CleaverBrooks CB

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viii

750-96 (revised 2010)

CB Packaged Boiler Manual

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Table of Contents5
General Description13
Overview13
The Boiler13
Burner and Control System14
Control and Component Function15
Controls Common to All Boilers15
Steam Controls: All Fuels19
Hot Water Controls: All Fuels20
Controls for Gas Firing20
Controls Common to Oil Fired Boilers (Including Combination)23
Additional Controls for Heavy Oil (No. 4, 5, and 6)25
Controls for Combination Burners Only26
Combustion Air27
Automatic Ignition27
Atomizing Air28
Oil Fuel Flow: Light Oil28
Oil Fuel Flow: Heavy Oil30
Gas Fuel Flow34
Modulating Firing34
The Pressure Vessel37
Overview37
Construction37
Water Requirements38
Hot Water Boiler38
Air Removal38
Minimum Boiler Water Temperature38
Rapid Replacement of Boiler Water38
Continuous Flow through the Boiler39
Water Circulation39
Multiple Boiler Installations39
Pressure Drop through Boiler40
Pump Location40
Pump Operation40
Pressure40
Steam Boiler41
Feed Pump Operation41
Water Feeder Operation41
Water Treatment42
Cleaning43
Hot Water and Steam Piping43
Pressure Vessel43
Boil-Out of a New Unit44
Washing out46
Hot Water Boiler46
Steam Boiler46
Blowdown: Steam Boiler46
Manual Blowdown47
Continuous Blowdown47
Frequency of Manual Blowdown47
Manual Blowdown Procedure48
Periodic Inspection49
Preparation for Extended Layup50
Sequence of Operation51
Overview51
Courtesy Of: C3 Surplus LLC51
Surplus Industrial Superstore51
Https://Www.c3Surplus.com51
Circuit and Interlock Controls52
Sequence of Operation: Oil or Gas53
Pre-Purge Cycle53
Ignition Cycle54
Run Cycle54
Burner Shutdown Post Purge55
Flame Loss Sequence55
No Pilot Flame56
Pilot but no Main Flame56
Loss of Flame56
Starting and Operating Instructions59
General Preparation for Startup: All Fuels59
Control Settings: Steam and Hot Water60
Gas Pilot61
Atomizing Air61
Firing Preparations for No. 2 Oil: Series 100-20062
Oil Flow62
Oil Pressure63
Starting63
Firing Preparations for No. 4 Oil: Series 800-90064
Oil Flow65
Oil Pressure65
Starting65
Firing Preparations for No. 5 Oil: Series 300-50065
Oil Flow66
Oil Temperature66
Starting66
Firing Preparation for No. 6 Oil: Series 400-60066
Oil Pressure67
Oil Temperature67
Starting68
Firing Preparations for Gas: Series 200-300-400-700-90068
Control Operational Test and Checks72
Revised 2010)72
Adjustment Procedures73
Overview73
Linkage: Modulating Motor and Air Damper73
Modulating Motor: Honeywell M954B or M954C76
Modulating Motor Switches: Low and High Fire76
Burner Operating Controls: General77
Gas Pilot Flame Adjustment81
Gas Pressure and Flow Information83
Pressure83
Gas Flow84
Pressure Correction84
Gas Fuel Combustion Adjustment86
Low Gas Pressure Switch89
High Gas Pressure Switch89
Fuel Oil Pressure and Temperature: General89
Fuel Oil Combustion Adjustment90
Burner Drawer Adjustment92
Oil Drawer Switch93
Low Oil Temperature Switch94
High Oil Temperature Switch (Optional)94
Low Oil Pressure Switch (Optional)94
Troubleshooting97
Inspection and Maintenance101
Overview101
Periodic Inspection101
Fireside Cleaning102
Water Level Controls and Waterside of Pressure Vessel102
Water Gauge Glass104
Electrical Controls104
Program and Flame Safety Control105
Checking Pilot Flame Failure106
Checking Failure to Light Main Flame106
Checking Loss of Flame106
Oil Burner Maintenance107
Oil Strainers107
Light Oil Strainers107
Heavy Oil Strainers107
Fuel Oil Treatment107
Cleaning Oil Nozzle107
Air Purge Nozzle (No. 6 Oil), Back Pressure Orifice Nozzle (No. 2 Oil)108
Ignition System108
Gas Burner Maintenance109
Motorized Gas Valve109
Solenoid Valves110
Cam Spring110
Forced Draft Fan110
Safety Valves111
Fuel Oil Metering Valve, Adjusting and Relief Valves112
Air Pump and Lubricating System114
Air Pump114
Lubricating Oil114
Lubricating Oil Strainer and Cooling Coil115
Air Cleaner115
Air-Oil Tank115
Lube Oil Cooling Coil116
Flexible Coupling Alignment116
Air Pump Replacement117
Dismantling117
Reassembly117
Refractory118
Furnace Liner118
Liner Installation118
Rear Door119
Front Inner Door120
Opening and Closing Rear Head121
Closing and Sealing122
Electric Motors122
Control Linkage123
Oil Heaters: Electric, Steam, Hot Water123
Ordering Parts and Parts Lists125
Ordering Parts125
Where to Order Parts126
Returning Parts for Repair126
Factory Rebuilt Parts126
Parts Lists127
Rear Head Sealing127
Rear Head Sealing - Davit128
Fireside Gasket129
Front Head Electrical130
LWCO Water Column Piping, 30 - 125# MDM131
LWCO Water Column Piping, 15# MDM132
LWCO Water Column Piping, 150# MDM133
LWCO Water Column Piping, 15# Level Master134
LWCO Water Column Piping, 150# Level Master135
Entrance Box136
Control Panel137
Furnace Liner & Bricking139
Front Head Linkage140
Temperature Controls141
Gas Piping142
L.O. Front Head Oil/Air Piping143
H.O. Front Head Oil/Air Piping144
Steam Electric Heater145

CleaverBrooks CB - Page 12

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