CleaverBrooks CB-LE Series Guide

Model CB-LE
Packaged Boiler
125 - 200 HP
Operation, Service, and Parts Manual
750-184
04/09
and Model CB Ohio Special 125-225 HP

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Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative
Manual Part No. 750-184
04/09 Printed in U.S.A.
©Cleaver-Brooks 2009
CLEAVER-BROOKS
Model CB-LE
Packaged Boiler
125-200 HP Light Oil, Heavy Oil, Gas, or Combination
Operation, Service, and Parts Manual*

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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 con-
tents carefully. The unit will provide good service and continued operation if proper operating and maintenance instruc-
tions are followed. 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 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 known ability to perform; however,
proper operating techniques and maintenance procedures must be followed at all times. Although these components af-
ford 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 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 at-
tempting 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
considerably 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
uneconomical 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 main-
tenance 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-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 fre-
quently to check for the presence of any mud, sludge, scale or corrosion.
It is essential to obtain the services of a qualified water treating company or a water consultant to recommend the proper
boiler water treating practices.
The operation of this equipment by the owner and his or her operating personnel must comply with all requirements or
regulations of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsis-
tency between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks be-
fore proceeding.
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.
FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
!DANGER WARNING

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TABLE OF CONTENTS
Chapter 1
Basics of Firetube Operation
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
B. THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
C. CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
D. STEAM CONTROLS (ALL FUELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
E. HOT WATER CONTROLS (ALL FUELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
F. IFGR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
G. CB OHIO SPECIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Chapter 2
Burner Operation and Control
A. THE BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
B. CONTROL AND COMPONENT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
C. COMPONENTS COMMON TO ALL BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
D. CONTROLS FOR GAS FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
E. CONTROLS COMMON TO OIL-FIRED BOILERS (INCLUDING COMBINATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Chapter 3
Waterside Care And Requirements
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
B. WATER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
C. WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
D. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
E. BOIL-OUT OF A NEW UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
F. WASHING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
G. BLOWDOWN STEAM BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
H. PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
I. PREPARATION FOR EXTENDED LAY-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Chapter 4
Sequence Of Operation
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
B. CIRCUIT AND INTERLOCK CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
C. SEQUENCE OF OPERATION - OIL OR GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
D. FLAME LOSS SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Chapter 5
Starting And Operating Instructions
A. GENERAL PREPARATION FOR START-UP, ALL FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
B. CONTROL SETTINGS - STEAM AND HOT WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
C. GAS PILOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
D. ATOMIZING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
E. FIRING PREPARATIONS FOR NO. 2 OIL (SERIES 100-200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
F. FIRING PREPARATION FOR NO. 6 OIL (SERIES 400-600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
G. FIRING PREPARATIONS FOR GAS (SERIES 200-400-700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
H. IFGR SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
I. START-UP, OPERATING AND SHUTDOWN - ALL FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
J. CONTROL OPERATIONAL TEST AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Chapter 6
Adjustment Procedures
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
B. LINKAGE - MODULATING MOTOR AND AIR DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
C. MODULATING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
D. MODULATING MOTOR SWITCHES - LOW FIRE AND HIGH FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
E. BURNER OPERATING CONTROLS - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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F. MODULATING PRESSURE CONTROL (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
G. OPERATING LIMIT PRESSURE CONTROL (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
H. HIGH LIMIT PRESSURE CONTROL (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
I. MODULATING TEMPERATURE CONTROL (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
J. OPERATING LIMIT TEMPERATURE CONTROL (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
K. HIGH LIMIT TEMPERATURE CONTROL (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
L. LOW WATER CUTOFF DEVICES (Steam and Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
M. COMBUSTION AIR PROVING SWITCH (CAPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
N. ATOMIZING AIR PROVING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
O. GAS PILOT FLAME ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
P. GAS PRESSURE AND FLOW INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Q. GAS FUEL COMBUSTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
R. LOW-GAS-PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
S. HIGH-GAS-PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
T. FUEL OIL PRESSURE AND TEMPERATURE - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
U. FUEL OIL COMBUSTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
V. BURNER DRAWER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
W. OIL DRAWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
X. LOW-OIL-TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Y. HIGH-OIL-TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Z. LOW OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
AA. ELECTRIC OIL HEATER THERMOSTAT (400 and 600 Series - Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
BB. STEAM OIL HEATER THERMOSTAT (No. 6 Oil) (400 and 600 Series - Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
CC. HOT WATER OIL HEATER THERMOSTAT (400 and 600 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
DD. STEAM HEATER PRESSURE REGULATOR (400 and 600 Series - Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Chapter 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Chapter 8
Inspection And Maintenance
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
B. FIRESIDE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
C. WATER LEVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
D. WATER GAUGE GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
E. ELECTRICAL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
F. FLAME SAFETY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
G. OIL BURNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
H. GAS BURNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
I. MOTORIZED GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
J. SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
K. AIR CONTROL DAMPER, LINKAGE & CAM SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
L. FORCED DRAFT FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
M. CB-LE FAN/MOTOR CASSETTE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
N. CB-LE INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
O. CB-LE AIRBOX GASKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
P. CB-LE FAN/MOTOR CASSETTE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Q. SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
R. FUEL OIL METERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
S. AIR PUMP AND LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
T. HEAD INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
U. REFRACTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
V. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
W. OIL HEATERS - ELECTRIC, STEAM, HOT WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
X. COMBUSTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Y. AIR PUMP BELT (CB-OS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

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Chapter 9
Parts
Insulated Front Head - CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Insulated Front Head Interior - CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Insulated Inner Door - CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Insulated Rear Head CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Insulated Rear Head CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Dry Oven Model CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Motor and Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Front Head Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Jackshaft Retrofit Assembly Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Mod Motor Linkage Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Air Damper Linkage Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Burner Drawer-Gas Pilot Models 100-600, 125-200HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16
Burner Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Control Cabinet (Hawk ICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Control Panel, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Entrance Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Front Head Electrical CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Front Head Electrical CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Straight Electric Oil Heater 60” Heavy Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Heavy Oil Piping 60” Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Common Oil Parts Heavy Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Side Mounted Air Compressor Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Air Compressor Piping CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Air Line Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Light Oil Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
Light Oil/Air Piping - Front Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Pilot Gas Train 125-150HP CB-LE & 125-175HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Pilot Gas Train 200HP CB-LE & CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Pilot Gas Train 225HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Gas Train 125-150 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Gas Train 175 HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
Gas Train 200 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
Gas Train 225 HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
Steam Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
Hot Water Temperature Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
Water Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
Fireside Gaskets, CB-LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
Fireside Gaskets, CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50

viii

Milwaukee, Wisconsin
www.cleaver-brooks.com
Chapter 1
Basics of Firetube Operation
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
B. THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
C. CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
D. STEAM CONTROLS (ALL FUELS) . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
E. HOT WATER CONTROLS (ALL FUELS) . . . . . . . . . . . . . . . . . . . . . 1-8
F. IFGR COMPONENTS (CB-LE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
G. CB OHIO SPECIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Chapter 1 — Basics of Firetube Operation
1-2 Part No. 750-184
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.
Notice
If your boiler is equipped with a C-B Hawk ICS boiler control
system, refer to C-B Manual No. 750-229 for information regarding
the control system.
\
Figure 1-1 Firetube Cut Away (Typical)

Chapter 1 — Basics of Firetube Operation
Part No. 750-184 1-3
The general information in this manual applies directly to Cleaver-
Brooks Model CB/CB-LE 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
*For additional information on Model CB Ohio Special boilers 125-225 HP, see
Section G at the end of this chapter.
Notice
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 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.
Notice
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.
Rated Capacity: 125
through 200hp
Operating Pressure Steam 15-250 psig, or higher
if 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

Chapter 1 — Basics of Firetube Operation
1-4 Part No. 750-184
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/CB-LE 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 measurements.
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.
Steam boilers are designed for low pressure or high pressure
applications. Low pressure boilers are limited to 15 psig design, and
are typically used for heating applications. High pressure boilers are
typically used for process loads and can have a design pressure of
75 to 350 psig.

Chapter 1 — Basics of Firetube Operation
Part No. 750-184 1-5
Steam and hot water boilers are defined according to design
pressure and operating pressure. Design pressure is the maximum
pressure used in the design of the boiler for the purpose of
calculating the minimum permissible thickness or physical
characteristics of the pressure vessel parts of the boiler. Typically,
the safety valves are set at or below design pressure. Operating
pressure is the pressure of the boiler at which it normally operates.
The operating pressure usually is maintained at a suitable level
below the setting of the pressure relief valve(s) to prevent their
frequent opening during normal operation.
The type of service that your boiler is required to provide has an
important bearing on the amount of waterside care it will require.
!Caution
Waterside care is of prime importance. For specific information or
assistance with your water treatment requirements, contact your
Cleaver-Brooks service and parts representative. Failure to follow
these instructions could result in equipment damage
Feedwater equipment should be checked and ready for use. Be sure
that all valves, piping, boiler feed pumps, and receivers are installed
in accordance with prevailing codes and practices.
Water requirements for both steam and hot water boilers are
essential to boiler life and length of service. Constant attention to
water requirements will pay dividends in the form of longer life, less
down-time, and prevention of costly repairs. Care taken in placing
the pressure vessel into initial service is vital. The waterside of new
boilers and new or remodeled steam or hot water systems may
contain oil, grease or other foreign matter. A method of boiling out
the vessel to remove accumulations is described in Chapter 3.
The operator should be familiar with Chapter 3 before attempting to
place the unit into operation.
C. CONSTRUCTION
Steam boilers designed for 15 psig and hot water boilers designed
for 250°F at 125 psi or less are constructed in accordance with
Section IV, Power Boilers, of ASME Code.
Steam boilers designed for operating pressures exceeding 15 psig
are constructed in accordance with Section 1, Power Boilers, of the
ASME code. Hot water boilers designed for operating temperatures
above 250°F or 125 psi are likewise built to ASME code.

Chapter 1 — Basics of Firetube Operation
1-6 Part No. 750-184
Figure 1-2 CB-LE, Dual Fuel, Typical
(Components and component orientation may vary)
1
2
3
4
5
67
8
9
10
11
12
13
14
1. Forced draft fan motor
2. Oil pressure gauge
3. Atomizing air pressure gauge
4. Modulating motor
5. Gas Train (not shown)
6. Fuel oil controller
7. Ignition transformer
8. Oil strainer
9. Air compressor
10. C-B Level Master controls
11. Low Water Cut Off/Pump Control
12. Vent Valve
13. Limit Controls
14. Control Panel

Chapter 1 — Basics of Firetube Operation
Part No. 750-184 1-7
D. STEAM CONTROLS (ALL FUELS)
1. Operating Limit Pressure Control (Figure 1-3): Breaks a circuit to
stop burner operation on a rise of boiler pressure at a selected
setting. It is adjusted to stop or start the burner at a preselected
pressure setting.
2. High Limit Pressure Control (Figure 1-3): Breaks a circuit to stop
burner operation on a rise of pressure above a selected setting. It
is adjusted to stop the burner at a preselected pressure above the
operating limit control setting. The high limit pressure control is
normally equipped with a manual reset.
3. Modulating Pressure Control (Figure 1-3): Senses changing boiler
pressures and transmits the information to the modulating motor
to change the burner firing rate when the manual-automatic
switch is set on “automatic.”
4. Low-Water Cutoff and Pump Control (Figure 1-4. 1-5): Float-
operated control responds to the water level in the boiler. It
performs two distinct functions:
• Stops firing of the burner if water level lowers below the safe
operating point. Energizes the low-water light in the control
panel; also causes low-water alarm bell (optional
equipment) to ring. Code requirements of some models
require a manual reset type of low-water cutoff.
• 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 installation and throughout the equipment’s
operating life. Failure to follow these instructions could result in
equipment damage.
5. Water Column Assembly: Houses the low-water cutoff and pump
control and includes the water gauge glass, gauge glass shutoff
cocks.
6. Water Column Drain Valve: Provided so that the water column
and its piping can be flushed regularly to assist in maintaining
cross-connecting piping and in keeping the float bowl clean and
free of sediment. A similar drain valve is furnished with auxiliary
low-water cutoff for the same purpose.
Figure 1-3 Steam Controls
Figure 1-4 CB Level Master (CB-LE
high pressure steam)

Chapter 1 — Basics of Firetube Operation
1-8 Part No. 750-184
7. Water Gauge Glass Drain Valve: Provided to flush the gauge
glass.
8. Vent Valve: Allows the boiler to be vented during filling, and
facilitates routine boiler inspection as required by ASME Code.
9. Stack Temperature Gauge: Indicates flue gas outlet temperature.
10.Auxiliary Low-water Cutoff: Breaks the circuit to stop burner
operation in the event boiler water drops below the master low-
water cutoff point. Manual reset type requires manual resetting
in order to start the burner after a low-water condition.
11.Safety Valve(s): Prevent pressure from exceeding the design
pressure of the vessel. The size, rating and number of valves on
a boiler is determined by the ASME Boiler Code. The safety
valves and the discharge piping 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 buildup of back pressure
and accumulation of foreign material around the valve seat area.
Apply only a moderate amount of pipe compound to male threads
and avoid overtightening, which can distort the seats. Use only
flat-jawed wrenches on the flats provided. When installing a
flange-connected valve, use a new gasket and draw the mounting
bolts down evenly. Do not install or remove side outlet valves by
using a pipe or wrench in the outlet.
!Warning
Only properly certified personnel such as the safety valve
manufacturer’s certified representative can adjust or repair the
boiler safety valves. Failure to follow these instructions could result
in serious personal injury or death.
E. HOT WATER CONTROLS (ALL FUELS)
1. Water Temperature Gauge: Indicates the boiler internal water
temperature.
2. Operating Limit Temperature Control: Breaks a circuit to stop
burner operation on a rise of boiler temperature at a selected
setting. It is adjusted to stop or start the burner at a preselected
operating temperature.
3. High Limit Temperature Control: Breaks a circuit to stop burner
operation on a rise of temperature at a selected setting. It is
adjusted to stop burner at a preselected temperature above the
operating control setting. The high limit temperature control
normally is equipped with a manual reset.
4. Modulating Temperature Control: Senses changing boiler water
temperature and transmits the information to the modulating
motor to change the burner firing rate when the manual-
automatic switch is set on “automatic.”
5. Low-Water Cutoff: Breaks the circuit to stop burner operation if
the water level in the boiler drops below safe operating point,
activating low-water light and optional alarm bell if burner is so
equipped.
Figure 1-5 Low Water Cutoff (CB-
LE low pressure and CB-OS)

Chapter 1 — Basics of Firetube Operation
Part No. 750-184 1-9
6. Auxiliary Low-Water Cutoff (Optional): Breaks the circuit to stop
burner operation if the water level in the boiler drops below the
master low-water cutoff point.
7. Safety Valve(s): Relieves the boiler of pressure higher than the
design pressure or a lower pressure, if designated. Relief valves
and their discharge piping are to be installed to conform to ASME
Code requirements.
F. IFGR COMPONENTS (CB-LE)
1. Flue Gas Transfer Port, IFGR Damper, and Flange Collar (Figure
1-6). The flue gas transfer port is a tube that allows the flue
gases to travel from the exit of the fourth-pass tubes to the
entrance of the combustion air fan. The IFGR damper controls
the volume of flue gas induced into the combustion air stream.
The damper is located in the flue gas transfer port and is
positioned by the control linkage.
2. IFGR Damper Linkage (Figure 1-7). The IFGR damper is
positioned by the control linkage. The linkage could consist of a
single arm, or it could consist of several arms driven from the
jackshaft to provide modulating control (see Figure 1-16).
3. Over-Travel Mechanism. The over-travel mechanism has two
functions. It allows the linkage to pass through the front door,
and it allows jackshaft rotation to exceed (over travel) IFGR
linkage movement. A set of springs allows the linkage to stay in
a fixed position while the jackshaft rotates.
4. Fuel Change-Over Linkage. When a boiler is equipped to fire
either gas or oil (dual-fuel boilers), and the required NOx levels
are below 60 ppm on natural gas, a dual-linkage arrangement is
used to provide the different recirculation rates required for each
fuel. Two jackshaft drive arms are provided, one for oil and one
for gas. The linkage is manually connected to the appropriate
arm, based on the fuel being used. On dual-fuel boilers with two
jackshaft drive arms, as defined above, a proximity switch is
used to prove that the correct linkage connection is made. (Refer
to the wiring diagram provided with the boiler.)
5. Fan/Motor Cassette. The fan and motor assemblies are designed
as a cassette so that they can be removed from the front of the
boiler, without opening the front door. The front door davit arm
can be used to remove the assembly.

Chapter 1 — Basics of Firetube Operation
1-10 Part No. 750-184
6. Burner Drawer . The gas spudding pattern for the IFGR system
may be different than that of a non-IFGR CB Burner of the same
horsepower (HP) model designation.
7. Combustion Air Inlet. The combustion air inlets are located at the
top of the front door. Air enters from the rear of the air inlet
shrouds, which reduces the sound level and captures heat from
the boiler and stack flue outlet.
8. Front Door Insulation. If NOxemissions are below 60 PPM, the
front door is insulated inside to control temperature build up. The
insulation is held in place with wire mesh.
Figure 1-6 Induced Flue Gas Recirculation System, General Arrangement
COMBUSTION AIR INLET
FRONT DOOR
CASSETTE MOUNTING BOLTS
AIRBOX GASKET
CASSETTE LIFTING EYES
FAN/MOTOR CASSETTE
FLANGE COLLAR
COMBUSTION AIR FAN
OVER-TRAVEL MECHANISM
IFGR DAMPER LINKAGE
QUICK DISCONNECT LINKAGE
JACKSHAFT ARM
BURNER DRAWER
BURNER DRAWER SUPPORTS
INNER PLATE CLAMPS
FRONT DOOR BOLTS
FLUE OUTLET
AIRBOX
FLUE GAS TRANSFER
PORT WITH IFGR DAMPER
FOURTH-PASS TUBES
DAMPER DRIVE ARM
THROAT AND LINER TILE
FURNACE
GAS SPUDS
BURNER HOUSING
FLUE GAS FLOW
COMBUSTION AIR FLOW
BACKPLATE GASKET
WINDBOX
INSULATED PARTITION
REAR BURNER DRAWER GASKET
INSULATION
(20-30 PPM NOx SYSTEMS)

Chapter 1 — Basics of Firetube Operation
Part No. 750-184 1-11
G. CB OHIO SPECIAL
The model numbers CB125S - CB225S indicate boilers built by
Cleaver-Brooks specifically for the State of Ohio market. These
boilers comply with state rules and regulations applying to boilers
with less than 359 square feet of heating surface.
The CB-OS is not a low-emission design and therefore lacks the flue
gas recirculation components found on the CB-LE. Other differences
are noted below and elsewhere throughout this manual. Unless
indicated otherwise, information in this manual regarding boiler
operation, maintenance, and parts applies equally to CB-LE and
CB-OS models.
Two Pass Design
The principal difference between the Ohio boilers and CB-LE boilers
in the corresponding size range is the construction of the pressure
vessel. Ohio Special boilers (identified by an “S” suffixed to the
model number) are of a two-pass design, as opposed to the four-
pass design of the CB-LE.
Rear Head
Due to the two-pass design of the Ohio boiler, the rear head lacks
the baffle found on comparable CB-LE boilers. The upper portion of
Figure 1-7 IFGR Damper Linkage
SINGLE FUEL ARRANGEMENT
IFGR DAMPER CONTROL
JACKSHAFT
GAS JACKSHAFT DRIVE ARM
DUAL FUEL ARRANGEMENT
30°*
60°*
OVER-TRAVEL MECHANISM
JACKSHAFT LINKAGE ROD
QUICK-DISCONNECT LINKAGE
OIL JACKSHAFT DRIVE ARM
PROXIMITY SWITCH JACKSHAFT ARM
*NOMINAL: ACTUAL POSITION VARIES
NOx REQUIREMENTWITH
AND 60 PPM SYSTEM
(Except 60 ppm)

Chapter 1 — Basics of Firetube Operation
1-12 Part No. 750-184
the head - opposite the boiler steam space - is almost completely
filled with refractory. When sealing the door, follow instructions as
outlined in Section 8 of this manual.
Front Head
The Ohio Boiler utilizes an insulated inner (intermediate) front door.
Due to the two-pass design, the front head lacks the second-to-third
pass baffle found on comparable CB-LE boilers. See Section 8 for
front head sealing procedure.
Dimpled Tubes
The second-pass tubes are 2” O.D. and of dimpled design for
increased heat transfer.