EasyManua.ls Logo

CleaverBrooks FLX Series User Manual

CleaverBrooks FLX Series
136 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
Manual Part No. 750-177 R6
MODEL
FLX
PACKAGED BOILER
1,500,000 to 12,000,000 Btu/hr
Hot Water and Steam
Fuel: Light Oil, Gas or Combination
5/2014

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the CleaverBrooks FLX Series and is the answer not in the manual?

CleaverBrooks FLX Series Specifications

General IconGeneral
Boiler TypeFiretube
Heat Exchanger MaterialCarbon Steel
Fuel TypeNatural Gas
Operating PressureUp to 300 psi
ApplicationsCommercial, Industrial, Institutional

Summary

CHAPTER 1 General Description

General Boiler Overview

Covers manual scope, boiler input range, fuel types, and design pressures.

Boiler Construction and Components

Details the five-pass steel boiler construction, ASME code compliance, and system components.

Steam Boiler Applications

Explains steam boiler design for low and high pressure applications based on psig.

Hot Water Boiler Applications

Describes hot water boiler use in heating, operating pressure, and temperature ranges.

Steam and Hot Water Controls

Explains steam and hot water controls including pressure/temperature limits and low water cutoffs.

CHAPTER 2 Profire V Burner

Burner Introduction and Specifications

Introduces V series burners, listing certifications and model sizes for FLX boilers.

Burner Control Panel and Operation

Details panel components like switches, lamps, and flame safeguard controls for burner operation.

Combustion Air Handling System

Explains combustion air system components, including blower, diffuser, and air supply requirements.

Firing Head and Oil System

Describes the radial spud firing head and key components of the oil system, including nozzle and valves.

Gas System Components and Operation

Details gas train components like valves, regulators, and pressure switches for gas operation.

Pilot Gas Train and Installation

Covers pilot gas train components and installation considerations, including draft conditions.

Burner Startup and Operation

Outlines startup procedures, burner operation, and initial checks before firing.

Burner Firing Modes and Sequences

Explains Low-High-Low and Full Modulation firing modes and their operating sequences.

Burner Adjustments Overview

Introduces adjustments for efficiency, covering combustion, stack temperature, and smoke measurements.

Gas System Adjustments

Guides on adjusting gas pilot flame, pressure, flow, combustion, and pressure switches.

Oil System Adjustments

Provides instructions for adjusting oil pressure, temperature, and combustion for various oil burners.

Combination Gas-Oil System Adjustments

Guides on adjusting combination gas-oil systems, starting with oil then adjusting gas.

Modulation and Air/Fuel Control

Covers linkage adjustments, modulating motor, air shutters, and fuel/air ratio control.

Burner Maintenance Procedures

Outlines maintenance for controls, air handling, firing head, pilot, electrodes, and flame scanner.

Burner Troubleshooting

Lists common burner problems and their solutions, covering start, ignition, shutdown, and motor issues.

Burner Specifications

Lists model characteristics, maximum input, burner models, and fan motor specifications.

CHAPTER 3 Pressure Vessel Care

General Waterside Care

Emphasizes proper water treatment for boiler life, covering hot water system circulation and air removal.

Steam Boiler Water Requirements

Details deaeration, feed water supply, and minimum feed water flow rates for steam boilers.

Water Treatment Objectives

Outlines water treatment goals to prevent scale and corrosion, and recommends consulting experts.

Blowdown Procedures

Explains periodic blowdown to lower solids concentration, its effectiveness, and the blowdown procedure.

Boiler Cleaning and Boilout

Describes cleaning the boiler, necessary chemical solutions for boilout, and the boilout procedure.

Waterside Inspection and Layup

Covers periodic inspections, waterside checks, and preparation for extended boiler layup.

CHAPTER 4 Sequence of Operation

General Operation Sequence

Outlines the overall sequence of controls for pre-purge, ignition, run, and shutdown cycles.

Circuit and Interlock Controls

Explains the burner control circuit, types of controls, and their functions in the system.

Oil or Gas Firing Sequence

Details the operational sequence for oil or gas firing, including pre-purge, ignition, and run cycles.

Flame Loss Sequence

Describes actions taken during flame loss, safety shutdowns, and lockout conditions.

CHAPTER 5 Adjustment Procedures

General Adjustment Principles

Explains the need for adjustments due to variable conditions and the role of combustion analysis.

Linkage, Motor, and Switch Adjustments

Covers adjustments for linkage, modulating motor travel, and low/high fire switches.

Boiler Operating Controls Adjustment

Details setting adjustments for operating limit, modulating controls, and pressure/temperature controls.

Steam Pressure Control Adjustments

Covers adjustments for modulating, operating limit, and high limit pressure controls for steam.

Hot Water Temperature Control Adjustments

Details adjustments for modulating, operating limit, and high limit temperature controls for hot water.

Gas System Adjustments

Guides on adjusting gas pilot flame, pressure, flow, combustion, and pressure switches.

Fuel Oil System Adjustments

Provides instructions for adjusting oil pressure, temperature, and combustion for various oil burners.

CHAPTER 6 Troubleshooting

General Troubleshooting Approach

Emphasizes safety, understanding the system, and systematic checks for pinpointing issues.

Burner Start and Ignition Issues

Addresses problems like burner not starting, lack of spark, or spark but no flame.

Flame and Shutdown Issues

Covers troubleshooting pilot flame, main flame, low fire operation, and shutdowns during firing.

Motor and Rust Issues

Details problems with the modulating motor not operating and excessive rust on tubes.

Water on Base Issues

Explains causes for water on the base, including condensation and gasket leaks.

CHAPTER 7 Inspection and Maintenance

General Maintenance Program

Stresses the importance of a planned maintenance program for safety, efficiency, and longevity.

Periodic Inspection Procedures

Outlines requirements for periodic inspections, including pressure vessel and component checks.

Fireside and Upper Pass Cleaning

Describes cleaning soot from heat exchanger surfaces and the upper pass areas of the boiler.

Controls and Safety Devices Maintenance

Details maintenance for relief valves, low water cutoff devices, and flame safeguard controls.

Burner System Maintenance

Covers maintenance for oil burners (strainers) and gas burners (valves), including refractory and casing seals.

CHAPTER 8 PARTS

Flextube Casing Parts

Lists parts for Flextube casings for Hot Water, Low Pressure Steam, and High Pressure Steam.

Controls Parts

Details parts for steam pressure controls, water level controls, and water columns.

Safety Valves Parts

Provides information on safety valves required for different pressure ranges and boiler sizes.

Related product manuals