CleaverBrooks CBT User Manual

750-382
04/2019
Model CBT
Tubeless Vertical Boiler
Operation and Maintenance Manual
CBT-M — Full Modulation
CBT — On/Off Operation

CleaverBrooks CBT Specifications

General

Brand	CleaverBrooks
Model	CBT
Category	Boiler
Language	English

Summary

Introduction to Cleaver-Brooks Model CBT Boiler

Pressure Vessel Details

Description of the boiler's 2-pass vertical tubeless pressure vessel design and construction.

Burner Systems

Details on full modulation (CBT-M) and on/off (CBT) burner types, features, and technology.

Gas Train Assembly

Overview of the gas train assembly, components, and compliance with certifications.

Boiler Control Systems

Explanation of control systems for full modulation and on/off boilers, including abbreviations.

Component and Connection Locations

Diagrams illustrating the location of key components and connections on CBT boilers.

Optional Equipment for CBT Boilers

List of optional features and accessories available for the Cleaver-Brooks Model CBT Boiler.

Installation Guide for CBT Boilers

Lifting and Moving the Boiler Safely

Instructions for safely lifting and moving the boiler unit, including cautionary notes.

Boiler Water Treatment Requirements

Guidance on water treatment to ensure boiler effectiveness, lifespan, and prevent damage.

Boiler Room Requirements and Clearances

Specifications for the boiler room environment, including ambient conditions and clearances.

Gas Piping Installation and Sizing

Requirements for gas piping installation, pressure, sizing, and sediment traps.

Boiler Waterside Connections

Procedures for making essential waterside connections, including safety valve installation.

Electrical Connections for the Boiler

Instructions for making electrical connections to the boiler, adhering to codes.

Wiring Diagrams for CBT Boilers

Diagrams illustrating electrical wiring for both full modulation and on/off boiler systems.

Flue and Combustion Air Venting

General Venting Connections and Categories

Guidelines for flue gas exhaust venting and definition of appliance categories.

Flue Venting Installation

Recommendations for flue venting installation, including material and support requirements.

Vent Terminal Location Requirements

Critical considerations for vent terminal placement to avoid hazards and property damage.

Horizontal Through-Wall Venting (Inside Air)

Installation procedures for horizontal through-wall venting using inside air for combustion.

Horizontal Through-Wall Direct Venting

Installation guidelines for direct vent systems where air is drawn from outside.

Horizontal Through-Wall Flue Vent Termination

Specific requirements for terminating horizontal through-wall flue vents.

Vertical Venting with Inside Combustion Air

Installation details for vertical venting systems using inside air for central heating.

Vertical Venting with Direct Vent Combustion Air

Installation for vertical venting systems drawing combustion air directly from outside.

Duct Design for Direct Vent Combustion Air

Guidelines for designing flue and combustion air ducts for direct vent systems.

Boiler Commissioning Procedures

Full Modulation Boiler Setup

Steps for commissioning full modulation boilers, including operating conditions and controls.

Filling the Boiler

Procedure for filling the boiler with water and checking for leaks prior to operation.

Initial Control Setpoints Configuration

Setting initial safety control parameters before starting the boiler.

Water Level Control Setup

Configuration and checks for LWCO and ALWCO controls within the boiler system.

CB Falcon Controller Setup and Interface

Configuring the CB Falcon boiler control system and its display/operator interface.

Lockouts, Holds, and Alerts Management

Understanding and managing different types of fault conditions in the CB Falcon system.

Controller Parameter Configuration

Detailed guide to configuring CB Falcon controller parameters for specific boiler models.

Burner Sequence and Operation

Explanation of the burner's operating sequence, including ignition and flame supervision.

Fan Speed Settings Adjustment

Guidelines for adjusting fan speed settings based on application and altitude.

Initial Startup Procedures

Step-by-step guide for the initial startup of the boiler and its systems.

Gas Train and Piping Commissioning

Checks and procedures for the gas train and piping before initial operation.

Boiler Power-Up Sequence

Steps for powering up the boiler's control and blower circuits.

Operation Checks for Safety Devices

Verification of gas valve, pressure switches, and air proving switch functionality.

LWCO and ALWCO Control Checks

Testing procedures for the Low Water Cut-Off (LWCO) and Auxiliary LWCO (ALWCO) controls.

Low and High Fire Adjustments

Procedure for adjusting the boiler's gas valve for low and high fire settings.

Modulation OFF Point Setting

Adjusting the parameter that determines when the burner shuts off during modulation.

Setting Boiler Combustion Performance

Steps for properly setting combustion parameters using a combustion analyzer.

Limit Controls Verification

Testing the High Limit Control (HLC) and Operating Limit Control (OLC) settings.

On/Off Boiler Startup Procedures

Specific steps for commissioning on/off boiler systems.

Ignition Adjustment for On/Off Boilers

Procedure for adjusting the ignition system for proper flame detection.

Gas Adjustments for On/Off Boilers

Guidelines for adjusting gas settings for optimal combustion on/off boilers.

Electrical Interference Test

Testing to ensure main power does not interfere with flame relay operation.

Boil-Out Procedure for New Units

Recommended steps for cleaning the boiler's interior before initial use.

Post Startup Checkout Procedure

Final checks and instructions to provide after initial boiler startup.

Falcon Control Functions Overview

Summary of CB Falcon control features for steam boilers and customer interface.

Remote Enable and 4-20mA Input

Configuration for remote boiler control via discrete and analog inputs.

Boiler Maintenance Procedures

General Maintenance Guidelines

Recommended maintenance program to ensure safety, efficiency, and longevity.

Bottom Blowdown Procedure

Instructions for performing bottom blowdown to remove boiler water solids.

Water Column Blowdown

Procedure for blowing down the water column and gauge glass for accurate level indication.

Water Column and Gauge Glass Blowdown

Detailed step-by-step guide for the water column and gauge glass blowdown process.

Fireside Cleaning and Disassembly

Steps for accessing, cleaning, and inspecting the fireside of the boiler and burner.

Ignition Electrode Maintenance

Inspection and maintenance procedures for the ignition electrode.

UV Scanner Maintenance (Full Modulation)

Inspection and cleaning of the UV flame scanner for full modulation burners.

Waterside Inspection and Cleaning

Recommended procedures for inspecting and cleaning the waterside surfaces of the boiler.

Safety Valve Inspection and Testing

Guidelines for inspecting and testing the boiler's safety valve.

Troubleshooting Boiler Operations

Guidance on diagnosing and resolving common boiler operational problems and lockouts.

Display Diagnostics Features

Using the CB Falcon display for diagnostic features and screen calibration.

Boiler Lay-up Procedures

Instructions for proper lay-up (dry or wet) to protect boiler surfaces during extended inactivity.

Boiler Parts and Assemblies

Recommended Spare Parts List

List of recommended spare parts for Cleaver-Brooks Model CBT boilers by HP size.

Safety Valves for CBT Boilers

Specifications and part numbers for safety valves based on boiler HP and set pressure.

Control Panel Components

Diagrams and part numbers for components within the control panel for full modulation.

Burner Assembly Parts

Detailed parts breakdown for burner assemblies across different HP sizes and modes.

Water Column Components

List and diagrams of parts for the boiler's water column assembly.

Feedwater Piping Components

Parts list and diagram for the feedwater piping system.

Gas Train Components and Diagrams

Parts list and diagrams for gas train assemblies in full modulation and on/off configurations.

Direct Vent Kit Part Numbers

Kit numbers for direct vent systems available for CBT boilers by HP size.