2500 Btu/cu-ft, specific gravity @ 1.6
Table B2-8. Minimum required PROPANE GAS pressure at entrance to OV ER S I Z E D UL,FM, & XL GAP gas
trains (upstream of gas pressure reg u la tor)
N ote: For altitude above 1000 feet, contact your local Cl eaver-Brook s representati ve.
Propane @ 2500 Btu/cu-ft, specific gravity @ 1.6

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-15
Table B2-9. Safety valve outlet size
SAFETY VALVE SETTIN
G
15 PSIG STEAM 150 PSIG STEAM
Boiler
Size
VALVES
REQ'D
OUTLET
SIZE
(IN.)**
VALVE
C APACITY
VALVES
REQ
'D
OU TLET SIZE
(IN
.)**
VALVE
CAPACITY
1500 1 2 3161 lbs/hr 1 1 1651 lbs/hr
2000 1 2 3161 lbs/hr 11-1/4 2585 lbs/hr
2500 1 2 3161 lbs/hr 11-1/4 2585 lbs/hr
3000 1 2 3161 lbs/hr 11-1/4 2585 lbs/hr
3500 1 2 3161 lbs/hr 11-1/2 4240 lbs/hr
4000 1 2-1/2 4676 lbs/hr 11-1/2 4240 lbs/hr
4500 1 2-1/2 4676 lbs/hr 11-1/2 4240 lbs/hr
5000 1 2-1/2 4676 lbs/hr 11-1/2 4240 lbs/hr
6000 1 3 6942 lbs/hr 1 2 6596 lbs/hr
** Female Pipe Thread Connection
[FPT]
PERFORMANCE DATA
Efficiency
Efficiency data provided in Table B2-10 is based on low pressure steam operation.
For high
pressure steam operation contact your local Cleaver-Brooks authorized
representative for expected efficiency data.
Table B2-10. Predicted efficiency, 10 psig operating (includes radiation and convection l o sses)
Boiler
S ize Gas
F uel O il F uel
Firing Ra te Firing R a t e
Low F ire High F ire Low F ire H igh F ire
1500
81 . 681.9 84 . 184.4
2000
81 . 180.0 83 . 682.5
2500
81 . 681.5 84 . 184.0
3000
81 . 380.3 83 . 882.8
3500
81 . 681.5 84 . 184.0
4000
81 . 380.7 83 . 883.0
4500
81 . 180.9 83 . 683.4
5000
81 . 380.0 83 . 882.5
6000
81 . 679.8 84 . 182.4

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-16
POLLUTANT UNCONTROLLED
CO ppm
90
lb/MMBtu 0.07
NOx ppm
187
lb/MMBtu 0.248
SOx ppm
270
lb/MMBtu 0.515
HC/
VOCs ppm
50
lb/MMBtu 0.025
PM ppm
–
lb/MMBtu 0.025
Emissions The following tables give typical emissionlevels for Nature Gas and No. 2 Oil.
Please contact your local Cleaver-Brooks authorized representative if an emission
guarantee is required.
Table B2-11. Model 4 emission
data - Natural Ga s
Table B2-12. Model 4 emission
data - No. 2 Oil
POLLUTANT UNCONTROLLED
CO ppm
xx200
lb/MMBtu 0.15
NOx ppm
100
lb/MMBtu 0.12
SOx ppm
1
lb/MMBtu 0.001
HC/
VOCs ppm
40
lb/MMBtu 0.016
PM ppm
–
lb/MMBtu 0.01
NOTES:
Based on fuel oil constituentlevels:
Fuel bound nitrogen = 0.05% (max) by weight.
Sulfur = 0.5% (max) by weight.
Ash = 0.01% (max) by weight.
ENGINEERING DATA
The following engineering information is provided for the Model 4 steam boiler.
Additional information may be
obtained from your local Cleaver-Brooks authorized
representative.
Feedwater
Steam boilers require make-up water for steam production. This make-up can be a
combinationof
condensate return and raw make-up, 100% condensate return or
100% raw make-up. Proper treatment of make-up water and boiler water is
essential to the longevity and performance of the boiler. Table B2-13 shows the rate
of make-up required and Table B2-14 shows the
recommended water quality
guidelines.
As a minimum, raw
make-up should be piped into a water softener and then to a
feed tank, which also can be the container that
receives the system condensate
returns. Chemical feed is recommended to be fed via a quill into the water make-
up line
feeding the boiler.

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-17
Parameter Boiler Water Limit
pH 8.3 - 10.5
Iron 0.1 ppm
Ox ygen 0.1 mg/liter
Specific Conductivity 2000 µ mho/cm
Suspended Solids 300 ppm
Total Hardness
0 ppm as CaC O
3
Table B2-13. Feedwater makeup rates Table B2-14. Water quality parameters
Boiler
Size Gallons/Minute
1500 2.5
2000 3.3
2500 4.1
3000 5
3500 5.8
4000 6.6
4500 7.5
5000 8.3
6000 9.9
Blowdown As steam is produced, unwanted solids are left behind in the boiler water and
become concentrated within the vessel. If these constituents are allowed to adhere
to the heat transfer
surfaces, they will impede the flow of energy into the water.
Their removal requires proper blowdown that will include bottom and possibly
surface blowoff. For proper
TDS control, surface blowoff with a TDS monitoring
device is recommended. Local codes will dictate the manner of treating the
blowdownaffluent.
Boiler Stacks
General - TheModel4 boiler operates with a positive vent pressure and a vent gas
temperature that is
non-condensing. Therefore, the stack must be a positive
pressure design.
Proper design and installation of the flue gas venting is critical to efficientand safe
operation of the burner. The vent should be
designed with proper supports and
clearances from combustible materials. Use insulated vent pipe spacers where the
vent
passes through walls and roofs.
The design of the stack and breeching must provide the required draft at each boiler
stackconnection.
Although constant pressure at the flue gas outlet is not required,
it is
necessary to size the breeching and stackto limit flue gas pressure variations.
Consideration of the draft must be given where lengthy runs of breeching or
unusually high stacks are employed. Please note: the allowable pressure range for
design of the stack and breeching is negative 0.25 " w.c. (-62 Pa) to a positive 0.25"
w.c. (+62 Pa) for proper light offs and combustion. NOTE: This pressure range does
not pertain to the boiler room; that is, the boiler room must be neutral or slightly
positive, never negative when using air from the boiler room for combustion.
When two or more Model 4 boilers are
connected to a common breeching/stack,
one should evaluate the affects of pressure variations that may occur during boiler
sequencing while boilers are firing. It may be determined that some type of
mechanical draft system be employed to ensure proper draft at each boiler is
maintained.
Combustion Air - The burner for each boiler must be supplied with adequate volume
of
uncontaminated air to support proper combustion and equipment ventilation. Air
shall be free of chlorides, halogens, fluorocarbons, construction dust or other
contaminants that are detrimental to the burner or boiler heating surfaces.
Combustion air can be supplied by means of conventional venting, that is, with
combustion air drawn from the area immediately surrounding the boiler (boiler

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-18
room is neutral or slightly positive
pressure), or with a direct vent to outside the
boiler room where air is drawn directly from the exterior of the building. R e gardless
of the method, all installations must comply with NFPA 54 (National Fuel Gas Code
-
NFGC) for U.S. installations and CAN/CSA B149/.1 and B149.2 for Canadian
installations.
Engineered Design - When determining boiler roomair requirements for the boiler,
the
"Engineered Design" method may be used. Following this method, consid era t ion
must be given to the size of the boilerroom,airflow, and air velocity asfollows:
A. Two
permanent air supply openings in the outer walls of the boiler room are
recommended. Locate one at each end of the boiler room, preferably below a height
of 7 feet. This
allows air to sweep the length of the boiler. Refer to Figure B2-3.
B. Air supply
openings can be louvered for weather protection, but they shouldnot
be
covered with a fine mesh wire, as this type of covering has poor air flow qualities
andis
subject to clogging with dirt and dust.
C. A vent fan in the boiler room is not recommended as it could create a slight
vacuum under certain conditions and cause variations in the quantityof combustion
air. Thiscanresultin
unsafe burner performance.
D. It is
forbidden to have the total area of the air supply openings at less than one
square foot.
E.
Size the openings by using the formula (Area in ft2 = cfma/fpma), where cfma =
cubicfeetperminuteof air; fpma
= feetperminute of air.
F.
Amount of air required (cfm):
1.
Combustion Air = Maximumboiler horsepower (bhp) times8 cfm.
2.
Ventilation Air = Maximumboiler horsepower (bhp) times2 cfm.
3. Total Air
= 10 cfm per bhp (up to 1000 feet elevation, add 3% more per 1000
feetof added elevation).
G.
Acceptable air velocity in the boiler room (fpm):
1.
From floorto 7 feethigh = 250 fpm.
2.
Above 7 feetfromboiler room floor = 500 fpm.
Example of required air openings (Engineered Method):
Determine the area of the boiler roomair supply openings for [2] size 4500 Model
4 boilersat 750 feet
elevation; each have a rating of 107 boiler horsepower. The
air
openings will be5 feet above the floorlevel.
The total boiler horsepower (bhp): 107 x 2 = 214 bhp.
From F.3 above, total air required = 214 bhp x 10 = 2140 cfm.
Air
Velocity: From G.1 above = 250 fpm.
Area required: From the formula in E above, 2140 cfm/250 fpm = 8.56 square
feettotal.
Area opening: 8.56 dividedby 2 = 4.28 ft2 per opening (2 required).
Notice
Consult local codes, which may supersede these req u ire m en ts.
See Table B2-15 for combustion air andflue gas flow.

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-19
Table B2-15. Model 4 fuel, combustion air, and flue gas flow rates
Boiler
S i ze
1500 2000 2500 3000 3500 4000 4500 5000 6000
Fuel Consumpi
on
Gas cfh 1500 1500 2500 3000 3500 4000 4500 5000 6000
Oi l gph 10.72 14.29 17.86 21.43 25.00 28.57 32.14 35.71 42.85
Combustion
Air
Gas
scfh 15,480 20,640 25,800 30,960 36,120 41,280 46,440 51,600 61,920
lb/hr 1207 1609 2012 2414 2817 3219 3621 4024 4828
Oi l
scfh 17,049 22,733 28,414 34,098 39,782 45,463 51,147 56,831 68,196
lb/hr 1269 1692 2115 2538 2961 3384 3808 4231 5077
Flue
Gas
Gas
scfh 17,520 23,360 29,200 35,040 40,880 46,720 52,560 58,400 70,080
lb/hr 1,278 1,704 2,130 2,556 2,983 3,409 3,835 4,261 5,113
Oi l
scfh 17,914 23,886 29,855 35,827 41,799 47,769 53,741 59,713 71,655
lb/hr 1,357 1,809 2,261 2,714 3,166 3,618 4,070 4,523 5,427
Notes: A. Gas consumption, expressed in
c ubic feet per hour, is bas ed on 1,000 Btu/cu.ft gas val ue.
B. Oil
consumption,expressed in pounds per hour, is based on 140,000 Btu/gal oil value.
C . Oil supply lines must be sized for 125 gph pumping rate. Oi l pump suction pressure to be -10" Hg to 3 psig.
Figure B2-3. Boiler room air supply - “Engineered Design”
GA S
VE NT
FRESH AIR OPENING
FRESH AIR OPENING
EXTERIOR WALL
EXTERIOR WALL

Model 4 1500 - 6000 MBTU/hr
Rev. 03-08
Section B2-20
Oil Piping
General - Oil operationof the Model 4 boiler requires proper oil to the standard
burner mounted oil pump. As the combustionof oil utilizes mechanical
pre s sure
atomization, line sizing to the pump must be sufficient to provide 125 gph of oil to
the
suction side of the pump.
Oil
Train Components - Oil flow to the burner is controlled by four solenoid valves.
The oil flows through a primary or
safety shutoff valve into a manifold block. This
valve and the low fire valve are
energized simultaneously by the flame
safeguard controlandwhen
opened, allow flow of oil to the low fire nozzle.
As the
damper motor moves to high fire position, the damper motor end switches
closeto
energize in sequence, the intermediate and then high fire oil valve. The
purpose of the intermediate valve is to smooth the transition from low to highfire by
balancing the oil input with increasing flow of air.
High fire ratingof the
burner is obtained whenall three nozzles are firing, assuming
proper oil pressure and normally sized nozzles.
Gas Piping
General - TheModel 4 boiler requires appropriate gas supply pressure and volume
for proper operation and long burner life. The gas
requirements specified in this
section must be satisfied to
ensure efficient and stable combustion. Installation
must follow these guidelines and of the local authorities that have installation
jurisdiction.
Gas Train Components - Model 4 boilers are equipped with a gas train that meets
the requirements of UL as standard. These components also comply with the
recommendations of FM, XL GAP (formerly IRI/GE GAP) and ASME CSD-1. The
gas train and its
components have been designed and tested to operatefor the
highest combustion efficiency.
Gas Pressure Requirements - For properand safe operation, each Model 4 boiler
requires a stable gas pressure supply. The pressure requirements are listed in
previous sections for standard gas train size, and
oversized trains for red u ced
available pressure.
Gas Piping - Model 4 units are standardly equipped with a gas pressure regulator.
If upstream
pressure to the standard regulator will be greater than 1 psig, an
additional upstream regulator should be provided with a pressure reliefvalve.
For buildings or boiler rooms with gas supply
pressure exceeding 28" w.c., a "full
lockup"type
regulator is recommended along with proper overpressure protection.
In addition to the
regulator, a plug type or "butterball" type gas shutoff cock should
be provided upstream of the regulator for use as a service valve. This is also
required to provide positive shutoffand isolate the boiler gas train during gas piping
tests.
Drip
legs are required on any vertical piping at the gas supply to each boilersothat
any dirt, weld slag, or
debris can depositin the drip leg rather than into the boiler
gastrain. The bottom of the drip leg should be
removable without di sa ssembl ing
any gas piping. The connected piping to the boiler shouldbe supported from pipe
supports andnot supported by the boiler gas train or the bottomof the drip leg.
All
gas piping and components to the boiler gas train connection must comply with
NFPA 54, local codes, and utility requirements as a minimum. Only gas approved
fittings,
valves, or pipe should be used. Standard industry practice for gas piping is
normally Schedule 40 black iron pipeandfittings.