Cleaver-Brooks CBH Series, CBH 25, CBH 30, CBH 50 A, CBH 50 Operation, Service And Parts Manual

$25.00

CLEAVER-BROOKS

PACKAGED

MODEL

BOILERS

Manual

Printed

U.S.A.

in

Part

No. 750-99

CLEAVER-BROOKS

MODEL

PACKAGED

Operation,

CBH

BOILERS

Service, and Parts Manual

Please direct purchase orders for replacement manuals

to

your

local Cleaver-Brooks representative

Manual

12/93 Printed

Part

No. 750-99

in

U.S.A

CONTENTS

CHAPTER

1 -

GENERAL

A.

The

B.

The

C.

Control

D.

Automatic

E.

Combustion

F.

Oil

G.

Gas

2 -

THE

A.

General

B.

Construction

C.

Water

1.

2. Water

D.

E.

Cleaning

F.

Boil-out

G.

Washing

H.

Blowdown -Steam

I.

Periodic

J.

Preparation

3 -

SEQUENCE

A.

General

B.

Circuit

C.

Sequence

D.

Sequence

E.

Flame

4 -

STARTING

A.

General Control

B. C. Oil

D.

Gas

E.

Normal

5 -

ADJUSTMENT

A.

General

B.

Periodic

C.

Water

D.

Water

E.

Operating Setting Pressure Temperature Combustion Low High Programming Control

F.

Oil Burner Oil Combustion

G.

Gas Gas Gas Combustion

H.

Switch

I.

Air

J.

Safety

DESCRIPTION Boiler Burner

Fuel

Fuel PRESSURE

Hot Steam

Burner

Burner Pump

Burner Pilot Pressure

Damper

......................................................

and

Control

and

Component

Ignition

Air

Flow

.........................................................

.....................................................

Requirements

Water

Boiler

Treatment

........................................................

of

a New

Out

Inspection

OF

..........................................................

and

Interlock of of

Loss

Sequence

AND

Preparation -Initial

Settings

Start-up

Operation

.........................................................

Inspection Level Gage

Controls

and

Controls -Steam

Gas

Pressure

Gas

Pressure

Operational

......................................................

Nozzles

.......................................................

Adjustment

and

Cam

Valves

...............................................

..................................................

...................................................

..................................................

VESSEL

.............................................

Boiler

....................................................

for

Operation -CB-20 Operation -CB-40

Start-up

Controls

Glass

Adjusting

Controls -Hot

Air

Control

Adjustment

.....................................................

and

Adjustment

....................................................

.............................................

.................................................

................................................

Unit

Boiler

..............................................

Extended OPERATION

OPERATING

- All

..............................................

- All

AND

..............................................

...............................................

Proving

Switch

Test

..................................................

Flow

Adjustment

AND

System

Function

.......................................

..........................................

........................................

Lay-up

.....................................

Controls

............................................

Fuels

.............................................

MAINTENANCE

............................................

..........................................

............................................

..........................................

....................................

Start-up

......................................

Fuels

....................................

Boiler

Water

Switch

........................................

.........................................

.....................................

.........................................

PRINCIPLES

.................................

................................

.................................

- Oil

or

Gas

- Oil

or

Gas

INSTRUCTIONS

............................

...........................

.................................

Boiler

..................................

OF

......................

.................

........................

OPERATION

..

1-1 1-1 1-1 1-2 1-9 1-9 1-9 1-12

2-1 2-1 2-1 2-1 2-1 2-3

2-4

2-5 2-6 2-7 2-7 2-9 2-9

3-1 3-1 3-1 3-2 3-4 3-6

4-1 4-1 4-1 4-2 4-3 4-4

5-1 5-1 5-2 5-2 5-3 5-3

5-4

5-5 5-6 5-6 5-7 5-7 5-7 5-8 5-8 5-9 5-10 5-11 5-11

5-12 5-14 5-15 5-18 5-18

CHAPTER

K.

L.

M.

N.

0. P.

Q.

6-

A. B. No C.

D.

E.

F.

7-

c

Motorized Solenoid Refractory Door

Closing Forced Fireside Lubrication

TROUBLE

Burner Pilot

Burner Shutdown

Damper

PARTS

Draft

Does

Ignition

Flame,

Stays

ORDERING

T

Gas

Valve

..................................................

.......................................................

and

Sealing

Fan

................................................

Cleaning

SHOOTING

Occurs

Motor

................................................

......................................................

not

Start

......................................................

But

No

in Low Fire .

During

..................................................

TS

............................................

........................................

...........................................

Main

Firing

INSTRUCTIONS

(ConUm.med)

Flame

.......................................

................................

..................................

AND

PARTS

LIST

.........

5-19 5-19 5-19 5-21 5-22 5-22 5-22

6-1 6-1 6-1

6-2 6-2 6-2 6-2

7-1

ii

DO NOT OPERATE, SERVICE, ALL

APPLICABLE SECTIONS

WARNING

OR

REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND

OF

THIS MANUAL.

DO NOT FULLY UNDERSTAND ALL APPLICABLE SECTIONS

FAILURE VERE

TO:

This operating manual presents information that will help to properly operate and care for the equipment. carefully. The unit will provide followed. thoroughly understood. Failure to follow all applicable instructions and warning may result in severe personal injury or death.

It

is the responsibility

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 techniques and maintenance procedures must be followed at all times. Although these componesnts afford a high degree protection and safety, operation firing

Any him/her

It

is solely the operator's responsibility to properly operate and maintain the equipment.

replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel

for proper operation.

maintain, service, or repair this equipment.

ALLOW

TO

PERSONAL INJURY

Owners,

No

attempt should be made

of

fuel.

"automatic"

of

certain repetitive chores and give him/her more time tot devote to the proper upkeep

OTHERS

FOLLOW

Operators

of

the owner to train and advise not only his or her personnel, but the contractor's personnel who are

features included in the design do not relieve the attendant

On

the other hand, a thorough understanding

TO

OPERATE, SERVICE,

ALL

APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SE-

OR

DEATH.

and/or

Maintenance

good service and continued operation

to

operate the unit until the principles

part

of

the unit were chosen because

of

equipment is not to be considered free from all dangers and hazards inherent in handling

Personnel

OR

REPAIR THIS EQUIPMENT UNLESS THEY

OF

THIS MANUAL.

if

proper operating and maintenance instructions are

of

operation and all

of

their know ability to perform; however, proper operating

of

any responsibility. Such features merely free

of

this manual is required before attempting to operate,

No

of

the components are

of

equipment.

amount

of

Study its contents

of

and

written instructions can

of

the responsibility

of

Because

ably from one boiler to another. This manual contains information designed to show how a basic boiler operates.

Operating controls will normally function for long periods

daily or monthly tesing, assuming that normal operation will continue uneconomical operation and damage and, in most cases, these conditions ca nbe traced directly to carelessness and in testing and maintenance.

It is recommended that a boiler room log or record be maintained. Recording activities and recording

Most instances

for the operator to periodically check his/her low water controls and to follow good maintenance and testing practices. Crossconnecting piping to low water devices must be internally inspected periodically to guard against any stoppages which could obstruct the free flow

the presence

The waterside condition check for the presence

The services are essential.

The operation of

his/her insurance company and/or other authority having jurisdiction. In the event

such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.

state, local, or other applicable codes, there are a variety

of

any unusual operation will serve as a valuable guide to any necessary investigation.

of

major boiler damage are the result

of

water to the low water devices. Float bowls

of

foreign substances that would impede float ball movement.

of

the pressure vessel is

of

any mud, sludge, scale or corrosion.

of

a qualified water treating company or a water consultant to recommend the proper boiler water treating practices

of

this equipment by the owner and his/her operating personnel must comply with all requirements or regulations

of

operation with low water. We cannot emphasize too strongly the need

of

extreme importance. Waterside surfaces should be inspected frequently to

of

time and

electric controls and safety devices which vary consider-

we

have found that some operators become lax

indefinitely. Malfunctions

of

daily, weekly, nonthly and yearly maintenance

of

these controls must be inspected frequently to check for

of

any conflict or inconsistency between

of

controls lead to

in

their

deficiencies

iii

FORCED

DRAFT

FAN

COMBUSTION

INLET

AIR

VENT

THE

FOUR PASS

Combustion rotary

air combustion boiler

only

through

air

enters

damper

chamber,

through

pass

CONSTRUCTION

through

and

the

diffuser

constitutes

P.ass two;

three.

From

the

air

inlet.

into

the

pass

one. Baffling

here a baffle

the

rear

the

OF A

The

forced

combustion

allows

gases

are

iv

TYPICAL

draft

chamber.

allows

gases

to

forced

gases

through

MODEL

fan

to

pass

to

forces

The

pass

the pass

CB

air

main

to

the

rear

four

BOILER

through

fire

tube

front

of

the

boiler

to

the

or

the

vent.

CHAPTER 1

AND

A.

THE BOILER

The

Cleaver-Brooks

packaged vessel, oil draft ponents.

The draft accordance

Vessel Code.

the

boiler.

This low capacities

The others, the stallation codes governing stallation, tion

boilers with Association Div. (F.I.A.), underwriters

steel

or

fan,

air

boiler

pressure

boiler

National

are

is a four

boiler.

manual

rated

and

is

to

should

the

to

be

in

the

optional

Factory

gas

control

The

with

Chapter 2 deals

covers steam

be in

Board

proper

consulted,

above

requirements.

B. THE BURNER AND

The

type

of

fuel used

series

classification.

Series Series 200 Series

A

boiler

100

700

equipped

Model

boiler

burner,

damper,

pass

pressure

the

ASME

boilers

or

from 25

of

also

conform

such

authorities

series comply, when

equipment,

of

Mutual

SYSTEM

by

These

Light Light

Gas

to

GENERAL

PRINCIPLES

A. THE BOILER B. THE BURNER AND C.

CONTROL D. AUTOMATIC IGNITION IE.

COMBUSTION

f.

OIL

fUEL

G.

GAS

fUEL

"CBH"

consisting

burner

and

horizontal

vessel is

Boiler

with

designed for

hot

water

thru

100

equipment

with

Fire

equipment.

permits

to

Factory

Industrial

(FM)

the

boiler

are:

oil (No. 2) oil (No. 2)

only

burn

oil

Boiler

of a pressure controls, associated

firetube

constructed

and

Pressure

tfiis

portion

high

generation

horsepower.

installation,

the

standards

Underwriters.

to

state

and

Prior

having

obtained

Risk

or

other

jurisdic-

etc. All

equipped

Insurance

Insurers insuring

CONTROl

determines

only or

gas

and

gas

includes

DESCRIPTION

AND

COMPONENT

AIR

flOW

is a

forced

com-

up-

in

of

or in

by

of

In-

local

to

in-

the

OF

CONTROL

equipment uses tor

The attached inspection

The type

annular

pilot

light

combination

ignition

The

operates fire. An operates ner later

to

butterfly

OPERATION

only

switch is

Model

oil

burner

and

entry which is oil fuel

of

standard

on a modulating

and

in

this

Combustion located

motor. fuel

energize properly tion.

An of tor the shut or

The single

in

the

burner

This

through a linkage

the

electronic

operation

monitors

event

the

excessive

burner

phase

SYSTEM fUNCTION

for

each

one

type

of

incorporated CBH

boiler

to

the

front

and

maintenance.

is

of

the

gas

burner

type. A

spark

only

gas-oil

both

fuels.

burner,

at

two

burning

optionally

its

components

manual.

air

is

provided

the

front is

under

same

motor

valve

proportioned

of

burner

or

oil

valves.

safety

and

in

the

flame

loss

down

steam

control

60

hertz

conjunction

of

pressure

distinct

fuel

at a time,

in

has

head,

the

high

is

gas

burner

ignited. A

is

normally

unit

whether

rates

equipped

firing

are

head.

Combustion

the

regulates

system

by

actuating Fuel for

control

to

shut

flame.

under

circuit

(or 50

fuel. Since

a gas/oil selec-

the

combination

the

burner

readily

pressure

of

the

is ignited by a

burner spark

uses a

firing on oil

- high fire gas-fired

principle.

described

by a

centrifugal

control

the

connected

input

and

most

efficient

programs

with a flame

the

burner

Other

or

operates

hertz

low

water

safety

water

when

the

burner

units.

assembly

accessible for

atomizing

high

radiant

gas

that

uses

ignited.

gas

pilot

or

gas,

and

low

boiler

The

bur-

in

detail

blower

air

delivery

of

the

damper

flow

of

gas

to

the

gas

switches

air

the

temperatures.

on

that

are

thus

combus-

sequence

detec• down controls

conditions

115

volt,

equipped)

A

for

in

1-1

Chapter

1-General

Description

and

Principles

of

Operation

alternating generally able

The wired the techniques.

The standard control, ture valve(s

The through control and timer at

the

The

gas

valves

spark firmed.

the

a

safety

The

proving ance

the

In plied, specific local with in

the

tion

chapter Chapter

C.

The valves

to

electrical programming familiar trols stand outlined

Identify out.

The will equipped boiler.

Boilers

operated

main

operating

into

burner

major

control

limit

controls,

),

and

sequence

shutdown

in

interlock

that

proper

same

pilot

operation

to

open.

ignited

The

event

of a flame

interlock.

safety

equipment

company

presence

addition

other

requirements

code.

the

burner

of

individual

and

3.

CONTROL

term

and

with

whether

the

in

and

actual

depend

and

having

energizes

control

"control"

controls

current.

power

the and

electrical

low

conjunction

control

interlocks

of

to

Refer

the

The

on 3 phase

supply

limit

circuitry

protect

system

and

operating

water

motor

devices.

devices

and

starter.

of

burner

is

governed

or

time.

monitors

prior

The

ignition

oil

burner

will

loss

and -depending

requirements-

adequate

the

standard

to

the

to

determine

limit

components

electrical

FUNCTION

components,

controls

control.

the

individual

or

not

outlined boiler's the

locate

upon

whether

operation,

manual.

each

furnished

the

optionally

forced

service

voltage.

and

other

provide

against

components

consist

cut-off,

with

This

de-energizes

or

include

may

of

wiring

control

AND

covers

including

or

The

item

type

it

incorrect

pressure

damper

operation

by

the

programmer

the

to

allowing

of

low fire

must

shut

the

as a result

combustion

controls

fuel

pressure.

basic

be

an

insurance

diagram

the

is

sequence

COMPONENT

the

those

operator

functioning

before

using

with

of

fuel for

is a

hot

ordered

draft

fan

motor

at

the

avail-

interlock

safe

included

of a programming

from

the

operating,

other

flame

likewise

burner

required

specific

circuits.

outlined

more

but

monitored

he

and

the

any

water

features

devices

operation

operating

in

the

or

tempera-

motor,

programming

to

flame

of

upon

that

controls

is

covered

not

must

can procedures

figure

given

which

fuel

start-up

limit

contains

controls

confirm

main

fuel

on

be

con-

down

action

carrier

furnished

The

important

of

or

by

and

air

insur-

prove

sup-

to

meet

controls

func-

in

this

limited

by

the become all

con-

under-

call-

boiler

it

steam

may

is

of

a

in

or

in

is

have

control

PROGRAMMING CONTROL

Automatically

and

shutdown operating, cludes, operation valve(s) cludes shutdown.

The both the

a

The operation, must down internal which

causes period.

The components

sequence

air

flame

oil

event

control

be

caused

causes a safety

control

Master and

operating

to

start

forced Flame

tector gized by a through

Lockout failure or

on control, inter-locks during short reset. should tempting

Timer:

ching quence

through the

burner.

Timer the

timer

operating Flame

pilot lay

in monitor of

pilot

components

AND

(Figure

limit,

in a timed

of

the

and

the

purges

detector

and

gas

of

loss

recycles

or

manually

by loss

checking

the

flame

contains that

text. relay

program

draft

relay senses a suitable

the

Switch

to

ignite

loss

of

lock-out

the

cooling

CAUTION.

be

investigated

to

Actuates

contacts

to

all

Position

and

cycle.

Detector:

and

energizes

response

main

proving

1-1)

programs

period

and

blower

damper prior

portion

flames

of a flame

automatically

following a

reset

of

circuit

lockout

relay

the

are

referred

(1K):

Energized

controls

sequencing

fan

motor

(2K):

Energized

flame

or a flame

loss

lockout

(LS

the

flame.

will

programmer's

period

The

re-start.

cams

in a non-adjustable program the

functions

Dial:

the (Figure

(figure 1-1):

the

to a flame

flame

period. A standardly

not

listed

FLAME

each

starting,

in

conjunction

interlock

and

proper

motor,

to

switch.

):

pilot

is

(oil

ignition

motor.

ignition

of

this

and

provides

signal.

power

following a

flame.

Additionally, occur

Indicates

stage

Incorporated

effective

in

the

to

hold

following

to

and

switches

and

starter.

when

flame.

it

routes

Trips

or

main

upon

simulating

checking

required

reason

and

corrected

to

open

the

burner's

necessary

reached

1-1)

Monitors

programmer's

signal.

or

gas)

here.

SAFEGUARD

operating,

devices.

sequence,

system, fuel

The

sequence

and

upon

control

protection

during

interruption.

safety

on

every

event

in

during

major

in

the

operating

when

all

are

to

energize

the

flame

When

control

in

the

burner

on a CB-40

the

opening

condition

period.

before

for

any

before

and

close

timed

operation

to

the

position

in

gas flame

It

continues

after

expiration

equipped

with

This

in-

the

in-

burner

monitors

in

normal

It

shutis

an

start

anything

this

integral

the

limit

closed

the

de-

de-ener-

circuit

event

it

of

flame,

of

can

be

lockout

at-

swit-

se-

operate

of

burner

or

oil

re-

to

A

1-2

Chapter

1-General

Description

and

Principles

of

Operation

boiler

detector.

BURNER

manually

A rectly

starting FORCED Directly

bustion an

oil

fired

motor

by

has a lead

SWITCH

operated

and

stopping

DRAFT

FAN

drives a forced

air.

Also

referred

unit

the

a V

-belt.

BLOWER MOTOR

BLOWER

MOTOR

sulfide

(Figure

start-stop

MOTOR

draft

to

oil

pump

STARTER

(infrared

1-1)

switch

burner

fan

to

as

blower

is

driven

sensitive)

used

operation.

(Figure

provide

motor.

from

for di-

1-1)

com-

On

this

FORCED (Figure

Energizes DAMPER

two

A

DRAFT

1-1)

forced

MOTOR

position

motor through a linkage fuel

ratio

under The spring

The

motor

is

powered

returned

to

actuates

-------mrTIMER

-

---------!!!!-GAS-OIL

FAN

draft

(Figure

that

system,

low fire

the one

MOTOR

fan

(blower)

positions

to

and

to

the

closed.

or

more

STARTER

1-1)

the

provide

high

fire

open

auxiliary

PROGRAMMING

AND FLAME SAFEGUARD

CONTR.OL

DIAL

SWITCH

motor.

air

damper

proper

conditions.

position

switches.

air-

and

COMBUSTION AIR PROVING

SWITCH

DAMPER

MOTOR

AUXILIARY

SWITCH

DAMPER LINKAGE

BUTTERFLY

GAS

VALVE

----OIL

OIL PRESSURE

PUMP

GAUGE

FIGURE

1-l.

TYPICAL

OIL

AND

GAS

FIRED

MODEL

CBH

BOILER

1-3

Chapter

It

also

1-General

operates,

through

valve. A

modulating equipment tion

G for

DAMPER

motor

on a gas

details.

POSITIONING

(Manual-Automatic) A

three-position

high

fire

through

the

or

switch

low fire

high-low fire

operation. AUXILIARY Actuated

SWITCH(S)

by

damper

Description

linkage,

can

be

fired

unit.

(Figure

for

manually

rate

or

motor

and

Principles

the

supplied

(Figure

butterfly

1-2)

as

optional See

of

Sec-

SWITCH

1-1)

setting

either

establishing a circuit

control

(Figure

shaft

for

automatic

1-1)

rotation.

HIGH-LOW

Each

OPERATING PRESSURE,

HIGH

Operation

gas

PRESSURE.

FIRE

boiler to

prove before has

additional valves ped

boiler

per

opening

GAS/OIL Toggle

either IGNITION Provides

of

gas

AND

CONTROLS

MODULATING

(OPTIONAL

GAS FIRING)

has a switch

that

the

ignition

can

switches

for

high

fire

has

an

during

SWITCH

switch

gas

or

used

oil

TRANSFORMER

high

voltage

pilot

or

light

CONTROL

FOR

that

serves

damper

take

place.

that

operation.

additional

the

pre-purge.

(Figure

to

manually

firing.

spark

oil

burner

is

in

An

switch

1-1)

for

control

as a low

a closed

An

oil fired

optionally

to

select

(Figure

ignition ignition.

fire

switch

position

boiler

oil

solenoid

equip-

prove

circuitry

1-1)

electrode

dam-

for

M lNG

DAMPER

MOTOR

(OPTIONAL

GAS FIRING)

FOR

FIGURE

1-2

TYPICAL

STEAM

CHECK

VALVE

BOILER

AND

GAGE

GLASS

CONTROLS

1-4

Chapter

!-General

Description

and

Principles

of

Operation

OPERATING Steam

Boiler OPERATING TROL -Hot

Water

Breaks a circuit of

boiler

pressure

setting.

a HIGH

Steam HIGH Hot

It

is

pre-selected

LIMIT

Boiler

LIMIT

Water

Boiler

adjusted

Breaks a circuit selected ting manually

HIGH-LOW A

placed damper circuit

pressure

limit

pressure

into

positioning

to

control

reset

FIRE

or

the

damper

LIMIT

(Figure

LIMIT

to

pressure

PRESSURE

1-2)

TEMPERATURE

Boiler

stop

burner

or

temperature

to

start

or

(Figure

temperature

PRESSURE

(Figure

1-2)

TEMPERATURE

(Figure

to

stop

or

temperature

setting.

to

restore

1-3)

burner

This

the

CONTROL

temperature

circuit

by

switch,

motor

proper

makes causing

CONTROL

1-3)

operation

above a selected

or

stop

the

CONTROL

operation

above control

circuit. (Figures

control

which,

setting

or

the

CON-

on a rise

burner

setting.

at a pre-

the

opera-

must

1-2 & 1-3)

when

of

breaks

burner

at

be

the the

to

operate

ance

at

with

either

load

MODULATING

Senses

and damper only When moved is fired

LOW

(Steam

This

level

changing

transmits

motor

as

optional

installed

from

the

on

oil.

WATER

Boiler)

float-operated

in

the

boiler.

tions:

(a)

Stops

firing

below

the

safe

in

the

control

bell

(optional

ments

for

some

of

low

water

high

or

requirements.

CONTROL

boiler this to

pressures,

information

change

equipment

on

a 200

operating

CUT-OFF

(Figure

control

It

performs

of

the

burner

operating

panel;

also

equipment)

models

cutoff.

require a manual

This

low

(Figure

the

firing

for a

Series

circuitry

AND

1-2)

responds

if

point

causes

to

type

fire

or

to

the

gas

boiler, while

PUMP

two

water

and

low

ring.

requires

rate

rate.

low

Code

in

accord-

1-2)

temperatures,

modulating

Provided

fired

boiler.

it

is re-

the

boiler

CONTROL

to

the

water

distinct

level

water

func-

lowers

light

alarm

require-

reset

type

manual

OPERATING

HIGH

LIMIT

AND

HIGH-LOW

CONTROLS

TEMPERATURE,

TEMPERATURE

FIRE

FIGURE

1-3.

TYPICAL

HOT

WATER

BOILER

AND

CONTROLS

1-5

Chapter

1-General

Description

and

Principles

of

Operation

resetting

to

down.

(b)

Starts

to

maintain

NOTE;

and

Determine

shipment

operating

AUXILIARY (Not

shown)

This

float-operated

stop

burner drops Manual manual

a LOW

(Hot

A stop drops

WATER

This pump gage glass water

WATER The

the regularly piping

below

reset

resetting

low

water

WATER

Water

float

operated

burner

below a safe

COLUMN

assembly

control

glass

provides a means

level.

COLUMN

water

column

to

and

start

the

stops

water

LOW

(Optional

operation

the

type

condition.

CUT-OFF

Boiler)

operation

houses

and

shutoff

column

assist

float

bowl

burner

the

at

the

that

and

installation

life.

WATER

control

master

(optional

in

order

(Figure

control

if

operating

(Figure

includes cocks,

DRAIN

drain

and

in

maintaining

clean

after

feedwater

proper

control

CUTOFF

equipment)

breaks

in

the

event

low

water

equipment)

to

start

1-3)

that

breaks a circuit

water

level

point.

1-2)

the

low

the

and

trycocks.

for

visually

VALVE

valve

is

its

piping

and

free

a low

water

shut-

pump

(if

used)

operating is

plumb

and

the

boiler cutoff

level.

throughout

circuit

water point.

requires

the

burner

in

the

boiler

water

cutoff gage

glass,

The

determining

(Figure

provided

can

be

so

flushed

cross-connecting

of

sediment.

after

to

after

to

and

gage

1-2)

that

A

similar water

drain

cutoff

valve

is

(optional

furnished

equipment)

pose.

WATER

(Figure This TEST This

filling,

PRESSURE

(Stearn

Indicates

GAGE

1-2)

valve

VALVE

valve

and

Boiler)

boiler's

GLASS

is

provided

(Figure

allows

the

facilitates

GAUGE

(Figures

internal

DRAIN

to

1-2)

boiler routine

1-1 & 1-2)

TEMPERATURE/PRESSURE

(Hot

Water

compound

A

water

STACK Indicates

Boiler)

gauge

temperature

THERMOMETER

temperature

(Figure

that and

of

indicates

water

tional)

SAFETY

safety

A lieve signed purchaser. A relief boiler

Safety

piping

Code

WARNING:

OR

RELIEF

valve(s)

the

boiler

pressure

for and

are

the

relief

to

be

of

or

same

installed

requirements.

Only

is

used

pressures the valve(s)

purpose.

valves

(Figure

the

VALVE

on a steam

pressure

and

to

valve

with

flush

the

to

be

boiler

pressure.

GAUGE

1-3)

pressure.

(Figure

vented

(Figures

higher

designated

is

used

their

escape

conform

1-7)

manufacturer

auxiliary

for

same

VALVE

gage

vented

inspection.

boiler's

1-2)

flue

gases.

boiler

than

on a hot

to

the

low

pur-

glass.

during

internal

(Op-

1-2 & 1-3)

to

re-

the

de-

by

the

water

and

drain

ASME

or

his

LOW GAS

PRESSURE SWITCH

1-6

GAS PILOT

PRESSURE REGULATOR

FIGURE

1-4.

GAS

PRESSURE SWITCH

MAIN GAS VALVE

WITH INTEGRAL

PROOF OF CLOSURE

SWITCH

TRAIN

WITH

HIGH

TWO

GAS

VALVES

GAS PILOT

SOLENOID

VALVE

representative repair

COMBUSTION

(Figure

A sure, sure

OIL Draws

pressure an rotary nected

OIL

Indicates

1-1)

pressure

whose

of

combustion

PUMP

oil

to

integral

filter.

to

BURNER

sensitive

contacts

(Figure

from

the

adjustable

The

the

fuel

zle. FUEL Electrically

quence ner

OIL

to

nozzles.

VALVES

operated

allow

The

these

AIR

PROVING

switch,

close

air

1-1)

supply

burner

nozzles.

pump

blower

motor.

PRESSURE

pump

(Figures

to

oil flow

function

valves.

actuated

to

prove

from

the

tank

and

pressure

is

driven

GAUGE

discharge

open

from

the

of

the

should

adjust

SWITCH

by

air

sufficient

forced

delivers

The

pump

draft

it

contains

regulator

by

a V

-belt

(Figure

pressure

to

1-1 & 1-6)

in a controlled

pump

to

the

valves

is

described

or

prespres-

fan.

under

and

con-

1-1)

noz-

se-

bur-

Chapter

!-General

in

the FUEL For

manually

LOW

OIL

(Figure

Switch below limit

circuit

for

correct

AIR

DAMPER

Controls the

burner

ficient

NOTE: the cies, may items. that shown

Description and Principles of Operation

oil

fuel flow

OIL

SHUT-OFF

PRESSURE

section

shutting

later

COCK

off

oil

SWITCH

in

(Figure

supply

(Optional)

1-3)

contacts

selected

pressure.

upon

open

loss

when

Switch

of

sufficient

fuel

oil

pressure

will

fuel oil

combustion.

(Figure

the

amount

in

proper

combustion

Depending

insurance

the

gas

consist

Refer

are

applicable. A typical

in

figure 1-4.

flow

of

to

1-5)

of

combustion

proportion

at

high

upon

carrier

control

some,

your

boiler

or

to

or

low

the

other

system, all,

to

air

fuel

firing

requirements

governing

of

determine

this

chapter.

1-1)

to

burner.

interrupt

pressure

admitted

input

rates.

or

gas

the

following

gas

train

drops

the

to

for ef-

of

agen-

train,

those

is

INTERMEDIATE

FRONT

HEAD

GASKET

NOTE: tration must head.

Burner

shown

purposes

be removed

AIR BAFFLE

in

only.

Burner

prior

PLATE

place

to

for

illus-

drawer

opening

FIGURE

1-5.

BOILER

WITH

FRONT

HEAD

OPEN,

CBH

50-100A

OIL

AND

GAS

FIRED

1-7

Chapter

1-General

Description

and

Principles

of

Operation

GAS

PILOT

solenoid

A period main ing ming

GAS For

gas GAS

to

flame

and

de-energizing

relay.

PILOT

manually pilot

valve.

PRESSURE

Indicates

GAS

PRESSURE

(Figure

Reduces

1-4)

incoming

requirement

VALVE

valve

admit

is

established.

SHUT-OFF

opening

gas

pressure

of

between

(Figure

that

opens

fuel

to

the

The

is

controlled

COCK

or

closing

GAUGE

to

(not

pilot.

REGULATING

gas

pressure

5"

1-4)

during

pilot.

sequence

by

(not

the

shown)

(Optional)

to

10"

the

It

closes

of

the

shown)

gas

VALVE

suit

the

W.C.

ignition

after

energiz-

program-

supply

pilot's

to

BUTTERFLY The

pivoted necting the

MAIN

An it valve. closure" lock is

GAS

linkage

rate

of

GAS

electrically

admits

The

main

valve

switch

circuit. A second

often

used.

VENT

(Optional) A

normally

the

two

main

mosphere

should

GAS

disc

in

from

gas

flow

VALVE

actuated

flame

may

connected

VALVE:

open

solenoid

gas

any

VALVE

this

the

to

(Figure

shutoff

gas

be

motorized

(Figure

valves

be

(Figure

valve damper the

burner.

is

1-l)

actuated

motor

to

1-4)

valve.

When

through

equipped

the

butterfly

with a "proof

into a pre-ignition

shutoff

1-4)

valve

installed

to

vent

gas

present

in

the

by

regulate

gas

between

to

the

main

con-

open,

gas

of intervalve

at-

gas

1-8

FIGURE

1-6.

FUEL

OIL

CONTROL

VALVES

line

when

the

vent

valve

closes

energized. MAIN For

gas pressure stream to

GAS

COCK

manually

supply

downstream

regulator. A second

of

the

main

provide a means

whenever a test

mam

gas

valve.

LOW

GAS

PRESSURE

A

pressure

main

pressure. ting, the

main

ner

from

gas

the

actuated

line

Should

switch

gas

valve(s)

starting. with a device being

tripped.

HIGH

A main sure. switch

main from

a

GAS

pressure

gas

Should

contacts

gas

starting.

device

PRESSURE

actuated

line

pressure

the

valve(s)

The

that

must

tripped.

LEAKAGE The

body

that

is

CONNECTION

of

the

used

whenever conduct a test closed

valve.

gas

valves

when

(Figure

opening

gas

is

made

switch

pressure

the

contacts

This

that

must

switch

pressure

will

to switch

be

gas

for

possible

are

de-energized.

the

gas

1-4)

and

closing

of

the

main

shut-off

valve(s),

of

shutting

for

may

off

leakage

SWITCH

that

is

closed

is

above a preselected

pressure

to

switch

drop

will

open a circuit

close,

or

is

be

manually

prevent

usually

SWITCH

that

is

closed

is

below a preselected rise

above

open a circuit

close,

or

prevent

is

usually

manually

valve

it

is

necessary

reset

has a plugged

leakage

valves

the

main

gas cock, be

installed

the

gas

across

(Figure

whenever

below

this

the

equipped

reset

(Figure

whenever

the

setting,

causing

the

equipped

after

opening

or

desirous

across

The

are

fuel line

down-

line

the

1-4)

set-

causing

bur-

after

1-4)

pres-

the

burner

with

being

to

the

Chapter

1-General

On a Model fire oil

two

electrodes

from

the

ignition

and

ignition

gized.

The

ter

low

Air

for ondary" (Figure ation, and

forced

mixture The

supply matically regulating amount ficient

Description

100

boiler

nozzle

is

ignited

supplied

ignition

transformer.

cycle,

transformer

ignition

fire is

the

1-3)

air

established

E.

COMBUSTION

combustion

air)

is

furnished

mounted

pressure

through a diffuser

with

the

fuel

of

combustion

throttling

the

air

of

air

for

correct

combustion

the

transformer

is

damper

at

rates.

F.

Oil

An

oil

fired

boiler

fuel

pump

(Figures

oil

from a storage capacity oil to

The can

SUPPORT FROM BUILDING

than

not

delivered

the

storage

pump

has

be

adjusted

CONSTRUCTION

the

maximum

to

tank.

an

integral

to

is

1-1 & 1-5)

tank.

the

provide

and

Principles

with

spark

by a spark

with

low

fire

are

and

of

fuel,

by

in

the

built

up

for

proper

air

the

output

to

ratio

both

FUEl

equipped

The

burner

pressure

the

TO STEAM

of

Operation

ignition,

high

At

oil

arcing

voltage

the

between

beginning

solenoid

simultaneously

is

de-energized

proven.

AIR

(also

called the front

in

plate

forced

the

head.

entire

for a

draft

In

thorough

combustion.

is

governed

furnish

of

air

low

of

and

to

by

the

fuel

high

FlOW

with a belt

that

withdraws

pump

burning

has a greater

rate

nozzles

regulator

necessary

VENT

is

returned

atomizing

the

low

current

valve

ener-

af-

"sec-

fan

oper-

head

auto-

fan

by

proper

for ef-

firing

driven

fuel

and

all

that

of

D.

A

gas

burner

unit),

is

ignited

Some

insurance burner though

The electric the Flow regulator have pilot

At

solenoid simultaneously

former igniting trode itself. de-energized

(Model

standardly

gas

pilot

spark.

utility

rate

combustion gas

the

beginning

supplies spark

within

The

mains

(flame

(Figure

stream

valve

gas

AUTOMATIC IGNITION

(and

an

oil

by

regulations

100)

flame

Fuel

or size)

air

to

of

and

energized.

which

the

pilot

after

burner

an

interrupted

be

ignited

this

model

is

ignited

for

the

from a tank

is

regulated

1-4

).

The

flow

provide a suitable

the

ignition ignition

high

voltage

arcs

tube

solenoid

main

flame

on a combination

require

with a gas

has

automatically

pilot

is

(bottle)

burner

into

and

cycle,

transformer

The

ignition

current

between

and

the

wall

and

transformer

is

ignited.

the

type that a light

spark

supplied

by a pressure

is

designed

mix

the

single

of

gas

pilot.

pilot

ignition.

by

from

supply.

with

flame.

pilot

trans-

for

the

oil al-

an

to

the

gas are

the electube

are

Discharge MUST

inlet

NOTE:

SAFETY

opening

be

larger than

WATER LEVEL

Back-pressure be less than 10%

FIGURE

VALVE

of

1-7.

INSTALLATION

steam

of

exhaust

safety

valve

system

setting-!--

RECOMMENDED

PROCEDURE

MUST

1-9

Chapter

1-General

HIGH FIRE ORIFICE

VALVE BLOCK

OIL

(HFOV)

Description

and

Principles

OIL SHUTOFF SOLENOID

of

OIL PRESSURE

VALVE

(LFOV-1)

Operation

GAUGE

t

CHECK

VALVE

OIL

TERMINAL

BLOCK

-sUPPLY __.OIL

OIL

RETURN

FIGURE

MANIFOLD BLOCK

INTERMEDIATE

HIGH FIRE I OIL VALVE :

(HFOV-1)

HIGH FIRE

VALVE !

OIL

(HFOV-2) )J

HIGH FIRE

OIL NOZZLE

~-

1-8.

SCHEMATIC

---

\----1---L_j------j__J.-----\

OIL FLOW DIAGRAM, MODEL

MANUAL

SHUTOFF

-·

LOW FIRE

OIL NOZZLE

OIL

VALVE

ORIFICE

FITTING

CBH

25-40 AND 50A

t

OIL

STRAINER

OIL

SUPPLY

OIL

RETURN

1-10

FIGURE

1-9

SCHEMATIC

OIL FLOW DIAGRAM,

MODEL

CBH 50-100

Chapter

1-General

Description

and

Principles

of

Operation

pressure read

Oil flow noid

quence,

(LFOV-1) energized ing fire nozzle.

When position, motor,

to

on

the

to

valves.

the

of

these

the

energizes a high

the

oil

the

At

primary,

and

by

the

valves

damper

an

auxiliary

burner pressure

burner

the

nozzles

proper

the

low

programming

allows

motor

nozzles.

gauge.

time

or

safety,

fire

valve

the

moves

switch

fire

valve.

This

is

controlled

in

the

control.

oil

to

flow

to

actuated

pressure

by

operating

shut-off

(LFOV-2)

The

to

the

high

by

is

sole-

se-

valve

are

open-

low

fire the

Figure 40

and

the

valves

the

high

The

oil

100

size flows

The

intermediate

high

fire

change

ing

the

damper

fold

is

I

1-8

shows

50A size

fire

discharge

valve. from oil

orificed

the

boilers.

prevents a sudden

valve

from

into a manifold

valve

The

low

to

input

with

opens.

The

to

maintain a constant

valves

The

opens.

the

is

purpose

high

fire

the

increasing

return

used

on

orifice

pressure

pump

on

block

energized

for

this

smoother

line

the

block

the

(Figure

prior

is

flow

from

25

through

between

drop

50

through

to

make

by

balanc-

of

the

pressure.

when

1-9).

to

air mani-

the the

as

PILOT GAS

MAIN GAS

MAIN

SHUTOFF

FIGURE

GAS

VALVE

1-10.

SCHEMATIC

MAIN

VALVE(S)

GAS

FLOW

DIAGRAM

1-11

Chapter

!-General

Description

and

Principles

of

Operation

G.

GAS

The

gas

flow

system

flow

indicated

Metered gas

piping through a pressure reduced quirements; gas burner. from

Gas cock ating trols

(opened) is ignited the time

At solenoid programmer pilot energizes allowing burner. upon This motor damper, bustion

to

valve

Gas

this

for

the

into a pressure

pressure

the

mixed

by a controlled

pilot

required

the

beginning

valve

flame

The

the

is

mechanically

and

thus

air.

by

gas from

through a main

the

pressure

through

and

through a butterfly

required

line

prior

pilot

operation

is

established. A solenoid

flow

of

allows

position

with

flame.

for

is

control

is

the

electrically

flow

through

rate

varied

properly

the

combustion

The

energized

proven,

fUEl

is

shown

arrows.

the

utility

regulator

suitable

an

electrically

for

to

the

regulator

the gas

to

electric

pilot

main of

the

and

the

of

flow

of

the

vane

controlled

in

the

proportioning

flOW

with

(Figure

flows

gas

where

pilot

main

flows

where

gas

and

flow

to

air.

burns

flame

ignition

through

the

pilot

programming

operated

butterfly

to

the

in

the

same

the

direction

1-10)

into

the

burner's

shut-off

the

to

the

operated

gas

valve

operation

gas

shut-off

through a shut-off

the

when

the

pilot

This

spark

only

ignition.

cycle,

circuitry

ignited.

main

valve

burner

butterfly

by

the

maimer

gas

pressure

burner's

to

is

taken

pilot

valve

energized

where

mixture

to

establish

during

the

in

When

control

gas

valve

to

depends

valve.

damper

as

the

and

cock;

main

the

cock.

oper-

con-

the

pilot

the

air

com-

of

re-

is

it is

High-Low The

firing; steam water damper either ance

Modulating

An modulating reversible

at

any

Through a linkage damper constant

Gas the

combustion

with The

unless to

indicate a sufficient

Some

valves.

mally

for

venting line vent

Burner

standard

either boiler,

boiler,

motor

the

high

with

load

Burner

optionally

damper

and

position

and

air-fuel

flows

through

combustion

main

gas

the

combustion

insurance

Additional

open

vent

gas

when

main

valve

closes

burner

low

or a temperature

makes

causing fire

requirements.

equipped

will

within

the

zone

valve

requirements

should

gas

Operation

is

equipped

or

high. A

or

breaks

the

or

the

Operation

motor.

move

its

arrangement

butterfly

ratio

throughout

the

burner

where

air

to

produce

cannot

air

supply

requirements

valve

to

any

valves

when

the

pressure

burner

low fire

gas

This

in

either

range.

gas

it

be

proving

specify

be

placed

be

are

main

for

two control

control

the

circuit

to

rate

fired

boiler

type

of

direction

it

controls

valve

to

maintain

the

firing

orifice

is

present

ring

intimately

main

energized

switch

of

combustion

two

call

for a

between

in

de-energized.

gas

valves

position

on a hot

to

operate

in

accord-

has

motor

or

the

range.

to

enter

mixed

flame.

(opened) is

closed

main

them

main

open.

on

the

stop

air

air.

gas

nor-

gas

The

a

at

a

is

a

1-12

CHAPTER 2

This

chapter

care

of

the

Water boilers vice. dends and placing vital. remodeled oil, grease boiling lations

The adequately less your the

Feedwater for use. See pumps, with

A boiler, proper

operated

or the

The

chapter

operation.

requirements

are

essential

Constant

in

the

prevention

the

The

waterside

steam

out

is

described

subject

it

is

of

boiler

amount

equipment

and

prevailing

as a part

circulation

as

severe, possibly

pressure

operator

before

A.

is

devoted

pressure

attention

form

of

pressure

or

other

the

vessel

of

water

be

covered prime performs

of

waterside

that

receivers

codes

intended

vessel.

should

attempting

TH

A.

GENERAl B. CONSTRUCTION C. WATER RECWIREMENTS

1.

2.

D. WATER TREATMENT E.

ClEANING F.

BOilmOUT

G.

WASHING

H.

BlOWDOWN-STEAM

t PERIODIC INSPECTION

J.

PREPARATION FOR EXTENDED

GENERAl

primarily

vessel.

for

both

to

boiler

to

this

of

longer life, less

costly

hot

importance.

aU valves, piping,

of a hot

damaging,

repairs.

vessel

of

new

water

foreign

to

remove

later

in

supply

in

this

has

an

care

should

are

installed

and

the

by

its

designer

familiarize

to

steam

life

and

area

Care

into

initial

boilers

systems

matter. A method

these

this

chapter.

and

treatment

manual.

The

important

it

witl

be checked

practices.

water

system,

system

stresses

himself

to

place

p

HOT

STEAM

the

waterside

and

hot

length

will

pay

down

taken

service is and may

accumu-

Neverthe-

type

of

bearing

require.

and

boiler

in

accordance

must

to

avoid

occurring

with

the

unit

ESSU

WATER

water

of ser-

new

contain

cannot

service

ready

requires

shock

BOlliER

OF

A NEW UNIT

OUT

divi-

time,

in

or

of

in

feed

be

to

this

into

E

VESSEL

BOlliER

lAYaUP

B. CONSTRUCTION

All

pressure

with

the Steam ceeding 15 psig, valve

practices, Pressure boilers exceeding 240°F. but

because

psig

design Pressure peratures pressure be

as

IV

of

Those ceeding 15 psig section I water built

to

ASME

boilers

Heating

for

operation

Heating

between

is 60 psig,

high

as

Low

Pressure

steam

Power

boilers

this

vessels

Boiler

for

but are

of

static

and

constructed

160 psig

boilers

are

Boilers,

for

operation

Code.

Boilers,

may

C. WATER REQUIREMENTS

1.

HOT

WATER

Air Removal

The

hot

water tends 2 to 3 inches reduces trapped the

Any oxygen will collect shell.

the

at

system.

BOilER

outlet

possibility

the

top

or

air

or

be

trapped

are

constructed

and

Pressure

operation

within

constructed

with

be

head

Boiler

240-250°F,

but

because

Heating

designed

constructed

includes a dip

into

of

the

which

the

of

this

water

built

may

to

Code.

and

constructed

of

the

over 250°F

the

boiler.

of

any

shell

is

released

at

the

at

in

accordance

Vessel Code.

pressure

limits

of

good

to

section

Code.

temperature

as

30 psig design,

be

built

section

For

water

minimum

of

static

Boiler

Code.

for

operation

in

accordance

ASME

tube

This

air

which

from

entering

in

top

of

are

not

IV, Low

Hot

up

IV

of

head to

section

Code.

likewise

which

dip

may

the the

ex-

safety

water

not

to

160

Low

tem-

design

may

ex-

with

Hot

ex-

tube

be

into

boiler boiler

2-1

Chapter 2-The

The

air

vent boiler pression of through

the

should

tank.

boiler

this

Minimum

mum

recommended

170

degrees

than

170

are

reduced

water

vapor

corrosion This

condensation

unit

which greatly matter since heat

oversized

which

an

from problem water

temperatures

Pressure

tapping

be

piped

Any

will

tapping.

Boiler

F.

Water

When

degrees F are

in

temperature

condenses.

occurs

in

operates

for

can

be

efficient

the

can

boiler

combustion

be

minimized

Rapid Replacement

system prevent of or cannot

that

cannot water mal operation"

This having burner the

When it though The continuous help with

layout

the

cold

water

thermal

stresses. A formula,

be

given,

200

degrees

be

in

a few

stress.

problem

the

so

that

circulating

individual

is

recommended

the

relief

device

circulation

prevent

"cold"

and

controls

possibility

into a hot

but

or

completely

minutes'

This

applies

as

well

can

be

circulating

the

pump

zone

that

heat

users

or

rapid

zone

water.

Contiru.1ous Flow

system arranged

through

The

trols

boiler through stratification even

A power tinuous operating

Before

operation

should

will

water

rule

of

can

initial

should

that

the

boiler

of

be.

not

the

boiler

within

temperatures

thumb

be

used

flow

rate

conditions.

firing

be

there

under three checked

be

by-passed.

of

to

Vessel

on

the

into

the

air

which

find

its

way

Temperature-

boiler

water used,

The

the

boiler

problem

intermittently

the

actual

controlled

extracts

by

above

of

170

Boiler

should

of

pumping

boiler,

it

should

240

degrees

replaced

time

to

as

during

avoided

pump

burner

is

running.

cannot

circulating

they

be

do

not

by-pass

through

replacement

Through

piped

will

and

be

all

way

valves

to

eliminates

the

unit

to

1/2

to 1 gpm

determine

through

or

refiring

top

center

expansion

is

trapped

out

of

water

temperature

temperatures

the

combustion

to a point

net

result

and

breeching.

is

more

and

load.

by

boiler

all

gases.

However,

maintaining

degrees

Water

be

large

thus

causing

or

"magic

be

borne

water

with

without

causing

periods

initial

in

some

interlocked

operate

pumps

kept

running -even

require

valve

will

the

boiler

of

boiler

the

Boiler -The

the

water

operating

and

make

sure

Constant

the

possibility

and

results m more

the

system.

per

boiler

the

minimum

the

boiler

after

line

of

or

at

the

boiler

The

mini-

lower

where

is

severe

which

This

is

design,

the

possible

boiler

F.

-

arranged

quantities

shock,

number"

in

mind

in a boiler

80

degrees

of

"normal-

start-up.

systems

with

unless

are

used,

hot

water.

thus

allow

and

water

controls.

circulation conditions.

system

that

circulation

horse-

under

boiler

the

com-

top

is

gases

the

that

on

a

is

not

a

this

The

to

ther-

by

the

can

so

con-

the

of

con-

an

has

been

drained,

flow

of

water

Water

The

circulation boiler

Multiple

boilers be through by line plates psi) accomplish

If

tional

wide

In fire'' be mon would portant

Circulation

chart

output

of

taken

use

of

from

are

must

care

is

flow

variations

extreme

position,

loafing.

header

not

in

rate

Boiler

equal to

insure

the

boilers.

balancing

each

used, a significant

be

this

not

through

cases,

The

be

consideration

stallations.

Pressure Drop

pressure

2.31 ft.

drop

hd.) Cleaver-Brooks which

has

more

drop.

Pump

system outlet discharge and pump.

decreases

impose

It

circulating pumps in

Pump

and desirable that culating

location

circulating

connection

to

the

expansion

This

air

the

system

is

common

pump,

are

usually

the

boiler

Operation -Pumps

stopped

to

interlock

the

burner

pump

Pressure

The

design requirements ted

upon

the

with

air

or

with

Caution

proper exists ternal

must

relationship

within

the

surfaces

the

operator

exists

Fig. 2-1

of

boiler

and

system

Installations

or

unequal

adequate

This

cocks

boiler.

taken

across

purpose.

taken

to

the

in

firing

one

and

the

net

result

water

up

to

the

Through

of

less

through

boilers

than a 10

-

pumps

on

system

tank

location

entry

into

head

practice

and

located

room.

by

manual

cannot

is

running.

of

the

will

often

boiler.

Some

an

be

exercised

boiler

are

fully

should

through

shows

the

water

temperature

-

size

are

or

can

best

and

gauges

If

balancing

pressure

the

balancing

insure

adequate

boilers,

rates

between

boiler

other

may

boiler

would

temperature

desired

in

point.

multiple

Boiler -There

than

three

all

standardly

operating

degree

It

is

recommended

take

the

boiler

load.

This

on

the

is

preferred

the

system

on

the

to

install a standby

these

adjacent

are

switches.

the

pump

operate

system

dictate

systems

inert

gas,

to

make

of

pressure

so

that

all

wetted

determine

boiler.

maximum

in

relation

drop.

When

used,

care

proportional

be

accomplished

in

the

cocks

drop

or

this

can

the

be

in

the

or

boilers

be

that

to

the

This

boiler

feet

head

equipped

in

any

F.

temperature

suction

and

puts

from that the

side

because

and

boiler.

main

circulating

to

the

normally

It

with

the

burner

unless

and

the

pressure

are

pressurized

such

as

sure

to

temperature

of

the

boilers'

at

all

times.

that

G.P.M.

to

full

multiple

must

flow

supply

or

orifice

(e.g. 3-5

device

to

propor-

result

in

boilers.

"high

may

the

com-

system

is

an

im-

in-

will

be

( 1 psi-

system

that

the the

they

boiler

of

the

does

not

system

boilers

started

is

also

so

the

cir-

usage

exer-

nitrogen.

that

the

in-

It

a

it

is

2-2

Chapter 2-The

Pressure

Vessel

15 20 30 40 50 60 70 80

Boiler

Output

( 1

()()())

Btu/Hr

500 100 50 33

670 1,005 1,340 1,675 2,010 2,345 2,680

Boiler

Size

(BHP)

100 3,350 670 125 4,185 150 5,025 1,005 200 250

300

350 400 500 600 700 800

6,695 1,340

8,370 1,675 10,045 2,010 1,005 11,720 2,350 1,175 784 587 470 392 336 294 13,400

2,680 1,340 16,740 3,350 1,675 1,120 20,080 4,020 2,010 23,430 4,690 2,345 1,565 26,780 5,360 2,680 1,785 1,340 1,075

System

10

200

134

20

67

100

30

Maximum

45

67 268 134 89 335 402 470 536

168 201 235 268

112 84 134 157 118 179 134

335 223 168

836

418 503 670

279 335 447

838 558

670

895

1,340 1,005

Temperature

40 50

Circulating

25 33 50 67

40 54 67

101

107

134 112 209 168 140 251

201 335 268 419

335

503 402

670 535 838

670 558

805 670

1 '175

940

Drop

- Degrees f'

60

Rate -

20

17

27

22

33

45 56 67

80 94

78 90

168 224 192 168 280 240 210 335

447

785

895 765

70

80

90 100

GPM

14 12

11

19 17 15

25 22

29 38 33

48

58

67

77

96 120 105 144

126

30

42 37

45

50 59

52 67 60 84

75

93

112 149 134

186

251

287

223

261 383 335 298 479 575 502 670

419

585

372 448 402 520

670 595 535

10 13 20 27 33 40 47 54 67 84

100

167 201 235 268 335

470

for

this

reason indicated held

to

the

When when system,

initially

cutting

the operation system

It

the

and/or

is

advisable

return perature. ply

water perature knowledge easily

detect

appropriate Special

any might boiler ticularly

caution

condition,

lead

or

hot

true operated water

for

that

on

the

water

level

shown

firing a newly

an

existing

boiler

MUST

be

other to

have a thermometer

line

to

With

this

temperature

differential

of

the

pumping

any

excessive

corrective

must

or

combination

to

the

transfer

water

in

the

for

purposes

the

normal

the

internal

pressure

in Fig. 2-2.

boiler

or

boilers

pressurized

boilers

indicate

determined

to

system

will

be

rate,

load

action.

be

taken

of

to

a cold boiler.

case

of

other

system

FIGURE

boiler

gauge,

installed

into

to

prior

to

return

and

known,

established.

the

condition

(See

to

guard

of

conditions

cold

water

boilers

than

supplying

load

(as

pressure,

must

boiler

an

operating

be

cut

equal

cutting

installed

water

with

the

operator

and

Figure

to a hot

This

which

an

example,

2-1.

CIRCULATION

as

be

or

into

to

the

in.

in

tem-

sup-

tem-

With

can

take

2-1

).

against

which

is

par-

are hot

CHART

boilers

It

equipped

cannot

be

over

temperature

do,

cause

damage.

2.

STEAM BOILER

Feed Pump

Make

certain

are

open

BEFORE prevent After pump With trance level

Feedwater maintain conditions. and

possible

opening

motor

correct

switch.

reaches

pumps

required

Check

maintain

breakdowns. NOTE:

Prior alignment used. A

with

coils for

emphasized

within

Operation

that

the

all

turning

damage

valves,

to

establish

rotation,

Pump

should

proper

must

water

feedwater

as

necessary

to

operating

of

properly

domestic

that

boiler

can,

valves

to

in

on

feed

the

momentarily

correct

close

boiler

shut

level

shown

have

adequate

level

under

pumps

to

prevent

pump,

flexible

coupling

aligned

rapid

and

water

pump

mechanism.

energize

pump

feed

down

in

Figure

all

periodically

carefully

coupling

hot

water).

changes

sometimes

feed

line

motor

feed

rotation.

pump

when

en-

water

2-3.

capacity

operating

unexpected

check

if

one

will

last

in

to

is

2-3

Chapter 2-The

Pressure

Vessel

14@

130

120

110

100

90

110

ci

..:

,;7'0

~

...

~60

"'

...

"'

..

... 50

40

J()

20

10

r

+-L-t+

8+-

*FOR

TEMPERATURES CONSULT SPECIFIC

CLEAVER-BROOKS

RECOMMENDED

MINIMUM

BOILER

PRESSURE

ABOVE

RECOMMENDED

OPERATING

320°

F,

FOR

PRESSURE

SATURATION

TEMPERATURE

140

130

120

110

100

90

81)

~OI,LI~G)1

7'0

60

50

4@

30

20

10

0

~

FIGURE

a long mechanical

Wat~r

This boilers necessary the should

as

NOTE:

F~~d~r

type

operating

water

close when

shown

In

to

feeder

valves be

only locked are boiler

D.

Maximum of

pressure

with

good engineering

functions

of

+

§!

~

time

0

...

2-2.

g

~

...

PRESSURE -TEMPERATURE

and

provide

operation.

Op~ration

of

operation

at

open

the

discharge

15 psi

water

is

usually

steam

supply

valve.

reaches

in Figure 2-3.

the

event

that

water

are

provided

established

open

'Qut

in

the

installed

with

closed

open

it

that

position.

is

or

these

they

illegal

unsealed

WATER TREATMENT

effectiveness

vessels,

properly

and

at

the

and

treated

long

lowest cost

operating

boiler

!i

~

....

trouble

applicable

or

less.

line

valve

The

water

the

proper

column

installed,

valves

are

sealed

If

these

to

operate

open

trouble-free

consistent

practice

feed

water.

~

INDICATED

free

It

is

only

and

feeder

level

isolation

it

must

are

not

or

valves

the

valves.

life

are

The

~

iii

TEMPERATUitE

to

S!

~

("F)

CHART

...

FOR

...

HOT

recommendations reliable

water followed rigidly wanted

Objectives

a)

b)

c)

d)

The requires ter selection the amount practices,

solids

of

and

water

Prevention sludge transfer costly

deposits

and

down

Elimination boiler

water.

Prevention caustic

embrittlement

Prevention

accomplishment

proper

introduction

of

pre-treatment

water

of

makeup

source,

etc.

g

~

...

WATER

of a water

treating

to

prevent

corrosive gases.

treatment

of

hard which

can

lead

to

time

and

of

corrosive gases

of

intercrystalline

of

carryover

of

these

feed

water

treatment

of

the

water

its

chemical

water

These

treating

!!1

BOILERS

consultant

company

the

presence

in

scale

processes

needed,

deposits

impair

overheated

repairs.

of

boiler

and

objectives

into

methods

0

~

1:;

~

....

or

should

of

general

the

in

rate

the

are:

or

of

metal

supply

soft

heat

and

cracking

metal.

foaming.

generally

before

the

depends

and

boiler.

The

upon

characteristics,

plant

operating

include

a

be

un-

or

af-

2-4

Chapter 2-The

Pressure

Vessel

A.

High level

off

turns pressure vessel height.

B.

Pump turns on when reaches approximately

C.

Low

Water

will

shut

Iowen

D.

Fint

visible

FIGURE

2-3.

DETAILS

filtering, softening,

and

pre-heating.

chemical

Because compound" advisable methods. ployment analysis

treatment

of

the

variables

can

to

experiment

Sound

should

of

the

be

recommendations

feedwater,

densate. The

internal

vessel

should

to

determine accumulations and/or water

consultant

should

It

is

recommended

meter

be

to

accurately

admitted

the

water

pitting.

be

consulted

installed

to

the treatment

or

waterside

be

inspected

the

presence

of

If

these

or

determine

boiler

TYPICAL LOW

-

CUTOFF CONTROL

AND

/

~~

of

water:

at

this

B.

Distance

Cutoff

off

if

to this

point

BOILER

(STEAM

de-mineralizing,

After-treatment

of

the

considered a "cure-all"

be

augmented

foreign

conditions

feedwater

for

advice

that a properly

in

the

(steam

Feed pump

point.

initially

water

A-B

3/4

inch.

Poir;>t:

water

level

point.

of

gouge

WATER

boiler

involved,

with

homemade

boiler

surfaces

with

of

any

matter,

on

raw

water

the

amount

or

program

Fi

II

to this

level

is

Burner

glass.

LEVEL

BOILER)

water.

no

one

and

by a

water,

of

the

sufficient

contamination,

of

are

detected

treating

corrective

sized

make-up

of

hot

water)

in

maintaining

WATER

PUMP

deaerating

involves

"boiler

nor

is

treating

their

em-

periodic

and

con-

pressure

frequency

corrosion

the

company

action.

water

line

raw

water

to

aid

it

proper

The does assumption. water should generally

is system mended

Hot

Steam

boiler

These

damage

steam

til

purities.

wasted,

the

lation

occur.

waterside

general

not

feeling

require

The

treating

be followed rigidly.

operate

seldom

water

for

Water

and

may

practiced,

losses

water

and Steam

water

contain

impurities

to

pressure

system

tests

the

show

During

attention

raw

water

of

unwanted

Follow

the

used

the

company.

On a hot

generally

be

drained ment compounds

water

necessary

after

companies

and

Pressure Vessel

The

waterside clean Such life ficient safety

from

deposits,

of

the

operation

devices,

necessary

of

grease,

if

pressure

and

expensive

time. The

installation

the

boiler

will

be

and

cleaning

should

be

provided

of

start-up.

Th':!

pressure

or

hot system. densate) have

been

1)

Cleaning

2)

Partial

3)

Conditions

vessel

water

piping

Although

lines

previously

has

or

piping.

The

pressure on a periodic conditions

vessel

basis.

and

conditions.

exists

that a hot

water

treatment,

recommendations

company

or a water

Even

on

closed

the

systems

need

and a water

make-up

E.

ClEANING

Piping

piping

oil,

must

vessel

systems

grease

be

heating

condensate

elimination

the

period

must

be

given

as

make materials advice

of

system,

and

the

treatment.

for

recommendations,

application

the

pressure

sludge

present,

and

but

vessel

functioning

might

will

and

quite

re-work,

and

operating

subjected

the

waterside

to

during

and

the

represent,

the

steam

the

hot

water

cleaned

been

inadequate.

total

old

system

may

prevent

waterside

This

will

serve

as a check

but

though

and

remains

meter

lines.

connected

or

foreign

removed

surfaces.

should

up

or

of

undesirable

that

to

the

so

that

corrosion

your

water

be

condensate

chemical

entire

system

Consult

procedures.

vessel

and

foreign

not

only

interfere

possibly

repairs

conditions

should

of

the

pressure

the

course

steam

and

in

effect, a closed

and

piping

it

is

involved.

adequate

should

reveal

against

water

boiler

this

is a false

of a reliable

consultant

these

units

blowdown

to

be

alert

is recom-

to

the

matter.

to

prevent

On

wasted

unim-

treatment

an

accumudoes

not

treating

cleaning

should

water

treat-

cleaning

must

be

kept

material.

shorten

of

control

with

cause and

the

ef-

un-

down

which

be

considered

vessel

of

initial

return

system

possible

lines

(con-

may

that:

cleaning

be

inspected

true

internal

conditions

to

a

is

of

is

or

of

2-5

Chapter

2-The

Pressure

Vessel

indicated Inspection initial

starting tervals periodic conditions

If

any

unwanted consultant contacted

Any

sludge, flushed practiced scheduling

be

revised.

out

will also be

Any

oil

or

should

be

alkaline NOTE:

Temperature hydrostatic operation

ASME

F.

The

internal

may

have

used

in removed and

could boiling should familiar operation.

Your will procedure. or be

Suggested follows:

1.

CBH CBH CBH CBH CBH CBH CBH CBH CBH CBH

out

be

water

be

able

is

yet

unselected,

of

assistance.

Tri-sodium suggested The ditions chemical See

chart

Boiler Model

and

Size

25 30 40 50A 50 60 70

80

100 lOOA

by

chemical

should

thereafter.

inspections

and

be at

The

will

found.

conditions

or

water

for

recommendations.

mud

out.

The

on

steam

or

frequency

The

treating

or

sediment

effectiveness

boilers

need

for

indicated.

grease

removed

detergent

present

promptly solution.

tests,

should

Boiler

BOil~OUT

surfaces

oil,

grease

or

manufacturing.

since

they

lower

cause

over

procedures

ready

for

firing.

with

the

procedure

consultant

to

recommend a cleaning

In

the

event

the

procedure

for

phosphate

chemicals

quantities

but

per

Normal

will

an

amount

50

gallons

below

Water-

for

Gallons

210 205 230 275

- 295

375 350 550 535 610

-

analysis

made

regular

of

the

three

6, 9

frequency

depend

upon

are company

found

of

will be verified

of

blowdown

periodic

of

initial

on

the

by a

draining

heating

boil-out

fill

boil-out,

be

as

Code.

OF A NEW

of a newly

other

protective

Such

coatings

the

heat

heating

or

such

following

boiling

boiler

Flooded

235

310

440 420 650 630 715 5085 595

may

The

outlined

water

service is

and

for

cleaning

vary

of

of a tube.

begin,

operator

treating

information

out

caustic

according

one

water

Water-

Normal

1750 1710 2290

3125 3665

2920 4625 4460 5250

-

boiler

water.

months

or

12

month

of

further

the

internal

observed

water

should

will

have

the

blowdown

may

have

or

wash-

surfaces

with

of

water

or

for

normal

stated

in

UNIT

installed

transfer

under

new

pound

is suggested.

- 2460

boiler

coatings

must

Before

the

burner

must

burner

company

or

boil-out

unavailable

units

soda

are

of

boilers. to of

capacity.

Weight

Flooded

1960 1915

2585

3500 5420

5960

4960

after

in-

be

to

be

and

to

an

for

the

be

rate

be

may

is

as

the

con-

each

2.

When

procedure be

put troduce stirring pletely and heat

Use gloves, recommended caustic material in

contact

An

over

3. of

the point tapping

4.

Water must solution which

valves. valves.

Refer

to

stallation

5.

All

valves system solution

6.

Fill

pressure

of

tubes solution ture should

7.

The

boiler

at

a low

the

boiling

five

hours.

8.

Allow a small

boiler carry

9.

Continue Shut

10.

Let

boiler using with

Remove

11. waterside pressure

12.

Inspect

boil

13.

After or

relief

dissolving

is

suggested.

into a suitable

the

dry

at

all

times

dissolved.

in

small

and

amounts

turbulence.

of a suitable

and

protective

when

chemicals.

or

the

concentrated

with

skin

flow

pipe

top

boiler

openings

of

discharge. A relief

is

usually

relief

valves

be

removed

so

that

it

may

carry

Use

care

in

Section J in

instructions.

in

the

piping

must

be

closed

from

getting

vessel

are

covered.

and

then

of

the

water

be

at

ambient

should

rate

sufficient point. Do

not

amount

to

create a slight

off

surface

boil

burner

impurities.

and

down.

cool to

caution

that

safety.

hand

hole

surfaces

water

surfaces

stream.

and

out.

closing

openings

valves

fill

chemicals,

Warm

container.

chemical

until

Add

face

the the to

prevent

mask,

into chemical chemical

garments

handling

Do

not

permit

solution

or

clothing.

should

be

and

used.

and

steam

before

neither

removing

adding

it

will

contaminate

and

Chapter 5 for

leading

to

prevent

into

the

with

clean

Add

fill

to

the

top.

used

in

temperature.

then

be fired

to

hold

Boil

the

water

produce

of

steam

fresh

overflow

120°F

the

until

or

water

less,

plates

thoroughly

if

not

clean

and

reinstalling

boiler

and

the

following

water

should Slowly inthe

water

is com-

slowly

excessive

goggles,

is

strongly

or

rubber

mixing

the

to

attached

routed

or

safety

nor

to a

safety

the

to

valves

boil-out

grease

re-installing

valve

to

or

from cleaning

system.

water

until

the

cleaning

The

tempera-

this

initial

intermittently

solution

for

just

at

pressure.

water

to

that

water

clears.

then

is

discharged

and

wash

using a high

repeat

safety

fire

until

water

dry

come

one

safe

valve

these

in-

the

top

fill

at

least

enter

will

drain

the

2-6

is

heated dissolved corrode

The

above

procedure

a

unit

previously

clean,

however, possibility boiler

of

from

On a steam

wasted desirable densate treatment an corrosion water

until

impurities.

is

wasted,

of

accumulation

does

treating

On a hot generally be

drained

ment

necessary

companies

compounds

A. STEAM

No

later

than 3 months

boiler

into thereafter vessel

cooled covers

spected

should

to

near

removed

for corrosion,

deposits.

B.

HOT

WATER

In

theory, a

been

initially

that

water

treated)

ded

will

require However, entrance leakage up

or mation pressure

If

the

is

tight,

be

sufficient.

If

there waterside months operation by

conditions

flUSHING

Upon interior high removed

since

of

water,

air

may

of

vessel

operator

then

is

should

after

and

completion

should

pressure

by

consultation

to

at

least

180°F

gases

the

metal.

consideration

contaminating

the

system.

system,

tests

the

raw

not

which

may

used

or

the

show

During

attention

water

of

unwanted

occur.

be

omitted

known

must

materials

condensate

the

elimination

the

must

used

Follow

might

as

the

company.

water

after

and

system,

and

the

treatment.

for

recommendations,

application

chemical

entire

Consult

procedure.

G. WASHING OUT

BOlliER

after

initially

operation

as

conditions

be

and

hot

water

cleaned,

no

the

air

lead

sludge,

waterside.

is

absolutely

an

annual

any

initially

periodically

observed

Of

PRESSURE

be hose.

flushing

with

and

warrant,

drained

ambient

temperature,

internal

pitting,

BOlliER

system filled

and

with

further

system

and

cleaning

(new

unnoticed

introductions

to

pitting,

sediment,

certain

waterside

doubt

be

inspected

then

placing

thereafter

during

of

inspection,

flushed

your

If

this

out

deposits

may

water

starting

after

waterside

or

and

with

no

make-up

or

of

raw

corrosion

scale,

the

no

inspections.

VESSEl

the

as

require

consultant

to

drive

otherwise

in

the

to

be

internally

be

given entering

should

period

be

given

makeup

materials advice

cleaning

system

water

placing

service,

the

being

surfaces

formation

boiler

raw

water

or

treatment.

old)

may

or

undetected

water

etc.,

that

the

inspection

pressure

later

the

boiler

as

INTERIOR

pressure

required

are

immediate

off

any

case

of

to

the the

be

of

un-

that

con-

to

the

so

that

or

of

your

should

treat-

cleaning

the

and

pressure

properly

handhole

in-

that

has

(and

water

ad-

allow

make-

and

for-

on

the

system

may

vessel

than

into

indicated

vessel

with

not

fully

or

feed-

is

of

a

water

treatment

may

be

necessary Professional cleaning

These the ment, fresh

is

inspections

feed

water

the

water considered pressure

vessel consultant should and

Boiler

the and lowering

include

water

H.

SlOWDOWN

water

concentrated

its

replacement

of

Chapter 2-The

company,

to

advice

required.

will

treatment.

water

conditions,

make-up

in

establishing

washout

or

water

periodic

re-analysis.

blowdown

water

the

concentration

and

resort

is

recommended

indicate

The

required

periods.

treatment

pressure

- STEAM BOILER

is

the

from

with

feedwater

Pressure

in

extreme

to

acid

the

effectiveness

and

the

amount

are

all

factors

frequency

The

company

vessel

removal the

inspection

of

pressure

so

in

the

boiler

Vessel

cases,

it

cleaning.

if

acid

of

treat-

of

to

be

of

future

feedwater

service

some

of

vessel

that

water

a

occurs. Solids

this processes stances mations. capable of crusting

Solids of centrate treatment solids

Scale

insulation which and

more

metal. pressure time

Scale magnesium magnesium precipitated with

3

tates as form relatively thicker mitted occur that

The requires

are

brought

water

is

designed

that

However,

of

their

high

solids

become

the

boiler

on

from

has

a low

not

only

consequently

importantly

This

vessel

and

costly

is

organic

or

"sludge"

sodium

salts

scale,

with to

accumulate,

and

bring

lowering

the

in

treated

contribute

removing

efficiency, a

will

less

water

heating

is,

therefore,

forming

heat

barrier.

results

can

result

metal

repairs.

caused

salts,

silica

salts

in

by

the

materials

in a fluid

and

but

as

pure

steam,

the

solids.

the

sludge

about

overheating

or

use

of

removal

by

the

prior

to

remove

to

none

of

all

substances

be

present

soluble

and

tend

surfaces.

required

harmful transfer

This

in

lower

higher

cause

in

damage

primarily

and

the

boiler

use

of

to

suspended

the

boiler

the

If

foaming

can

boiler

feedwater

to

use

the

scale

these

are

small

in

the

to

crystalize

Internal

scale

value

retards

operating

fuel

consumption,

overheating

tube

causing

by

oil. Any

water

sodium

maintain

form.

dirt water

remaining

this

concentration

and

cause

of

this

water

even

through

unwanted

and

deposit

in

themselves

and

regardless

amount

the

boiler

high

temperature

chemical

to

prevent

and

sludge.

and

acts

heat

efficiency

failures

boiler

calcium

are

generally

phosphate

these

The

solids

do

not

boils

priming

harmful

the

metal.

concentration

blowdown.

though

external

sub-

for-

of

en-

water.

and

con-

the

as

an

transfer,

but

of

boiler

or

other down

and

along

precipi-

such

readily

off

water

is

per-

will

deposits

as

is

2-7

Chapter

TYPES

There mittent

2-The

OF

are

two

manual

down.

14.

Manual

Manual operation

or

of

continuous The

blowdown

or

lowest lowering water, which

part

the

it

also

accumulates

Equipment valve

and a shut-off necessary the be

to a safe

properly

B.

Continuous

boiler,

piping

but

supported

Continuous

a

surface diameter removal

The on

the provided minating the other vessel

A

controlled

tinual -yet

Periodic

to

increase

blow-off

of

surface

top

with

slightly

purpose

impurities

water.

adjustments

and

center

controlled

or

accordance

The

flow

control

provided

.point

C. frr®quenc:y

When blowdown solids removes water

by

of

discharge.

continuous

is

or

sediment

along

solids. When

utilized, dissolved

surface

manual

or

sludge. In

practice,

are

opened operating From results, frequent

schedule

the

frequent

lengthy

Pressure

SlOWDOWN

principal

Vessel

types

blowdown

Slowdown

sludge

the

blowdown

boiler

tappings

of

the

dissolved

regardless

is

employed.

are

boiler

solids

removes a portion

in

the

lower

generally

consists

valve.

are

not

normally

supplied

point

Slowdown

blowdown

larger)

concentrated

by

of

discharge.

and

is

tapping

free

used

(furnished

and

water.

blow-off opening,

line

of

the

an

internal

below

the

of

skimming

from

orifice

the

valve

surface

is

- flow

are

made

decrease

with

others.

of

the

test

valve

All

Manual

the

amount

analysis.

and piping

blowdown

primarily

sludge.

The

and

used

continuous

oil from

with a prescribed

or

continuous

blowdown

suspended

the

valve(s)

periodically

solids

of

in

and/or

standpoint

short

blows.

of

blows

This

of

blowdown:

and

continuous

is

necessary

of

whether

located

so

that

in

the

pressure

part

of a quick

These

along

furnished

others.

All

Piping

to

expand.

in

conjunction

is

the

when

pressure

collecting

working

water

sediment,

surface

of

used

to

concentrated

to

the

of

piping

must

Slowdown

is

utilized,

to

remove

the

amount

blowdown

is used

in

addition

the

bottom

accordance

chemical

control,

are

preferred

is

particularly

for

at

the

bottom

in

addition

of

the

of

the

vessel.

opening

with

piping

must

on

units

continuous

furnished,

vessel

pipe

level for

the

pressure

allow

valve

setting

blowdown

are

generally

be

to a safe

manual suspended blow'down

surface

of

dissolved

is

to

control

blowdown

with

control

economy

inter-

blow-

the

or

not

to

vessel

sludge

the

with

must

be

with

60"

is

and

is

ter-

oil

or

a conwater.

in

of

the

not the

to

the

an

tests.

and

to

in-

true

when

suspended

With

the

use

of uniform is

In or densate, tly vessel. proach blowdown

concentration

maintained.

cases

where

there

blowdown

since less

When

or

exceed

to

the

is a

sludge

dissolved

required.

It

is

generally

blown

down period, and

operating

and a schedule

treating

A

hot openings down

since

need

remains

corresponding

water

meter

recommended at

but

this

company

water

for

surface

blowdowns

to

is

conditions.

should

boiler

amount

lines.

D.

Manual

Blowdown generation

water dilution tion

feedwater.

Make proper clear point

Most

Slowdown

is

of

steam

input

then

of

the

sure

blow-off piping,

operating

of

obstruction,

of

safe

discharge.

blow-off

lines

most

boiler

generally a quick

and

Two

a slow

slow

opening

opening used. Valves will volved

valves

and

are

make

installed

recommendations.

If

a quick opening normally down

opening

valve

are

opened

accomplished

valve. When

crack continue

CAUTION: first closed bodies

The

opening

it

slightly

opening

and

as

or

length

Do

pump

water

pipe

of

the

to

fittings.

each

solids

content

frequent

of

the

feedwater

high

percentage

may

be

employed

accumulates

and/or

pre-determined

lower

least

may

these

once in

vary

depending

The

be

recommended

or a water

does

not

blowdown

are

seldom

be

alert

to

system

of

raw

recommended

Procedur®

effective

is

at

the

is also low

water

and

condition

and

that

are

provided

opening

valves

vary

valve

globe

type

or

depending

or

manufacture.

tandem

follow

valve

and

in

combination,

first

and

closed

with

the

second

allow

or

the

slowly.

not

open

the

lever

action

hammer

blow

is

apt

should

of

the

water

is high.

short

blows a

pressure

is

exceptionally

vessel

of

return

more

water

pure,

con-

less frequen-

in

the

pressure

suspended

limits,

solids

manual

ap-

concentrations

that a steam

every

blowdown

boiler

eight

upon

amounts

by a

be

hour

water

consultant.

normally

and

water

for

at a time

lowest

practiced.

water

rate

include

bottom

losses

make-up.

make-up

since feed-

blow-

The

and

when

providing a minimum

with

a low

concentra-

tank

and

waste

valve

the

a globe

globe

down

lines

slow

to

if used,

discharge

is

with

nearest

downstream.

valves

upon

manufacturers'

the

last

with

or

slow

stream

to

warm

opening

valve

break

be

determined

piped

two

valves,

the

may

pressure

If

seatless

type

or

former

blowing opening

up,

open

the

are

vents

to

boiler

be

in-

slow

valve

then

valve

and

valve

is

A

in

a

is

by

2-8

actual gage as a guide not procedures viewed operator valve

Close and a fast the and

Under left the closed.

water

glass

be

interpreted

by

should

operator. the

boiler.

then

no

circumstances

open

and

blowdown

I.

Insurance periodic authorized given and

When gradually that that normally again ture leak. baking heating desirable

If

request learn conditions side

Be gaskets or operation

Have dimensions, pressure found Also previous

Be inspector

After out Remove surfaces corrosion

inspection

to

permit

preparation

shutting

avoids

can

cause

be

to

prevent

differentials

Draining

of

surfaces.

to

the

internal

of

from

surfaces.

certain

is

items

available

or

previously

have

inspections.

prepared

including

proper

the

waterside

any

and

analysis. approximately to

adequate

as a rule

should

the

downstream as

Slightly

close

prevail.

party

watch

possible.

it

tightly.

the

operator

operation

operating

crack

PERIODIC

regulations

of

inspector.

and

the

damaging

harmful

drained

deposits

dry

an

him

prior

that a supply

available needed after

generating

temperature,

available

to

cooling

scale

leakage.

Sufficient

removal

for

inspection.

down,

pressure

until

uneven

that

the

unit

that

Some

out

the

inspection

authorized

whether

to

cleaning

along

to

inspection.

information

and

any

perform

hydrostatic.

and

with a high

or

check

Lowering

1/2"

blow,

the

(slow

Then

should

is

the

is however, since

If

the

glass

opening)

close

the

downstream

a blow-off

completed

INSPECTION

or

local

laws

the

pressure

notice

of

the

boiler

the

load

should

vessel

temperature

stresses.

contraction

can

too

he

of

place

for

any

deposits

for

Vessels

all

pressure

cause

expanded

quickly

may

be

heat,

however,

interior

is

being

inspector,

desires

or

flushing

manhole

with

any

the

on

the

capacity,

time

in

repairs

reference

testing

draining

pressure

from

internal

or

water

often

acceptable

this

water

glass

valve,

and

the

never

cooled

present

of

unit

service,

required

of

analysis

cannot

another

direct

valve

leave

and

will

require

vessel by

is

generally

from

service

be

reduced

at a rate

differential

should

is

relieved

and

tempera-

tubes

may

cause

on

may

the

boiler.

made

it

is

well

to

observe

of

and

handhole

other

gaskets

back

boiler

modifications.

the

design,

operating

defects

records

vessel,

water

waterside

or

external

in

the

should

be

the

first

to

valve

be

until

valves

an

not

to the the

be

at

the

to the

water-

into

of

by

the

flush hose.

Chapter

The

fireside cleaned ends, readily

valves,

the

valves

a

fittings

Be

sure

water)

switches manhole

pressure rather safety pairs.

Clean level water cocks. Also

Check leaks, or

than

factor.

out

controls

gage

all

wear,

repair

J.

surfaces

so

that

metal

and any

checked.

that

steam

feedwater

valves

are

and

the

glass

and

water

as

valves,

to

expansion

shut

off

front

or

vessel

extension

Cleaners

low

water

and

cross

and

check

and

piping.

and

corrosion

required.

clean

PREPARATION FOR EXTENDED

2-The

should

surfaces,

blow-off

prior

to

rear

doors.

prior

to

cords

are

should

cut-off

connecting

out

clean

steam

and

piping

other

Pressure

also

be

welds,

repairs

system

tanks,

opening

preferably

water

drain

valves,

and

Adequately entry. recommended

piping,

piping.

cocks

and

damage.

Vessel

thoroughly

joints,

tube

can

(hot

all

fuel

electrical

handholes,

vent

Flashlights

as

work

the

water

Replace

and

tri-

blowdown

valves

for

Replace

be

a

in

lAY-UP

Many

boilers

for

stand-by

non-use.

-

so

that

allowed There

Your pany upon

Whichever

a ditions above

ditions. Swing

prevent tubes.

Although

tinue

fuel problems boiler

periods,

fireside point sulphur certain high be damage faces

This

are

water

can

circumstances

periodic

methods

open

to

oils,

during

humidity,

serious

during

condition

used

service

Special

neither

to

during

flow

that

and

surfaces

residue

conditions,

boiler

waterside

deteriorate

two

consultant

recommend

method recheck

lay-up

boiler

of

pollution

limit

the

care

must

that

sulphur

is

even

cooling.

the

enough

tubes

the

does

for

heating

may

attention

from

methods

or

the

in

the

is

used,

of

fireside

to

for

special

head

warm,

control

permissable

be

can

seasonally

frequent

to

condensation

This

can

form

and

corrosive

to

or

time

that a boiler

not

generally

or

seasonal

have

extended

must

be

nor

fireside

corrosion.

of

storage -wet

feedwater

better

method

particular

common

and

allow

variations

area

at

stack

moist

taken

eat

air

regulations

sulphur to

cause,

shut

shutdowns,

moisture

an

acid

especially

effect

through

other

metal

given

surfaces

treating

installation.

sense

waterside

or

job-site

end through

avoid

especially

down.

expose

below

solution.

in

areas

of

the

or

heating

is

out

occur

during

loads

or

periods

depending

of

may

content

corrosion

Dormant

and

of

to

these

are

or

dry.

com-

dictates

con-

from

the

con-

unit

boiler

con-

in

the

dew

any

Under

with

acid

will

severely

sur-

service.

nor-

of

to

of

a

2-9

Chapter 2-The

mal

firing

operation operation proper especially flue

At

the

by

removing bustion side Sweep fireside ever, flushing applying protect an

anti-corrosive

To

prevent trol

Dry will freezing

the

boiler moisture waterside deposits, eliminate

materials

vaporizes

boiler

with a hot

gases

from

start

from

surfaces.

away

surfaces

all

and

some

the

cabinet,

storage

be

out

temperatures

must

would

surfaces

soot, etc.

moisture

such

of

moisture

cleaned

condensation

is

Pressure

operation

falling

lay-up,

any

soot

the

tubes,

Brushing

or

vacuum

may

the

surfaces

form

material

keep

the

generally

of

service for

be

cause

must

by

as

quick

Vessel

since

the

any

condensation.

must

water

boiler,

below

thoroughly

or

other

tube

sheets

will

any

be

flushed

must

be

dried

of

heat.

surfaces

by

to

from

control

employed

some

may

exist.

thoroughly

corrosion.

be

Steps

placing

lime

high

temperature

be

maintained,

to

prevent

the

dew

clean

products

and

generally

accumulation.

with

water,

eliminated

by

blowing

It

is good

coating

prevent

rust.

forming

circuit

energized.

when

time

In

this

dried

because

Both

fireside

cleaned

must

of

be

moisture

(at 2 pounds

However,

point.

the

fireside

of

com-

other

fire-

suffice.

howafter

air

practice

them

with

in

the

con-

the

boiler

or

where

method

all

scale,

taken

absorbing

for 3

of

the

The

or

to

any and

to

cubic

feet

30

cubic Fireside corrosive

tories

should

All

openings

hole

and

water

and

vents

reaching

should

Wet

be

storage

stand-by

not

practical.

tures

must

taken

to

definite

that

the cleaned treated

the short

water.

unit

period

suggested

corrosion. tained Nitrogen Fireside

refractory

of

volume)

feet

of

surfaces

material

be

to

handholes

steam

should

fireside

made

is

condition

The

be

protect

or

volume)

may

or

grease

brushed

the

pressure

should

valves

be

closed

surfaces.

and

absorption

generally

or

in

possibility considered. metal

surfaces.

recommendations,

pressure

internally

should

by

Internal

at

greater

is

surfaces

should

If

of

time.

the

often

vessel

and

re-filled

deaerated

be

fired

Additional

water

than

used

must

be

wash

silica

gel

on

trays

be

coated

or

clean

vessel

be

should

to

Periodic

used

for a

cases

where

of

Care

however,

be

drained,

water

to

boil

consultant

pressure

atmospheric

to

pressurize

thoroughly

coated.

(at 5 pounds

inside

with

tar

paint.

and

wash

such

shut

tightly.

be

closed.

prevent

materials

boiler

dry

freezing

must

Variables

it

is

thoroughly

to

overflowing

is

not

the

water

chemicals

to

should

the

cleaned

for

the

vessel.

an

anti-

Refrac-

coated.

as

man-

Feed-

Damper

air

from

inspection

renewed.

held

storage

tempera-

again

be

preclude

suggested

with

available,

for a

may

be

minimize

be

main-

pressure.

vessel.

and

in

is

2-10

CHAPTER 3

SEQUENCE

A. GENERAL B. CIRCUIT AND C. SEQUENCE

Applicable With System

D. SEQUENCE

Applicable With System

IE.

FLAME LOSS SEQUENCE CIB-40

A.

GENERAl

This

chapter

the

various

ignition The

timer

the

operation

to

provide

In

the

schematic

the

boiler, power right nents are ply drawing. nected mit

Abbreviations nents outlined nations diagram.

For

supply

side

(coils,

connected

is

shown

to

the

are

an diagrams, request Cleaver-Brooks

4095.

The

burner

condition

Boiler water

pressure

limit

high

below

outlines

controls

cycle, firing

in

the

of

all

an

overall

type

the

grounded

is

shown

of

the

solenoids,

to

it.

as a vertical

All

the

it

through

component

for

listed

in

this

chapter

to

aid

in

explanatory

and

when

the

water

is

up

cut-off

control temperature limit

pressure

their

cut-off

the

electrical

through

and

shutdown.

programming

other

controls

operating

wiring

diagram.

The

inductive

switches

to

the

in

Figure

applying

booklet

control

following

to

switch.

(steam

control

setting.

diagram

(common)

as a vertical

All transformers, hot

side

line

on

components

or

function

various

also

the

on schematic wiring

system

correct

The

boiler)

(hot

or

temperature

the

control

sequence.

inductive

of

the

contacts when

electrical

3-3.

employ

text

conditions

level

operating

water

CB-20

CIB-40

Programmers

sequencing

starting

sequences

and

components

provided

side

line

lights, etc.)

the

power

left

side

required.

The

sequences

these

to

the

Bulletin

are

in

closing

or

the

operating

boiler)

control

OF

to

Flame

OF

to

Flame

cycle,

of

on

compo-

sup-

of

are

con-

that

compo-

desig-

wiring

C17-

starting

exist:

the

limit

OF

INTERLOCK

OPERATION -

Standardly

Safe

OPERATION -

Optionally

Safe

of

for the the

the

per-

low

and

are

OPERATION

CONTROLS

Oil

or

Gas

Equipped

Guard

Equipped

Guard

C131~20

All

entrance

present

fan

starter.

These

action system

rectly

lay.

tions

justing

sequences

of except

relate

Chapters 4 and 5 contain

and

the

B. CIRCUIT AND

The

burner signed alternating

The

Hz,

by

Control

terminals

programmer The

ing requirement to

trols

listed quence:

for 115

programming

however,

1.2.

controls

upon

the

boiler

provided.

below

Burner Operating

(OLC)

Boilers

and

Control

Oil

or

Gas

Boilers

and

Control

and

switches

at

the

line

terminals

do

not

the

fuel

supply

for

the

interlock

to

the

action

specific

controls.

information

CONTROlS

control

current.

circuit

Ll

the

of

switch

limit

circuit

volt,

single

control

the

timing

power

and

terminals 3 and 4 thru

used

fuel -

applicable

wiring

The

and

L2.

in

the

oil

diagram

controls

referred

(BS)

pressure

is

The

are

closed

of

attempt

system

controls

of

the

programming

operating

on

INTERlOCK

is a

two

phase,

will

also

values

limit

or

must

extended

hot

line

circuit

gas -and

regulatory

to

determine

normally

to

in

or

temperature

the

and

power

the

forced

to

correlate

or

feedwater

setting

wire

system

60

Hz

operate

be

multiplied

to

programmer

is

extended

limit

controls.

vary

the

bodies.

used

following se-

draft

the

that

di-

re-

instruc-

and

ad-

de-

(cycles),

on

50

depend-

specific

Refer

the

con-

are

control

is

to

3-1

Chapter

3-Sequence

of

Operation

PROGRAMMING SEQUENCE FOR CB20 PROGRAM RELAY

BAR INDICATES

40 50 60

PREPURGE-----------------

TERMINAL

70

80 90 1 00

IGN. PILOT

ENERGIZED

11

0

PROGRAMMING SEQUENCE FOR CB40 PROGRAM RELAY

TERMINAL ENERGIZED 0

High

limit

pressure

(HLC)

Low

water Low fire switch Auxiliary

100 Gas-oil High-low fire Damper

The

controls

are:

Blower

Combustion

*Not

cut-off (LWCO)

switches (AS-1) (AS-2)

and

200 series

selector switch (GOS) 200

positioning

used

motor

air

used on

FIGURE

SHADED BAR

1 0 20 30 40

PREPURGE----------------~

or

(LFS)

control

in

starter

proving

some

temperature

only

(HLFC)

switch

the

running

interlock

switch

100 series

(DPS)

control

series

interlock

(BMSI) (CAPS)*

INDICATES

50

FIGURE

only

circuit

3-1.

TERMINAL

60

70

IGN. PILOT

3-2.

C. SEQUENCE

Applicable CB-20 system.

This up

thru

the

action system the

action wiring this

sequence.

NOTE:

to a standardly

flame

sequence

shutdown.

of

except

of

diagram

The

legend indicates stage cycle. or

on

safeguard

covers

the

for

the

reached

The

the

ENERGIZED

80 90 1 00

OF

OPERATION -

Oil

or

G~s

equipped

and

burner

No

attempt

fuel

supply

those

programming

supplied

on

the

position

bar-graph

wiring

operation

controls

for

this

the

timer

in

the

shown

diagram,

is

system

that relay.

of

11

program

made

or

directly

Refer

boiler

in

dial

(Figure

the

timer

burner

in

indicates

0 120

boiler

control

from

start-

to

correlate

feedwater

affect

to

following

and

operating

Figure

with

the

1-3)

the

3-1,

the

3-2

sequence cal schematic timing contacts. the since by

On a combination

be

set

for

With

the

programmer operating gramming

PRE-PURGE PERIOD

Dial at Dot

When

the routed and to

4.

the

through

Relay

blower

Programmer nal

10)

to driving tion. boiler

The be timer

the

This

prior

running

completed

rotation.

Continuity this

circuit

In

the

event time,

or

if de-energized. tion

to

the

of

bulletin

wiring

sequence

The

dial

indication

the

timer

other

components

fuel

the

proper

conditions

sequence

burner

switch

the

1K

is energized.

motor

terminal

energize

damper

allows

to

ignition.

a flow

interlock

within

of

the

interlocks

which

they

allows

any

of

subsequently

The

starting

the

limit

the

to

timer

position

will recycle.

The

blower

wired

into energized should

The

combustion

ated

by

prove

the

is

not

normally

Toward is de-energized motor. back

to a dosed

fire

position.

To

assure

prior

to

closed

14.

to

The returned of

the

NOTE: A burner

motor

the

circuit

and

to

interrupt

be

de-energized for

air

pressure

presence

supplied

the

end

of

to

break

The

return

position

that

the

ignition,

the

complete

timer

will

stop

to

the

low fire

switch

proving

of

the

spring

system

an

start

various

for

this

diagram

of

the

following

and

is

interrupted

during a normal

unit,

the

fuel.

energized

satisfied,

occurs:

is

turned

controls

starter.

13 is

powered

damper

the

open

of

purging

circuit

10

seconds

listed

the

sequence

these

are

open,

will

and

starter

to

interlock

prove

the

any

switch

from

the

combustion

on

purging

the

circuit

in

and

is in low fire

low fire

switch

interlock

until

the

position

are

closed.

cannot

circuits. control

that

various

programmer

description

not

to

and

gas/oil

and

with

the

following pro-

"on", to

Power

is also

(from

motor

which

or

high

air

to

terminal

after

below

not

closed

relay

complete

the

programmer

that

the

circuit

if

reason.

(CAPS)

forced

draft

air.

a 100

series

period,

to

the

motor

the

damper

(LFS)

circuit

damper

and

the

be

made

The

techni-

contains

details

refers

the

timing,

governed

cycle.

switch

all

must

other

power

terminals

routed

termi-

begins

fire posi-

through

12

must

the

start

complete

to

continue.

at

lK

will

its

revolu-

(BMSI)

starter

the

starter

is

actu-

fan

This

switch

boiler.

terminal the

damper

brings

to

position must

to

terminal

motor

contacts

if

a

the

to

is

the

of

this

be

is is

to

13

it

low

be

has

the

Chapter

flame

relay

ter

the

first

flame

relay

the

ignition stead, tion

IGNITION PERIOD

at

Spark

ignition

5.

The

terminal

"Pilot

Dial

A.

The

nal from

terminal

and

oil

present

flame

B.

3

The

valve

bustion flame relay

The within cycle

is

Gas

Pilot

and

700

ignition

are

air,

is

2K

pilot

a 10

to

happened,

lockout

The

cause condition fore

attempting

Dial

at

A.

Spark

Terminal

(LFOV), gized from

energized

the

and

Ignited

transformer

low fire

6,

7.

With

the

detected,

Ignited

Series)

transformer

energized

ignition

established.

is

energized.

flame

second

continue.

the

system

will occur.

for loss

should

to

"Main

Burner"

Ignited 7 is

now

already

this

terminal

at

the

3-Sequence

holds

15

seconds

should

cycle

timer

will

attempt

Ignition"

Oil

Fired

solenoid

which

in

combustion

low fire

flame

Oil

or

and

from

spark

When

must

be

period

If

for

will

of

flame

be

investigated

restart.

Burner

powered.

opened,

end

of

in

for

any

of

pull

in

cannot

complete

to

recycle

Burner

is

energized

valves

this

case

air,

flame

relay

2K

Gas

Fired

the

gas

terminal

and

gas

flam~

is.

established in

order

any

reason

shut

down

or

any

and

The

will

continue

when

terminal

the

main

of

Operation

reason.

pre-purge,

for

any

reason

be

started.

its

revolu-

or

lockout.

(100

Series)

from

are

energized

is

jumpered

ignition

is

ignited.

is energized.

Burner

pilot

solenoid

5.

With

present

the

detected,

and

proven

for

the

ignition

this

has

and

other

unusual

corrected

main

fuel

to

be 6 is de-

flame

proving

If,

af-

the

In-

termi-

to

spark

When

(200

compilot

flame

not

safety

be-

valve

ener-

period.

B.

Gas

Pilot

Main

gas

solenoid

valves

terminal

After a 10 main

flame, energizing pilot

valve.

If

for

any

lit,

relay

2K

to

close.

The

control.

Refer

description

Ignited

valve(s)

7.

Main

second

power

the

The

reason

will

safety

to

of

action.

Burner

(gas fired

(oil fired

flame

trial is

removed

ignition

gas

pilot

main drop

out

switch

flame

unit)

is

ignited.

period

from

transformer

flame

does

causing

will

loss

sequence

or

the

is

energized

for

the

terminal

and

is

extinguished.

not

light

the

fuel

trip

to

low fire

proving

the

or

valve(s)

lockout

section

from

of

5 de-

gas

stay

the

for

3-3

Chapter

The condition before

With powered the burner conditions:

With position, and

With motor high

With routed makes

the

On motor intermediate ing of ing

On a motor butterfly creasing Closing fire

This stops. quired

BURNER SHI.HDOWN

Dial

The temperature With the position When following

Relay energized flame tinues purge

Power circuit the position.

At opens

3-Sequence

cause

should

attempting

the

main

(from

damper

from low fire

the

damper

the

motor

remains

the

switch

is

powered

fire position.

the

switch

through

or

breaks

load

demands.

an

oil

fired

actuates

the

size

the

motor

the

flame

gas

fired

actuates,

valve

the

of

the

rate.

is

the

Demand

by

load

at

"Post

burner

the

high-low

damper

before

the

operating

sequence

1K

drops

and

relay

to

force

period.

is

removed

to

the

low fire

the

end

of

and

for loss

motor

circuit

of

de-energizes

end

will fire

motor

2K

de-energizes

of

be

to

flame

terminal

positioning

to

in

the

directly

in

the

circuit

unit,

switches

and

high

the

fire

to

the

unit,

through

to

allow a greater

size

of

motor

of

the

firing

conditions.

Purge"

until

in excess

fire

should

the

operating

occurs:

out.

The

closes.

drops air

through

The

timer

from

damper

position

the

operating

position

high-low

the

limit

motor.

of

Operation

flame

or

investigated

restart.

established,

10)

transferring

switch

subject

switch

the

damper

·a

closed

"high"

the

fire

to

low fire the

decreases

burner

of

control

Flame

out.

if

or

position,

and

moves

"auto''

to

the

opening

which

in

solenoid

the

high

the

high

opening

linkage,

flame

starting

boiler

steam

of

demand

return

limit

control

main

is

The

the

begins

terminal

The

it

is

not

cycle,

the

blower

fire

rate.

fuel

blower

any

other

unusual

and

corrected

terminal

and

to

in

motor

low fire position.

to

position,

control

damper

of

the

turn

energize

valves

fire

rate.

fire

valve

of

the

flow

to

high

gas

flow

cycle.

continues

pressure

is

properly

to

the control is

opened

valve(s)

extinguished

boiler

rotating.

11

breaking

motor

already

terminal 8 circuit

motor.

11 power releasing

following

the

"low"

is

broken

the

damper

an

open

power

which

motor

damper

increas-

Closing

reduc-

damper

disc

in

of

gas, in-

fire

rate.

to

a low

Timer as

or

water

generated.

adjusted,

low fire

opens.

is

and

motor

in

a post-

returns

in

con-

that

The

to

or

as

the

re-

the

de-

the

to

is

timer

stops

The

control

cycling

ature control starting

and

drops

the

and

D.

SEQUENCE

Applicable the

CB-40

system.

The

CB-40

ments

Insurance Mutual other terlock

the

tioned diagram follow

This

up

the

system

the wiring this

NOTE:

On a be

With operating gramming

of

insurance

Engineering

codes.

circuits

following devices

in

Section

to

this

High

fire

switch

Low

oil

pressure

100

and

Low

gas

pressure

200

and

High

gas

pressure

200

and

sequence

thru

shutdown.

action

set

of

except

of

diagram

sequence.

The dicates stage

The

the of

the bulletin schematic timing contacts. the since by

other

combination

for

the

programmer

conditions

sequence

as

it

reaches

is now

when

to close

burner

in

steam

the

again

operating

Oil

to

an

optionally

flame

control

Association

200

700

wiring

dial

safeguard

is

This

programmer

requiring

B.

determine

sequence.

(HFS)

switch

series

switch

series

covers

No

the

fuel

for

those

the

programming

supplied

legend

on

the

position

reached

bar-graph

diagram,

various

for

wiring

sequence

The

indication

the

timer

components

fuel

proper

used

underwriters

Association

switch

in

following

satisfied,

occurs:

its

readiness

pressure

contacts

goes

cycle.

Of'

OPERATION-

or

Gas

equipped

and

to

(F.LA.)

the

in

addition

Refer

to

the

controls

(IRI)

(LOPS)

only

(LGPS)

only

(HGPS)

only

burner

attempt

the

energized

operation

supply

controls

for

this

timer

of

the

burner

shown

indicates

circuits.

this

control

diagram

of

the

and

is

interrupted

during a normal

unit,

the

fuel.

original

for

subsequent

or

water

of

the

through

program

comply

contains

use

is

system

in

various

description

with

such and (FM)

of

some

to

the

boiler

provided

made

or

that

directly

relay.

boiler

dial

(Figure

the

timer

operating

Figure

the

The

that

not

to

and

gas/oil

and

with

the

following pro-

position.

re-

temper-

operating

its

normal

boiler

with

control

require-

as

Factory

the

Factory

and

certain

several

those

from

to

feedwater

Refer

in

following

3-2,

technical

contains

details

programmer

the

switch

in-

or

all

of

men-

wiring

and

to

start-

correlate

affect

to

the

1-3) in-

and

the cycle. or

on

sequence

the

refers

to

timing,

governed

cycle.

must

all

other

a

3-4

PRE-PURGE

Dial

at Dot

When routed and to

4.

the

burner

through

Relay

blower

Programmer

nal

10)

to

energize driving tion.

boiler

The

i<:

t • .1ired,

This

prior

timer

made.

the

If

the

allows

will

timer

cycle. The

running

be

completed

timer

rotation

Continuity sequence

In

the

time,

event

or

if

of

to

they de-energized. cuit

from being

the

sequence,

timer

The

energized should

The tuated prove

Toward

fire

will

position

blower

wired

into

be

combustion

by

the

When (LOPS) fuel

so

must

supply

the

is

de-energized motor. back

The

to

a closed

position.

Existing

complete

and

the

and

de-energized

air

presence

equipped,

F.I.A.

additional

provided

through plugged the

seconds

to

IMPORT not lay

When tender

by

the

into

purging

depending

program

used, must

the

is

activated

ANT:

the

be high

PERIOD

switch

the

lK

is

energized.

motor

terminal

the

damper

a flow

to

ignition.

stop

until

proof

of

will

interlock

within

to

energize

the

interlocks

continue.

any

of

subsequently

This

will

energized,

will

the

programmer

motor

circuit

to

interrupt

air

pressure

be

closed

pressure end

of

the

to

break

return

position

requirements

pre-purge

the

programmer.

use

of a "purge

the

programmer.

period

to

upon

control

If

purge

installed.

fire

to

is

turned

limit

controls

starter.

13 is

powered

damper

to

the

open

of

purging

the

high

fire

not

stop

circuit

10

seconds

relay

listed

these

are

open,

prevent

or

de-energize

its

revolution

starter

to

prove

the

for

any

proving

from

the

of

combustion

the

low oil

to

indicate

exists.

purging

the

spring

in

and

time

beyond

be

extended

the

bulletin

the

optional

jumper

switch

provide

"on",

to

Power

motor

or

air

fire

position

but

will

(to

terminal

after

3K. below

not

relay

the

if

occurring

this

to

will

interlock

that

circuit

reason.

switch

forced

air.

pressure

period,

circuit

the

motor

the

damper

and/or

This

is

extender"

This

by

setting

for

details).

purge

provided

closes,

the

additional

power

terminals

is

also

routed

(from

termi-

which

high

begins

fire posi-

through

switch

is

(HFS)

not

continue

12)

must

the

start

allows

closed

fuel

at

3K

will be

valve

later

circuit.

the

starting

this

into

The

lockout.

(BMSI)

the

starter

if

the

starter

(CAPS)

draft

is ac-

fan

switch

that

sufficient

terminal

to

the

damper

brings

to

low

others

that

require

normally

accomplished

that

device

selected

30, 60

allows or

(refer

extender

with

the

purge

is

the

re-

its

of

the

cir-

is is

to

13

it

is

120

is

re-

ex-

Chapter

time.

The

programmer damper this

3

timer low fire

To

prior closed

14. returned of

NOTE:

timing

restarts

assure

to

The

the

motor

is

position.

that

ignition,

complete

timer

to

the

low fire

The

ignition

any

reason

the

pre-purge.

remains

completed.

and

the

will

low fire

switch

revolution

the

damper

system

low fire

an

stop

trial

the

and

interlock

3-Sequence

timer in

is

high

Upon

motor

is in low fire

switch

until

the

position

are

closed.

cannot

flame

relay

The

timer

lockout

of

stopped

fire

position

completion,

returns

(LFS)

circuit

to

damper

and

the

be

started

pulls

will

complete

at

Operation

and

the

until

the

to

the

position

must

be

terminal

motor

has

contacts

if

for

in

during

its

the

start

position.

IGNITION

Dial

A.

Spark

The nal

5. terminal 6 which nal

7. present detected,

B.

Gas

The valve tion flame relay

The within cycle happened,

lockout

The condition fore

Dial

A.

Spark

Terminal

(LFOV), gized

energized

PERIOD

at

"Pilot

Ignited

ignition

The

low fire

With

combustion

the

low fire

flame

Pilot

ignition

are

air,

pilot

to

transformer

energized

ignition

is

established.

2K

is

energized.

flame

a 10

second

continue.

the

will

cause

for loss

should

attempting

at

"Main

Ignited 7 is

already

from

this

at

and

Ignition"

Oil

Fired

transformer

solenoid

in

this

flame

relay

2K

Ignited

Oil

from

spark

When

must

period

If

for

system

occur.

of

flame

be

investigated

to

restart.

Burru~r"

Burner

now

powered.

opened,

terminal

the

end

of

Burner

is

energized

valve

case

is

air,

ignition

is

ignited.

is

energized.

or

and terminal

and

gas

flame

be

established in

order

any

will

shut

or

will

when

the

is

jumpered

Gas

Fired

the

gas

5.

present

is

detected,

for

reason

down

any

and

The

main

continue

terminal

main

from

energized

to

spark

and

When

flame

Burner

pilot

solenoid

With

combus-

the

and

proven

the

ignition

this

has

and

other

unusual

corrected

fuel

to

be

6 is de-

flame

proving

termi-

from

termi-

oil

is

pilot

flame

not

safety

be-

valve

ener-

period. B.

Gas

Pilot

Main

gas solenoid minal

F.I.A.

regulations, valves

Ignited

valve(s)

valve

(oil fired

7.

Main

with a vent

(gas

flame

or

Burner

fired

unit)

is

ignited.

others,

valve

unit) is

energized

require

between

or

two them.

the

low

from

main

As

fire ter-

gas the

3-5

Chapter

3-Sequence

of

Operation

main

gas

valves open, energized

After a main energizing lot

If

lit, to control.

description

The

condition

fore

With

powered

the

burner

conditions:

With

position,

and

With

motor

high

With

routed

makes

load

On

motor

intermediate

ing

of

ducing

On a gas

motor

butterfly

creasing

Closing

fire

BURNER SHUTDOWN

Dial

The

temperature

With

the

position When following

Relays

valve(s)

the

10 second

flame,

valve.

for

any

relay

close.

Refer

cause

attempting

the

damper

from low fire

the

motor

the

is

fire

the

through

or

demands.

an

oil fired

actuates

the

size

the

motor

the

actuates,

of

rate.

at

"Pos~

burner

the

damper

the

lK,

reason

2K

The

should

(from

damper

the

switch

powered

position.

switch

breaks

valve

the

before

is

are

normally

and

closes.

trial

power

the

The

of

for loss

main

motor

remains

of

flame

fired

the

will fire

high-low

limit

sequence

3K

de-energized

is

ignition

gas

pilot

main

will

drop

safety

to

flame

action.

of

be

to

restart.

flame

terminal

positioning

circu-it

and

motor

to

in

the

directly

in

the

unit,

switches

high

the

fire

de-energizes

to

unit,

through

to

allow a greater

size

of

motor

Purge"

in

excess

fire

should

the

control

and

simultaneously

removed

switch

investigated

the

high-low

circuit

the

until

operating

occurs:

4K

open

out

flame

position

the

a closed

"high"

the

fire

to

the

decreases

vent

period

transformer

flame

does

causing

will

loss

sequence

or

established,

10)

transferring

switch

subject

switch

damper

position,

and

moves

"auto"

to

the

opening

which

solenoid

the

high

the

low fire

opening

linkage,

flame

steam

of

demand

control

return

limit

circuit

drop and

closes.

energized

valve

for

the

from

terminal

and

is

extinguished.

not the

fuel

trip

to

any

other

and

corrected

terminal

and

in

mqtor

or

low fire

to

position,

fire

control

damper

of

in

turn

valves

fire

rate.

high

fire

rate.

of

the

flow

to

high

gas

flow

pressure

is

properly

to

control

is

opened,

out.

The

Flame

is

proving

the

gas

light

or

valve(s)

lockout

section

unusual

power

releasing

to

following

the

"low"

is

broken

position.

the

damper

an

open

power

which

motor

the

damper

energize

increas-

Closing

valves

the

damper

disc

in

of

gas, in-

fire

to

a low

or

water

generated.

adjusted,

the

low fire

opens.

main

is ex-

and

also

of

5 de-

pi-

stay

the

for

be-

11

to

or

as

the

re-

the

rate.

the

fuel

is

tinguished blower boiler rotating.

Power circuit the

low fire

position.

At

the

opens

timer The

control

cycling

perature ting

control

mal

starting

The

CB-20 matically after a power safety pilot, out

will also

condition

Both

the

pre-ignition CB-20 the

shutdown

CB-40

condition

The

lockout

ing a

necessary

pressed

The

cause tion attempting

A. No

The

pilot a 10 second terminals 5 and 6 energized. by

the

within

7) will not

be

ately The

timer Approximately is

interrupted, Master light

and

flame

motor

in a post-purge

is

to

end

and

stops

and

E.

shutdown

or

controls

control

safety

should

pilot

pull-in

this

not

energized.

de-energized

blower

will

relay

and

continues

removed

the

damper

position

of

the

operating

de-energizes

as

it

is

now

when

drops

to close

the

burner

and

flAME

and

CB-40

each

time

failure.

the

main

occur

occurs

will

or

will recycle

situation

will

affecting fuel

switch

shutdown. A short

before

and

operation

for loss

be

investigated

to

restart.

flame.

flame

must

period

of

period,

be

powered

motor

stop

after a short

30

the

lK

is

the

alarm

relay

to

period.

from

terminal

motor.

if

it

the

reaches

in

steam

operating

its

readiness

pressure

the

again

lOSS

programmers

the

operating

Both

will

caused

flame,

during

the

of

after

relay

The

seconds

by

or

if

flame

the

prevent

air

flow

in

(if

it

lockout

or

air

must

be

switch

resumed.

flame

be

ignited

the

2K.

the

fuel

and

ignition

and

the

will

continue

after

lockout

de-energized.

bell

(optional)

2K

drops

force

air

The

11

The

motor

is

not

already

cycle,

terminal 8 circuit

blower

original

for

contacts

goes

cycle.

out.

through

timer

breaking

returns

motor.

position.

subsequent or

water

of

the

through

SEQUENCE

recycle

control

lockout

failure

by loss

or

flame

pre-purge

start-up

interlocks an

attempt

is self-correcting).

upon

supervisory

manually

cool

button

or

any

and

corrected

and

ignition

The

flame

If

2K

is

valve

circuit

the

fuel

circuit

pilot

valve to

period

the

switch

The

following a

to

ignite

of

flame.

simulating period.

or

ignition open.

to

any

abnormal

reset

down

can

unusual

proven

cycle

not

energized

valve(s)

is -immedi-

closed. -

operate.

of

operation. ignition (LS)

flame

are

energized.

closes

controls.

period

begins-

is

(terminal

will

The

the

begins

the

to

in

that

The

re-

tem-

opera-

its

nor-

auto-

or

the

Lock-

The

correct

The

follow-

be

de-

condi-

before

within

proven

will

The

circuit

trip.

failure

if

is

3-6

The

timer

resumes

cator

reaches

and

blower

out

switch

tion

can

be

18.

Pilot

but

If

the

pilot

cuit

is

energized

will

be

extinguished detecting drop circuit blower

The seconds The are

The

cator and out

switch

can

C. Loss

If

a

and/or

tector, conds

circuit

out

the

is

de-energized

motor

lockout

later

flame

energized.

timer

resumes

reaches

blower

must

be

resumed.

of

flame

outage

the

to

de-energize off fuel flow. tion.

Approximately switch The are

The cator and out can

If

out, manual ferred that

the can

manual and easier or

the to viates

sibly often

will

flame

energized.

timer

resumes

reaches

blower

switch

the

be

resumed.

burner

the

trouble

must

and

to

for

may

not

programmer

be

obtained

and

its

controls

in

the

delays

actual

can

operation

determine

from

eliminate

one

that

Remember most

part

it refuses any

of

to

the

operate.

the

motor

must

resumed.

no

flame

continues

switch

and

failure

the

motor

be

flame.

flame

The

trip

failure

the

motor

be

will

shooting

the

assistance

be

readily

and

this

bulletin.

will

event

be

prevented

the

normaL

overlooking

is

that

this

is

doing

safety

operation.

start

will

be

manually

(Refer

main

flame.

is

proven,

from

terminal

10

will

break

relay

to

will

relay

light

operation.

start

will

be

manually

(Refer

occurs is no

relay

the

blower

30

to

de-energize

light

operation.

start

will

be

manually

(Refer

not

start,

When

or

dot

position

be

de-energized.

re-set

to

the

main

seconds

within 4 seconds

2K.

The

stop

the

to

run.

trip

lK

will

and

alarm

When

or

dot

position

de-energized.

reset

to

caution

during

longer 2K fuel

sensed

will

valve

motor

seconds

and

alarm

When

or

dot

position

de-energized.

reset

to

caution

or

upon a safety

section

technical

bulletin

in

pinpointing

apparent.

other

controls

by

studying

the

Knowledge

make

troubleshooting

it

is necessary.

by

systematic

against

stage

at

the

which

Following a routine

an

obvious

relatively

is a

its

Never

safety

job

attempt

simple

device

when

features.

the

dial the The

before

caution

fuel

7.

The

later.

main

flow

valve

pilot

The

fuel

of

fuel.

opera-

above.)

approximately

be

de-energized.

bell

(optional)

the

dial the

The

before

operation

above.)

normal

trip

continues

later

master

by

within

circuit

the

bell

the

operation

the

and

opera-

lockout

relay

(optional)

dial

the The

before

operation

above.)

in

the

operating

should

be

problems

Familiarity

in

the

system

contents

of

the

of

system

much

Costly

down

checks

normal

sequence

performance

may

condition,

to

correct.

and

for

it

shuts

down

to

circumvent

indi-

timer

lock-

cirflame flame

to

valve

The

30

indi-

timer

lock-

de-

4 se-

shut

lK.

indi-

timer

lock-

re-

with

the

time

of

de-

pos-

the

or

Preventive of

all

components checking will

occur

either

pilot

Chapter

maintenance

of

the

relay under or

main

3-Sequence

should

to

conditions

flame,

recommended.

AB

AS-I, 2 ALWCO AUXILIARY LOW AR ALARM RELAY

BM BMF BMS BMSI BS

CAPS COMBUSTION CCF-P CONTROL CCT CONTROL CR-I

DISC DISCONNECT DM DMT DNS DAY-NIGHT DPS

FD FFL FVL

GOS GAS-OIL GPV GAS

HFS HFOV-I, 2 HLC HLFC HGPS

IT LOPS LOW

LDL LOAD LFOV LOW LFS LWCO LWL

LGPS

MGVAS MGVV

OLC OL'S

osov

PT

ALARM AUXILIARY

BLOWER BLOWER BLOWER BLOWER BURNER

CONTfWL

DAMPER

FLAME FLAME FUEL

HIGH HIGH HIGH HIGH-LOW HIGH

IGNITION

LOW LOW LOW LOW GAS

MAIN MAIN MAIN

OPERATING OVER OIL

PURGE

BELL

SWITCH-I,

MOTOR MOTOR MOTOR MOTOR

SWITCH

CIRCUIT CIRCUIT RELAY-I

MOTOR MOTOR

SWITCH

POSITIONING

DETECTOR FAILURE

VALVE

SWITCH

PILOT

VALVE

FIRE

SWITCH

FIRE

OIL

LIMIT

CONTROL

FIRE

GAS

PRESSURE

TRANSFORMER

OIL

PRESSURE

DEMAND

FIRE

OIL VALVE

FIRE

SWITCH WATER WATER

PRESSURE

GAS VALVE MGV GAS VALVE AUXILIARY GAS V:ENT VALVE

LIMIT

LOADS

SHUT-OFF

TIMER

FIGURE

MNEMONIC

DESIGNATION

ELECTRICAL

and

scheduled

be

followed.

see

that a safety

of

failure

or

from loss

WATER

FUSES STARTER STARTER

AIR

PROVING

FUSE-PRIMARY TRANSFORMER

TRANSFORMER

LIGHT

VALVE-I, 2

CONTROL

SWITCH

LIGHT

CUT-OFF

LIGHT

SWITCH

CONTROL

VALVE

3-3.

DEVICES

of

2

CUT-OFF

INTERLOCK

SWITCH

OF

Operation

inspection

Periodic

lockout

to

ignite

flame

is

SWITCH

3-7

CHAPTER 4

S

AR

A.

GENERAl

INITIAl START -UP

The

instructions

plete

installation trical, completed.

The with quickly mentioned call-out

1.

Chapter 5 contains should wiring

Verify blown dropped-out ters Check reset at

The proper perature.

available entire Chapter

On a steam column test burner

CAUTION:

fuel,

operator

the

locate

photographs

be reviewed

diagram

supply

fuses

and

the

if

necessary.

the

black

boiler

operating

system

2 for

to

valve

is

burner,

controls

and

open

in

has

water

should

and

in

the

should

of

fuel

or

fusetrons,

overloads

lockout

dot.

should

level

Make

vent

operating.

sure

used.

should

water

boiler,

air

until

Prior charge valves blowdown

I G

A.

GENERAL START-UP

13.

CONTROL

C.

OIL

BURNER START-UP

(100 and 200 SERIES)

!J.

GAS {200 and 700 SERIES) NORMAL

E.

PREPARATION FOR

this

chapter

been

and

vent

have

boiler

The

and

identify

following

and

the

adjustment

prior

also

and

proper

etc.

having

switch

open

displaced

to

on

timer

be

fined

using

that

In a heating

be

filled

requirements.

the

escape

firing

piping

and

discharge

or

(All

made

stack

familiarized

the

paragraphs

to

have

open

Check

manual

the

dial

water

treated

and

test

during

of

make from

drain

FUElS)

assume

and

that

connections

all

components.

various

contents

procedures

actual

been

voltage.

circuit

reset

reset programmer setting

with

water

of

ambient

feedwater

application

vented.

valve

on

filling.

steam

is

certain

safety

piping

valves

PERATI

PREPARATIONS FOR INITIAL

(All

FUELS)

SETTINGS

BURNER START-UP

OPERATION

that

com-

all

elec-

are

himself

To controls refer

to

of

Chapter

and

this

firing.

of

noted

is

The

studied. Check

should

the

for

breakers,

all

star-

features.

and

to

the

tem-

the Refer

water

Leave

after

the

dis-

or

relief

from

all

piped

be

is

to

(ALL

Inspect the gas

Check for momentarily counterclockwise

Before all positioned.

For spection completed that

B.

Inspect ting. be pressure, safety

water highest

limits Inspect

a proximately pressure tweeD setting. may but boiler

G I

FUELS)

{All

FUELS)

all

damper

fired

operating

valves

safety's

especially

might

CONTROl

the

The

pressure

set

slightly

valve(s).

boiler

desired

of

the

high

pressure

control

operating

The

be 2 or 3 lbs.

must

the

ST

a

safe

point emission possibly damage

linkage

and

burners.

proper

closing

in

sake

piping

present a hazard.

operating

but

10%

should

the

pressure

high

10 lbs.

setting

not

exceed

temperature

of

cause

to

for full

also

of

rotation

the

when

viewed

boiler

feed

the

line

make a final

checking for

or

wiring

SETTINGS

limit control above

lower

The

temperature

be

water

temperature

vessel.

limit

control

steam

boiler

above

setting,

limit

on

above

valve

pressure

a low

control

hot

property.

UCTIO

of

discharge

water

or

injury

and

the

butterfly

motor

are

or

control

on a steam

highest

than

set

if

feasible,

the

setting.

to

free

of

blower

starter.

from

pump,

if used,

opened

pre-start-up

any

(All

desired

the

control

slightly

for

proper

this

should

the

operating

and

pressure

operating

On a hot

should

so

steam

personnel

movement

gas

valve

motor

Rotation

front

of

or

properly

loose

other

situation

FUElS)

for

proper

boiler

setting

on a hot

above

and

within

setting.

be

or

midway safety steam

limit

be 5 to

s

that

cannot

on

boiler.

be

sure

in-

or

in-

set-

should

steam

of

the

the the

On

set

ap-

limit

be-

valve

boiler

setting

water

10°

or

of

by

is

4-1

Chapter

4-Starting

and

Operating

Instructions

above

the

operating

ting. Inspect

ting operating

Adjustment covered

Inspect float

the

which

in

the

and

high-low

should

limit

procedures

Chapter low

verify

properly. In

the

event

the control settings required tive

Set burner trance

devices

are

see

or

contact

damper

switch

switches

C.

not

correct.

your

positioning

"off'

Oil

(100 and 200 Series)

PREPARATION Verify place.

(Figure

On a 200 series

switch

pilot

Open

return

pump

may

lines

filled

Manually

the

flow

dicates a steady

proximately).

ter

that

Temporarily

1-1).

to

gas

all

line.

should

be filled by use

and

by

oil

pump

may

a few suction flow is

A

line.

established.

vacuum installed tightness served Chapter

and

5 for

system. Check

"low". motor on trol

The allow

that

Turn

will

the

gauge.

will begin damper

a flow

the

"Oil".

cock.

valves

The

be filled

those

priming

hold

picks

be

verified

If

moments

Continue

(or

compound

in

the

of

the

recorded

further

damper

burner

start

The

will

of

limit

temperature

be

slightly

flame

control

lower

for

than

control.

for

these

5.

water

cut-off. Check for

that

boiler

is

listed

here,

If

additional

local

Cleaver-Brooks

control

equipped

is

with

ascertain

information

Cleaver-Brooks.

but

(supplied

switch

close

by

at

all

other

others).

"low".

BURNER START -UP

FOR

driving

close

boiler,

Close

in

the

line

from

with

of

large

or

other

in

the

up

when

pressure

no

pressure

stop

oil

suction

system.

for

information

positioning switch

and

oil

timer

rotating.

open

air

through

INITIAL

belt

the

set

main

oil

the

fuel.

the

fuel

diamet-er

blower

and

reading

the

this

procedure

pressure

Its

readings

future

pressure

in

for

the

FIRING

for

the oil

the

gas/oil

gas

cock

suction

storage

Short

pump.

pipe

means.

motor

circulates

the

pressure

of

·shows

on

pump

-vacuum)

line

will

guidance.

on

switch is

to

"on".

will

the

programming

pre-purge

the

fireside

oil

shut-off

and

should

the

control

proper

that

of

set-

the

controls

freedom

functioning

optional

that

their

representa-

Leave

power

pump

en-

is in

valve

selector

and

open

line

and

tank

to

the

suction

Long

lines

suction

should

starter

oil.

until

The

gauge

175 psi (ap-

the

gauge

prime

until

the

gauge

reveal

be

the

ob-

Refer

oil

piping

set

The

blower

be

indicated

con-

period area

of

and

the

is

of

is

oil

be

oil

in-

af-

oil

to

at

pressure the pleted. tion

vessel.

low fire

The

to

continue.

position

low fire switch

Now check for

ignition" ignition

should

door

flame The

off

valve

With proper

Turn

complete in

the

burner Review

3 for a takes

INITIAL Set manual switch will

In

some ped completely may several ignition successful burner

On running vapors a few

CAUTION:

legend

transformer

be

visible

sight

glass.

can

be

main

burner

is closed.

evidence

oil

pressure,

burner

its

event

switch

cycle

programmer

switch

the

sequence

complete

place

during a starting

START-UP

damper

position

fuel oil

"on".

After

light

and

instances

in

the

fuel

expelled

be

possible

cycles

does

lighting

and

pilot

an

ignition

to

purge

before stopping. After

moments

The signed

of ignition attempt

that

When

fire

position boiler mal

operating

hot

A system up

period. content prior

As

normal

at

low fire,

"high".

flame

is

water

to

is

for

properly

boiler

water

through

If

of

the

increasing

pressure

turn

Observe

The

damper

after

ignition

appears

is energized. An

when

viewed

If

the

unit

seen.

will

not

of

a good

the

unit

to

"off'.

and

stop.

being

turned

of

operation

description

AND

switch

valve

(Figure

the

pre-purge

operate

lines

at

on

initial

preventing

and

for

the

until

all

lines

not

then

occur, do

attempts

adjustments.

failure

before

burner

fan

the

boiler

re-setting

and

to

provide a pre-purge

operation

spark to

alter

might

circumvent

established

approximately

warmed,

pressure

or

must

have a continuous

the

conditions

system

the

and

fuel

input.

or

temperature

damper

burner

motor

this

pre-purge

must

be closed for ac-

spark.

on

When

the

through

has a gas

light

since

spark

(or

is

ready

The

programmer

Reset

locked

off.

of

and

FIRING

to

"low".

1-1).

period

its

low fire

firing,

ignition

replaced

burner

are

filled

without

blower

of

any

ignition

control

prior

and

pilot

the

system

leave

the

30

unless

it

temperature

vessel

permit,

boiler

during

the must

positioning

as

it

progresses

will

return

the

timer

electric

the

gas

pilot)

to

the

safety

out

prior

given in

the

action

operating

Open

Turn

the

rate.

air

may

until

by

fuel oil.

to

go

with

not

repeat

re-checking

will

unburned

failure

safety

switch.

system is de-

to

establishing

flame.

in

this

feature.

burner

minutes

reaches

sooner.

the

entire

be

is

approached

switch

to

is com-

"pilot

dial,

the

spark

the

rear

pilot,

its

oil

shut-

and

be

fired.

will

switch

to

the

Chapter

that

cycle.

the burner burner

be

trap-

it

through

oil.

un-

continue

fuel

wait

period

Do

not

any

way

in

low

or

until

its

nor-

flow

warm-

water

warmed

to

high

is

It If

of

4-2

Chapter

4-Starting

and

Operating

Instructions

fire position. the

high operate these

lines

flow

through

cause

the

low fire flame.

the

After analysis fuel flow Refer

to properly necessary mum desired

Refer

to

operating CAUTION:

D.

There

fire oil lines

the

burner

become filled

the

increased

unit

is

test

should

and/or

adjustment

perform

that

burner

rate

sufficiently long

results.

Section E of

and

shutdown

It

is

off

ol"

GAS

possibly

and

for

several

high

combustion

thoroughly

be

made

air

flow

procedures

this

be

this

advisable

fuel

BURNER STARTsUP

(200 and 700 Series)

PREPARATION Close

main On a 200 series boiler,

switch gested periods

Check

to connections was see

Verify new should system unless

Determine entrance stalling a gas to rates.

Check "low". motor timer

The allow pressure the completed. action

Now check for the

to

"gas".

that

of

extended

the

linkage

insure

Chapter

that

set

at

the

Chapter

the

presence

installation, a representative

be

present

to

supervise

this

that

to

5 for

that

Turn

will

will begin

damper

a flow

vessel.

low fire

The

to

continue.

legend

gas

cock

Although

oil

pump

it

has

and

set

factory

5.

has

already

sufficient

the

gas

pressure

information

damper

burner

start

rotating.

will

open

of

air

The

position

low fire

ignition

"pilot

FOR

and

gas

attached

free

screws

but

and

when

purging

train.

test

positioning switch

and

for

through

damper after

spark

ignition"

may

be

air

it

may

be

necessary

cycles

to

assure

with

oiL

Failure

fire nozzles

warmed a combustion

with

regulated

test

and

allowed

chapter

sequences.

to

valves.

INITIAL

open

set not

belt

firing.

to

movement

are

if

adjustment

availability

gas

is first

been

gas

pressure

This

gauge

on

to

the

programming

the

pre-purge

the

this

switch

appears

promptly

air

to

instruments

as

in

Chapter

adjustment

to

fire

enough

for

normal

check for

Review

FIRING

pilot

gas

the

gas-oil mandatory, be

removed

the

butterfly

and

tight.

The

of

the

turned

of

the

new

done.

exists

can

be

noted

in

the

pressures

switch

"on".

fireside

motor

pre-purge

must

and

will

gas

The

be

pilot.

in

to

trapped

that

of

oil

may

extinguish

and

required.

5.

To

it

at

maxi-

achieve

firing

tight

shut-

Chapter

cock.

selector

it

is sug-

during

valve

that

all

linkage

is

required

gas. On a

gas

utility

into

the

gas

line

at

the

by

in-

line.

Refer

and

flow

is

set

blower

control

period area

and

of

the

return

period

closed for

When

the

timer

in to

to

is

5.

to

is

dial,

the

ignition

are

energized.

through

The shut-off cates valve phragm that open ing diaphragm the shows when yellow showing valve

As ner Check

With gas switch the

Review ter takes

INITIAL

Set burner

cates cock. present

switch

its

necessary

On running vapors

a few

CAUTION:

When

extinguished

Burner

or

downstream

to

spin

and

the

burner.

provided

the

sight

main

burner

cock is closed.

"main

opens

it

since normal

flag

soon

switch

evidence

valve,

burner

3 for a

place

damper

Main

normal

an

two

burn

down,

close

cause

burner"

when

valve,

is energized.

there

valve

in

the

black

when

opened.

is closed. ·

as

valve off

to

see

unit

in

the

event

switch

of

the

complete

during a starting

START-UP

positioning

switch

"main

"off'

moments

main

burner",

flame

in

the

and

shutdown

to

"bleed"

ignition

to

purge

before stopping. After

The signed

of ignition attempt that

flame

promptly

will

normally

after

shutdown

of

for a

longer

immediately main of

valve

The

nothing

transformer

The

gas

glass

will

determine

energized.

the

click

The

is no

operation

may

window

the

In

the

on

the

action

and

let

that

the

of

a good

is

ready

programmer

being

sequence

description

"on"

and

should

line.

In

allow

cycle.

failure,

the

burner

before

burner

to

fan

operation

spark to

might

is

established

continue

the

cut-off

period,

gas

cock.

leakage

main

gas

prevents

and

gas

pilot

flame

may

be viewed

on

the

rear

door.

not

light

since

the

When

of

gas

be

valve

case

programmer

gas

to

turned

of

AND

slowly

this

programmer

air

resetting

provide a pre-purge

alter

when

the

that

In

the

its

solenoid

valve

will

pressure

the

position

determined

on

top

of

the

is closed

of a motorized

stem

indicates

is

confirmed,

valve

pilot

and

be fired.

locked

off.

operation

of

and

FIRING

switch

Circumvent

due

to

when

the

open

ignite

event,

Several

from

the

blower

of

any

ignition

and

control

prior

and

pilot

the

burner

to

the

valve.

or

during

turn

burner

Investigate

before

valve

tight

"low".

unless

the

system

observe

burn

If

is

timer

dial

the

case

will not

available.

by

observing

valve

and

turn

finish

has

closed.

operating

Reset

out

given

the

action

operating

timer

the

there

turn

the

to

run

efforts

line.

will

unburned

failure

safety

system

to

establishing

flame.

in

this

is

shut

for a

gas

remaining

flame

blower

switch

and

re-lighting

tight

closure.

valve

main

gas

indi-

main

gas

of a dia-

indicate actually

Dur-

of

the

which

yellow

valve,

that

the

bur-

its

cycle.

main

the

safety

prior

in

Chap-

that

cycle.

Turn

the

dial

indi-

main

gas

is

air

burner

through

may

be

continue

fuel

wait

switch.

is

de-

period

Do

not

any

way

feature.

that

it

down.

second

continues

motor

"off'

correct

the

seating

Foreign

to

is

4-3

Chapter

4-Starting

and

Operating

Instructions

material

renovated in

cleaning,

strainer.

When

flame

fire

position

boiler

is

properly

mal

operating

A

hot

water system up content prior

After ed

to

"high''

valve the

ondary

the fire, a

instruments,

lated cedures

analysis

be ently

The regulator from vice. require ing.

Refer ing

E.

START-UP Check Check

reset Programmer

water

period.

of

to

increasing

normal

at

low fire,

"high''.

fire

movement

air

damper,

air

unit

is

combustion

as

required. in and

allowed

long

main

have a vent

obstructions

Local

discharge

Make

to

Section E of

operating

NORMAl

water

setting

and

may

be

gas

lines

purging

is

established

for

approximately

warmed,

pressure

boiler

If

the

Observe

position.

may

thoroughly

Chapter

to

enough

gas

codes

sure

must

through

conditions

system

pressure

turn

is

it

extinguish

analysis

and

fuel flow

adjustment

fire

at

to

pressure

for

or

piping

that

and

shutdown

OPERATION-All

level

and

of

all

lockout

timer

mechanisms.

dial

present

unless

and

the

and

fuel

or

the

In

the

not

is

possible

warmed

Refer

5.

maximum

achieve

regulator

opening

proper

insurance

this

operating

should

in

adequate

providing a suitable

leave

unless

or

temperature

have a continuous

vessel

permit,

boiler

input.

temperature

damper

burner

event

properly

that

the

low fire

and should and/or

to

the

To

properly

it

is

necessary

desired

which

operation

to

the

outside

piping chapter

information.

supply.

controls.

be

either

care

the

burner

30

minutes

it

reaches

sooner.

during

positioning

as

coordinated

and

requirements

is

the

entire

must

be

is

approach-

it

progresses

the

butterfly

increased

flame.

running

be

made,

air

flow

adjustment

perform

that

rate

and

results.

the

pilot

must

of

the

not

obstructed.

for

normal

fUElS

Check

at

the

black

new

or

is

taken

in

low

or

until

its

nor-

flow

warm-

water

warmed

switch

to

gas

with

sec-

After

in

high

with

regu-

pro-

this burner suffici-

gas

be

free

the

de-

may

build-

start-

all

dot.

of

On a combination selector fuel.

Turn burner

Allow warmed fire.

OPERATING Normal

tioning of

With on a high-low mands.

The ating reached,

a. b.

c. d.

NOTE:

SHUTDOWN

When control increase,

following The

guished.

blower

through

At de-energized. position

Refer

Unit

switch

the

and

boiler

up

operation

switch

the

high-low fire

the

switch

burner

limit

unless: Burner Low

water

level

control.

Current

Pressure

mum

level.

There such

tripped

or

the

opens

or

sequence

fuel

valve

The

motor the

the

end

and

to

Chapter

is

ready

should

burner

controls

to

before

set

firing

will

continue

pressure

is

manually

condition

or

fuel

of

combustion

can

as

through

operating·

due

if

the

timer

continues

furnace

of

the

The

stops.

to

fuel

unit

be

switch

to

assure

run

at

allowing

should

at

"auto"

control.

set

at

"auto",

basis

or

supply

be

other

motor

circuit

is

breakers,

interlock

limit

to

pressure

burner

occurs:

de-energized

resumes

during

post

purge

timer

has

3 for

timing

re-start.

(Series

set

for

"on".

to

turned

is

overload,

switch

Observe

proper

low fire

burner

be

with and

burner

according

operate

temperature

detected

is

interrupted.

air

drops

reasons

devices

pressure

or

water

is

operation

running

the

post

the

returned

sequence.

the

until

to

the

under

to

until

"off'.

for

flame

blown

in

or

turned

and

blower

200)

damper

by

to purge

to

the

fuel

appropriate

action

functioning.

properly

go

to

high

posi-

the

control

will

operate

the

load

de-

the

oper-

setting

low

water

below

temperature temperature

flame

mini-

shutdowns

outages,

fusetrons

the

system.

"off',

extin-

and

force

period.

motor

its

original

the

of

is

air

is

4-4

CHAPTER

5

J s

A..

B. PERIODIC INSPECTION C. WATER D. WATER E. OPERATING

F.

G.

H.

t AIR DAMPER ADJUSTMENT

J.

K. MOTORIZED

l.

M. N. DOOR

0. P. FIRESIDE

Q.

N

GENERAl

lEVEl

GAGE

Setting Pressure Temperature Combustion

low High Programming Control Oil Burner Oil Combustion GAS Gas

Gas

Combustion

SWITCH AND CAM ADJUSTMENT

SAFETY SOlENOID

REFRACTORY FORCED DRAFT FAN UJBRICATION

and

Controls

Gas

Operational

BURNER

Nozzles

Pump

BURNER

Pilot

Pressure and

VAlVES

ClOSING

CONTROlS

GlASS

CONTROlS

Adjusting

- Steam

Controls -Hot

Air

Proving

Pressure

Adjustment

VAlVES

ClEANING

Control

GAS

AND

Switch

lest

Flow

VAlVE

Switch

SEAliNG

I

Boiler

Water

TE

Boiler

CE

While before tions used further maximum to inspection ing bolts mis-adjustments stallation.

A well necessary

each

boiler

shipment

such

as

and

operating

adjustment

operating

placing

the

boiler

should

piping, wiring,

and

setscrews

planned

down

A.

GENERAl

is

tested

from

the

burning

occurred

maintenance

time

characteristics load after

efficiency

into

be

made

and

aU

to be

or

for

factory,

conditions

installation

and

initial

service, a

of

all

fastenings

sure

that

during

program

costly

correct

controls, connect-

shipment

repairs,

operation

variable

of

the

may

to

economy.

complete

such

as

no

damage

avoids

promotes

condi-

fuel

require

assure

Prior

nuts,

and

in-

un-

or

safety

and

aids inspection should boiler

daily, activities.

in

obtaining

Cleaver-Brooks

Even ical matic systematic

matic" responsibility, tive

chores,

and

schedule

be

established.

room

log

weekly

though

devices

maintenance.

and

This

economies

the

that

in

operation,

and

features

providing

boiler

code

and

local

with a listing

It

is

recommended

or

record

monthly

provides a valuable

equipment.

boiler

make

periodic

do

but

rather

be

and

has

it

automatic

these

maintenance.

not

relieve

free

him

time

maintained,

yearly

length

electrical

him

to

inspectors. of

guide

of

or

devices

the

operator

of

certain

devote

An

procedures

that

recording

maintenance

and

aids

service from

and

mechan-

semi-auto-

require

Any

"auto-

from

repeti-

to

upkeep

5-l

a

Chapter

Good

appearing

authorized operate, equipment.

all

operation

Alertness

proper

operator

mitting

extensive

steam,

soon

well tive checking

screws,

The this efficiency changes. time burner. A combustion

adjust

and

5-Adjustment

housekeeping

personnel

adjust

The

material

of

in

gauge

aware

prompt

repairs

water

as

they

as

hazardous.

maintenance

the

packing

air-fuel

will

alert

which

Variations

to

another

fuel

input

economy.

boiler

or

repair

boiler

and

equipment

the

boiler

recognizing

reading,

of a developing

corrective

or

fuel

are

noticed.

Include

tightness

glands,

ratio

should

the

operator do

may

for

B. PERIODIC

Insurance

periodic

authorized Chapter 2 contains

spection. Inspections

necessarily,

down spection tenance,

be

done basis thly

or

While waterside vessel, tunity the

boiler refractory, painting pendable care replacements possible, shutdown.

Replacement ordered

Cleaver-Brooks

and

built

regulations

inspection

inspector.

information

of

this

scheduled

time

such

as

can

often

be

replacements

at

other

times.

for

establishing a schedule

other

periodic

this

inspection

and

fireside

it

provides

for

detailed including

or

items

of

during

be

sufficiently

to

the

inspection

piping,

etc.

Comprehensive

repainting

should this

that

may

coordinated

spare

parts,

boilers

give

long

and

Maintenance

helps

maintain a professional

room.

unexpected

leaks

measures

of

not

in

require

maximum

Only

should

the

boiler

room

should

not

or

heating

an

unusual

leaks,

fuel

analyzer

etc.,

action

hsould

Leaks

in

the

such

connections,

etc.

be

checked

to

losses

produce

composition

re-adjustment

operating

be

and

necessary

malfunction

that

down

be

are

program,

should

INSPECTiON

or

local

laws

of

the

pressure

relative

type

are

usually,

for

periods

an

off

season.

used

or

repairs

This

maintenance

pertains

surfaces

operator

valves,

and

be

planned

time.

be

required

with

if

prior

to

are

life

and

to

accomplish

that

also

serves

for

primarily

an

of

all

the

replacement

Any

major

this

not

on

shutdown.

designed,

excellent

of

This

of excellent

components

pumps,

cleaning,

should

period

hand,

trained

permitted

its

be

kept

system.

noise,

can

make

may

prevent

time.

repaired

wasteful

preven-

as

regularly

locknuts,

often

in

combustion

visible

from

be

efficiency

require

vessel

to

though

normal

major

cannot

as a good

annual,

programs.

the

pressure

gaskets,

for

and

repairs

of

should

engineered

service

and

to

the

im-

the

per-

Any

set-

since

flame

one

of

the

used

by

an

this

in-

not

boiler

in-

main-

easily

mon-

to

the

oppor-

spot

of

ex-

taken

or

also,

boiler

be

on

to

of

as as

to

a

of

if

the

job.

Good scientious ficiency contribute

maintenance

and

economy

to

long

C. WATER

WATERSIDE

The

need

to

periodically

and

the

waterside

over-emphasized.

damag~

or water.

Always column samples cordance

water Chapter inspection

A water mercury burner low other to tain

Usually, and level control ism can

Since the made low out. operation established repair

Figure plate structions schedule. long testing will

The ping ner attendance rate. the THE replace

are

the

use

of

be

sure

should

of

boiler

with

consultant.

2 for

blowdown

procedures.

typical

energize a water

burner

column.

switches.

limit

water

switch

water

the

will

remake

is

restored. be

that

must

be

restarted.

low

water

original

to

adjust

water

If

a

low

or

replace

5-l

attached

periods

on

continue controls'

the

water

is

operating

If

a

control

BURNER

the

water

circuit

condition

is

at

the

control

equipped

be

manufacturer,

cut-off

water

or

if

levels,

is a

should

These

of

the

indefinitely.

operation

allow

at

the

control

operating

and

from

years

of

lEVEl

OF

PRESSURE

check

of

the

pressure

Most

instances

result

of

operating

untreated

of

the

boiler

be

blown

water

procedures

Refer

level

The

One

connected

proper

the

Some

manually

cut-off

these

or

device

its

as

replica

to

controls

time

assumption

supply

at

the

does

proper

to

instructions

control

switch

and

will

occurs.

pump

or

is

of

the

limit

applications

with a manual

devices

controls

point

should

setting

check

for

required.

of

a

steam

be

followed

which

may

to

the

low

fire.

water

not

point

IMMEDIATELY.

at

once.

practices

care

their

performance.

CONTROlS

and

will

obtain

operation

AND

VESSEl

water

level

controls

vessel

cannot

of

major

with

low

(or

incorrectly

water

level.

down

and

to

operating

break

routinely.

condensate

recommended

sections H and I in

is

mounted

has 2 float

is

connected

stop

the

On a steam

the

feedwater

feeder

automatic

circuit

reset

of

changes

normally

that

are

no

attempt to pump

reasons

the

boiler.

may

be

boiler

While

to

lower

then

when

before

generally

alter

become

low

on

lead

normal

checked

under

the

treated)

The

by

and

internal

actuated

burner

boiler

valve

to

level.

reset

the require reset

mechan-

the

burner

should

the

point

cut-in

from

while

circuit

SHUT

or

erratic

correct:

water

These

a

definite

function

to

laxity

operation

by the

constant

at a normal

to

DOWN

Repair

con-

ef-

and

be boiler water

water

Check

in

ac-

your

in

the

to

the

if

a

the

circuit

main-

type

water

that

a

set

by

be

of

cut-

in

cut-off

in-

for

in

stop-

bur-

stop

or

5-2

On a

steam water bowl

at float

ball,

or

water

Remove make and

free

in a plumb

mine ment ment.

A

scheduled

steam

It

is

impractical devices content Many loss of feedwater

necessary. Since ment

usually

and

monthly devices, mechanism quently, internal check that

it

boiler,

cut-off device(s)

least

once a

the

internal

column.

the

pipe

certain

that

and

boiler

hot

water

the

of

obstructions.

position for

piping is

installation

blowdown

should

on a hot

of

the

water

will

treatment

makes maintenance

it

is

essential

from if possible, moving

cross

is

clean

D. WATER

A

broken once. maintenance when packing. Do

be valve

or

discolored glass

Periodic

replacing

forced below

opening.

replacement

program.

not

Chapter

5--Adjustment

and

WARNING

SAFE INSPECTION

OFF

MONTH. ER

OPERATION

DEVICES. OPEN

UNDER

IN LOW

BY

STOPPING WATER BURNER POOR

LEVEL

AT

PHYSICAL

AND

FIRE

WATER

TO

PROPER

OF YOUR

MAINTENANCE

AND

CONSTANT

POSITION,

LOWER. IF

CONDITION.

GENERATOR

INSPECT

CHECK

FLOW

SAFE

OF

ALL

THEM

ATTENDANCE

OPERATION

TO

GENERATOR,

CONTROLS

WATER

REPAIR

LEVEL

-::

OR

DEMANDS

LOW

WATER

AT

LEAST

AND

WITH

FREQUENTLY

AND ALLOW1NG

DO NOT

OR

APPEAR IN

REPLACE

PERIODIC

CUT-

ONCE A

BURN-

CUT

OFF

AT

ONCE.

• •

FIGURE

the

head

mechanism

should

month

moving

plugs

from

cross connecting piping is

vertically

and

be

to

blowdown

water

boiler

system

systems

require

that

the

boiler

it

impractical

the

bowl

to

check

parts,

and

connecting

and

free

a glass. Use a

use "loose

the

glass

be removed from

to

check

and

parts,

and

the

tees or crosses

Controls

proper

throughout

of

the

maintained.

would

are

make-up

might

to

of

GAGE

Always use new

must

performance.

aligned

life

water

controls

the

low

water

since

the

become involved.

fully closed

and

not

otherwise

and

system

to

perform

of

the

low

water remove annually

and the piping

obstruction.

the

or

clean

bowl housing. Also

to

make

GLASS

should

packing"

and

be

be a

proper

possibly

entire

5-l.

of

the

clean

the

bowl

clean

be

mounted

Deter-

after

ship-

of

equip-

cut-off

water

and

additional

arrange-

daily

cut-off operating more

float

certain

replaced

part

of

gaskets

size

rubber

which

could

plug

low

the the

and

on

any

be

fre-

ball,

at

the

LOW

a

WATER

Close packing onto glass into allow body. tighten.

If

vice, to valves

blowdown pletely.

Check try-cocks operation that ment. may

PLATE

the

valves

nut, a packing

each

end

the

lower

Slide

the

glass is

open

the

operating

slightly. After glass is

valve

and

the

gage cocks

If

they

fail

prematurely.

E.

In

general

that

they

are mercury make well. kinked

Controls

manufacture

bration. curate variation pressure adjust This and

Most maintenance

Examine

switches. On

sure

that

Make

or

damaged.

are

The

although

between a scale

gauge

control

is

predicated,

thermometers

of

the

tightness

when

replacing

washer,

of

the

glass.

upper

gage

valve

end

to

be

the

packing

replaced

blowdown

temperature

and

clean

are

not,

nuts

while

and

open

gage cocks for freedom

as

required.

are

mounted

the

glass will

OPERATING

when

adjusting

level,

especially

temperature

the

bulb

is

sure

that

connecting

carefully

and

do

dial

settings

it

or

thermometer

setting

operating

beyond

not

is

not

to

agree

however,

being

controls

of

electrical

calibrated normally

unusual

occasional

and

Insert

body

dropped

onto

the

slowly

by

cracking

warmed

the

gage

CONTROLS

controls

those

properly

are

generally

setting

reading with on

accurate.

require

connections.

Maintenance

the

glass. Slip a packing

one end of

far

enough

into

the

each

valve

boiler

It

sensing

to

pressure

is in ser-

bring

the

up, close

valves

is

imperative

in

exact

be

strained

check

containing

bottomed

tubing

during

require

quite

have a slight

and

an

and

these

readings.

very

inspection.

ring

the

to

lower

and

glass

gage

the

com-

of

align-

and

to

see

controls

in its

is

not

their

re-cali-

ac-

actual

to

re-

gauges

little

Keep

Chapter

controls terior air

Examine cracks: over may that using leading should left

Dust heating

5--Adjustment

clean.

of

the

hose

taking

any

this

the

normally

lead

to

controls

the

to

be

on

controls

and

dirt

of maintenance tacts

are

plated discoloration abrasive tact with ing contacts. only

Thermal alloy given

If

current loads. it

will

cessive Power

dual Similar standard

materials

points

which

tool

or a hard

Replacement

if

the

relay

type time

over-loads

is

If

this

be

necessary

current

supply

element

fuses

one-shot

SETTING

Burner demands achieve

(a)

controls

will

the

The tion

(b)

The brief

operation.

(c)

Eliminates

Normal damper

rather the

rate

operation

positioning

than

burner

to

the

ments. When

the til

firing a cold

burner

normal proached. trol

on a cold

If

control,

care

mercury

condition,

erratic

of

this

leveling

various

cleaned

at

can

motor

of

these

with

and

since

this

the

points

silver

units

and

when

to

re-solidify

trip

normal

condition

draw.

to

the

fuses

should

AND

provide

following

burner

prior

to

burner

period

either

to

automatically

other

in

be

kept

operating

If

the

burner

start,

and

any

dust

accumulates

remove

not

to

damage

tube

switches

indicated

bright

surface

switching

nature

indicator

controls

if

necessary.

all

times.

cause

excessive

starter

slight

such

surface

has

and

is a

requirement.

silver

pitting.

as

only

wastes

are

covered.

paper

of

the

worn

and

sandpaper

(overloads)

tripped,

before

out

repeatedly

replace

them

continues

to

determine

boiler

must

(fusetrons)

be

used

fuses

are

ADJUSTING

properly

operational

desirable

will

be

operating

shut

down.

will

operate

on

each

frequent

of

switch

"low"

the

burner

in

or

accordance

boiler,

under

it

manual

pressure

is

not

it

will

Maintenance

with

a low

the

mechanism.

for

by a dark

of

the

action.

are

if

actuated

Make

correctly

provided.

by

Covers

wear

relay

contacts

Starter

are

not

Do

not

on

the

metallic

Use a burnish-

to

clean

contacts

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thin.

are

of

the

alloy

relay

can when

with

after

replacement

the

cause

be

protected

or

circuit

in

branch

not

set

circuits

recommended.

to

match

advantages

objectives:

in

low

at

low fire for a

start

during

on-off

should

the

"auto"

"high".

shift

is

recommended

from

with

This

load

flame

or

temperature

under

manual

immediately

in

the

pressure

damage

scum

mercury,

certain leveled

Piping

pressure

should

and

over-

harmed

use

files

the

silver

and

polish

necessary

meltingmust

be

reset.

motor

new

over-

of

breakers.

fire

normal

cycling.

be

with

position

allows

one

firing

require-

control

is

move

in-

or

be

and

con-

by

or

con-

be

ex-

with

and

load

and

posi-

the

that

unap-

con-

to

high

fire

as

the

circuit ignition. for

high position plete the desirable

Any operate Settings ting desirable the pressure, is

to

of

valve slight, valve water pressure

Ideally, under new set

that

The

fire

as

its

travel.

pressure

conditions.

control

at

that

are

recommended,

if

operating

because

the

valve

leakage.

will

replacement.

boiler

limits

the

actual

construction,

to

operate requirements. controls

should

utilization In

the

setting

be

given

to Upon

each length, of mately travel

the

plus

pilot

one-half

from

temperature The

mechanics PRESSURE The

pressure limit

control equipped See ment

The pressure setting shown

with

the

following

procedures.

switch

reaches a pressure

and

on

the

differential.

In

an

installation

control ting will

The to The boiler control

of

should

provide

high-low

10

psi.

suggested

is 2

may

the

lower

to 3 psi.

soon

as

the

program

holds

the

burner

high-low

and

rapidly

vessel

setting

or

in

do

This

the

as

metal

must

excess

not

exceed

fire

burner

the

rapid

of

with

load

conditions

pressure

the

pressure,

too

closer

the

Continued

cause

burner

must

of

loaci

erosion

The

control

be

within

the

boiler.

operating

conditions.

the

boiler

under

As

soon

as

be

reset

of

the

firing

system.

of

these

controls,

the

time

required

start,

there

is a

the

fixed

time

and

main

flame.

low

to

minute to

drop

of

high

below

setting

required

fire,

CONTROLS-Steam

controls

and

an

that

as

the

high-low

adjustable

portion

in

the

control

closes

be

less

fire

be

at a pressure

main

scale,

that

steam

adjusted

frequent

control

than

setting

The

set

low,

does

pressure,

to

should

the

on a low

differential

to

control

will

damper

heat

and

not

cause

the

safety

90%

lower permit.

near

the

greater

and

the

controls

Often,

is

initially less possible

to

provide

consideration

for a prepurge required

This,

may

desirable

the

controls

serve

differential

of

this

opens equal

MINUS

not

the

its

maximum,

burner

operating

give

control

in low fire

will

be

move

motor

input

can

refractory

the

valve

of

the

settings

Avoid

the

operating

the

possibility

leakage,

necessitate

settings

temperature

should

especially

started

than

full

thereafter

maximum

burner period

for

the

plus

for

damper

allow

pressure

limits.

are:

Boiler

as

the

fire

control

section

when

to

the

for

the

main

equal

the

amount

require

differential

cycling.

be

set

to

limit

pressure

setting

quite

close

releases

during

calling

to

that

can

com-

subject

to

un-

boiler

setting.

valve

set-

greatly

having

valve

set

pressure

however

early

on a hot

and

be

set

and

load

the

must

restart.

of

some

proving

approxi-

motor

operating

are

setting.

adjust-

steam

scale

to

that

very

close

set-

since

_this

open

at

setting.

steam

on

this

control

to

on

or

of

5

5-4

of

steam be motor, pressure When burner

narrow On a rise

trol returns to

operate the motor pressure low fire

set

will pressure close, to the upon period control

adjusted

causing

the

will

limits.

opens

to

control

and

continues

rate.

point

open

drops,

causing

have

the

burner

start,

before

to

pressure.

below

pressure

in

low

at

return

of

close

OPERATING (Steam)

Set scale ential ing difference The pressure pressure

(Honeywell

"cut-out"

using

on

the

screw

until

between

"cut-in"

MINUS

should

setting.

HIGH

(Steam) Set

adjusting shut The operating downs, valve ting allow press

LIMIT

(Honeywell

"cut-out"

screw.

off

burner

setting

limit

and

setting.

after

tripping boiler the

reset

HIGH-LOW (Honeywell

Set

the

"cut-out" burner using

be operating return at

The

will

the

large

sufficiently

limit

to

the

operating

"cut-in"

In

so

that burner

the

maintain

steam

its

contacts

fire

low

fire

will

again

the

to

Should

the

operating

to

turn

the

operating

the

burner

high-low

does

not

but

rather

decreasing

and

LIMIT

(burner

the

large

short

the

(burner

not

PRESSURE

(burner

The when

should

pressure

preferably

This

on a pressure

pressure

button.

FIRE

L404A)

pressure-the

return

adjusting

below

control

low fire

limit.

pressure-the

any

case,

it

de-energizes

to

limit

control

controls

steam

pressure,

and

position.

rate.

If

close

to

burner

rise,

the

boiler

limit

off

the

to

fire

control

immediately

operates

steam

the

burner

PRESSURE

L404A)

off)

adjusting

scale

turning

indicator

cut-out

on)

pressure

the

differential.

exceed

90%

L404C)

off)

pressure

control

pressure

be

sufficiently control

not

control

to

requires

return

CONTROL

(Steam)

to

low

fire-on

screw.

the

so

position

point

the

go

to

low fire,

opening

are

properly

pressure

the

high-low

the

damper

The

burner

steam

pressure

energize

to

high

boiler

pressure

control,

burner.

limit

control

restart.

adjusted

go

at

low for a

pressure

to

drive

pressure

screw.

the

points

and

cut-in

of

the

CONTROL

will

break a circuit

reaches

to

exceed

increase.

to

normal

point

the

This

cut-out

that

the

prior

at

control

the

should

damper

set

within

fire con-

continues

drops,

the

damper

fire.

If

will

remain

reach

its

contacts

When

contacts

It

is

desirable

so

to

high

causes

to

high

CONTROL

on

the

Set

differ-

small

adjust-

to

the

desired

pressures.

is

the

cut-out

The

cut-out

safety

on

scale

this

above

avoid

90%

of

manual

To and

at

which

main

setting

should

of

burner

to

shutting

which

the

at

point.

the

motor

steam

at

the

boiler

that

fire

brief

fire.

main

valve

using

to

point.

the

shut-

safety

reset-

reset,

then

the

scale

the

will

off

bur-

Chapter

ner

drives

scale.

This

a

MINUS

be

ner the low fire

the

adjusted

"on"

burner

position

pressure

TEMPERATURE Hot

Water

The

temperature operating control

ferential when equal ture of for

In control setting since

The set

are

setting.

the

water

to

the

equal

differential.

instructions

an

installation

of

should

this

operating

slightly perature vessel. degrees trol justed ture

Relative

The

above

setting.

so

that

of

the

settings

to

high

setting

amount

so

that

when

Boiler

limit

equipped

dial

to

the

See

the

water

will

provide

limit

above

and

high

the

The

it

operating

5-Adjustment

fire-is

is

equal

of

the

it

is

sufficiently

of

the

operating

starting

prior

will

to

CONTROLS-

controls

control

and

with

The

switch

temperature

setting

dial

setting

following

on

control

that

does

temperature,

be

adjusted

less

temperature

the

highest

within

limit

the

control

operating

high-low

is

below

the

control.

of

the

temperature

and

Maintenance

set

on

the

differential

to

the

cut-out

differential.

pressure

It

below

control

operate

advancing

that

as

an

in

briefly

to

serve

the

high-low

adjustable

the

control

high

reaches a temperature

and

closes

portion

MINUS

at a tempera-

the

of

this

adjustment.

not

as

frequent

desired

limits

should

limit

fire

control

burner

require

widely

control

temperature

the

differential

burner

of

the

be

should

"on"

very

as

should

water

set 5 to

tempera-

controls

should

the

bur-

so

that

at

the

fire.

as

the fire dif-

opens

amount

section

close

possible

cycling.

be

tem-

pressure

10

con-

be

ad-

are

as

follows:

High

Limit

Open-

Operating

OpenClose-

High-Low

OpenClose-

With

settings

tional

sequence temperature, contacts per

motor

at

190° Limit

180°

170°

Fire

170°

165°

similar

the

170

and

Control

F.

Control

F.

Control

F.

occurs.

high-low

degrees

place

(Low

(Hlgh

to

these,

On a rise

F.

to

the

Fire)

the

following

fire

control

de-energize

burner

in

boiler

opens

the

its

opera-

low

water

its

dam-

fire

range.

If

temperature

ner

will

fire

control perature will

be

opens

If

ner

of back

at

temperature

will

180

degrees

to

return

switched

shut

170

decreases

to

closes

increases

170

degrees.

increases

down

is

degrees

high

fire

at

its

during

back

to

when

reached.

the

during

as

soon

165

degree

high

low

fire

during

the

operating

When

operating

low fire,

as

the

setting

fire

rate

the

when

the

low

fire,

limit

temperature

limit

the

bur-

high-low

As

tem-

burner

control

the

bur-

setting

drops

will

close

5-5

Chapter

to rate degrees, will close

The cording controls desirable, shutting mediately

OPERATING TEMPERATURE

(Hot

Set

5-Adjustment

restart

unless

at

settings

to

Water)

"cut-out"

the

burner.

temperature

which

to

move

listed

job

requirements.

with

these

since

this

down

while

going

LIMIT

(Honeywell

(burner

time

the

to

CONTROL

inserting a screwdriver to

engage

The out ferential ferential back

HIGH (Hot

Set

the using circuit above above necessary tors

control

a

temperature perature ferential,

HIGH-LOW

(Hot

Set

the the dicating below temperature to

the

operating

The

burner

scale. ture

should the

burner trol

so

briefly

to

high COMBUSTION Air

pressure switch prove

the

"cut-in"

temperature

is

adjustable

is

adjusted

of

the

snap

LIMIT

Water)

(Honeywell L 4008E)

"cut-out"

adjusting

and

lockout

the

setting.

the

operating shutdowns.

the

setting

requires

to

drop

and

then

FIRE

Water)

(Honeywell

"cut-out"

burner

will

dial.

the

cut-out

control

low fire

limit.

"cut-in"

drives

This

MINUS

temperature-the to

setting

the

be

adjusted

"on"

that

the

in

the

low fire

fire.

against

which,

the

presence

slotted

(burner

MINUS

switch.

TEMPERATURE

(burner

screw.

on a rise

The

is

not

manual

increase.

below

press

CONTROL

temperature-the

return

This

setting

position

high

is

amount

so

temperature

burner

AIR

when

and

The

continues

the

burning

are

typical

relations

will

prevent

in

high

fire

L4008A)

off)

temperature

through

head

on)

temperature

the

from 5

by

rotating

off)

This

setting

limit

temperature

On

30 lb.

to

exceed

resetting

To

the

cut-out

the

L4008A)

to

setting

so

that

prior

fire-is

equal

to

that

when

position

PROVING

the

diaphragm

made,

of

combustion

Maintenance

unit

will fire

high-low

rate

and

However,

to

the

fire

upon

the

adjusting

differential.

to

30

the

at

to

drop

fire

to

high

will

vary

setting

each

other

burner

or

from im-

restarting.

on

scale

cover

opening

screw.

is

the

The

degrees

wheel

its

to

control

F. Difon

CONTROL

temperature

control

in

water

should

hot

240

after

reset

allow

setting,

manual

low

fire-on

should

of

the

operating

the

burner

to

shutting

point

set

on

the

cut-out

of

the

it

is

sufficiently

of

the

starting

prior

degrees

point

be

the

differential.

operating

on

will

break

temperature

be

sufficiently

to

avoid

water

genera-

F.

tripping

water

less dif-

reset

button.

at

which

the

sufficiently

will

return

off

at

which

differential

tempera-

below

can

operate

to

advancing

SWITCH

actuates

completes a circuit

air.

Since

low

16.5

fire.

ac-

the

from

by

cut-

dif-

the

scale

the

un-

The

on

tem-

in-

limit

the

It

con-

the

to

the

is

pressure value

should

be pressure, nuisance

The timer purge the it

is

when

be

set

to

test

only or

timer

necessary

of

the

adjusted

actuate but shutdowns.

switch

during

CB-20 -Turn

main

power.

base.

Check

and

locate

the work a narrow points. wood leaf

Use tacts.

An

alternate

wedge

for

this

extreme

CAUTION:

contacts. Reinstall

the

CB-40 -Remove

extender

jumper.

details. Turn

the

burner

the

timer

will

and

limit

controls

after

a few

seconds.

to

its

open

position

Attach a test minal W to til

this

to

the

Turn or

wood purge 40

relay.

With dition, whether

If

the allotted recycling. require

LOW

Turn

moves

operating circuit should

with

low value cause

ground.

circuit

adjusting

the

burner

wedge

extender

the

programmer

turn

unit

air

switch

time,

The

manual

GAS

PRESSURE

adjusting

to a pressure

gas

if

pressure

be

finally

gas

close

enough

unnecessary

combustion

the

damper

under

under a condition

not

too

close

in

the

pilot

the

high

to

do

the

off

both

Remove

the

instruction

position

strip

of

method

between

the

contact.

care

not

to

Line

control

the

See

and

purge the

switch

start

(provided

are

made).

The

and

lamp

or

volt

Turn

is

broken.

switch

from

the

or

purge

returned

the

burner

cycles

is

not

the

CB-40

normally.

adjusted

CB-20

control

resetting

screw

pressure.

is

below

adjusted

pressure,

to

normal

shutdowns.

air

is

full

that

situation.

to

that

programmer

low fire

period ignition fire

portion

following:

the

burner

the

programmer

manual

of

contact

paper

between

is

timer

cam

bend

or

voltage

is

restore

extender

instruction

on.

The

blower

the

The

damper

stop

there.

meter

the

adjustment

Then

add a half

to

remake

off.

Remove

CB-20

relay

extender

switch

to

control

will

to

restart.

SWITCH

until

indicator

setting

The

but

slightly

control

this

value.

to

should

prevent

operating

When

at

its

open,

the

of

point

will

of

period.

of

switch

for

the

M3A.

the

to

insert a thin

and

damage

present

main

or

manual

motor

low

water

timer

motor

from

switch

the

Replace

jumper

to

operating

on

and

make

will

lock

below

will

The

not

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pressure

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minimum

switch

It

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minimum

to

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stop

the

pre-

To

stop

prepurge,

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the

from

control

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the

spring

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at

most

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the

purge

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ter-

screw

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turn

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the

on a CB-

con-

observe

within

keep

out

and

on

scale

·the

break

control

operation

set

at

this

its

for

so

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a

to

5-6

control

gas

some

does The

on a drop To manual

HIGH Turn

moves maximum

consideration

line

distribution

conditions

not

cut

switch

of

reset

allow

reset

GAS

adjusting

to a pressure

operating

out

must

gas

button.

PRESSURE

break a circuit control with a to

This on a rise To manual

LOW

excessive

value

cause

switch

reset

should

close

unnecessary

must

of

gas

allow

reset

OIL

PRESSURE

gas

enough

button.

(Optional) This

control

its

operation

set

point. single-throw pressure knobs indicates place

on a pressure

the

bottom

a

point pressure. The

burner

ceeds

rise.

on

the

slightly

the

prevents

when

The

face

the

of

Then

will

lower

mercury

Pressure

point

the

PROGRAMMING

This

control

any

attempt

contacts follow bulletin. trol

cabinet

requires

be

may

require

instructions

Do

not

door

operation. The

manufacturer's

shooting The

as

moistened

Replacement the

information.

flame

operating

plug

detector

conditions

with

of

in

amplifier

recommended.

When

replacing a control

must

pressure

and

it is

advisable

unnecessarily.

be

manually

pressure

gas

pressure

screw

until

setting

gas

pressure.

if

pressure

be

adjusted

pressure

to

normal

shutdowns.

be

manually

pressure

gas

above

pressure

SWITCH

burner

the

oil

control

switch

settings

of

the

control.

at

which

drop.

scale.

Adjust

below

set

operate

the

"low"

as

setting.

CONTROL

no

made

to

alter

occasional

given

use

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should

bulletin

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detergent

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be

given

may

decrease

that

reset

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the

to

rise

SWITCH

indicator

slightly

The

exceeds

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to

should

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prevent

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reset

the

to

drop

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igniting

pressure

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The

switch

Initially

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set

"high"

normal

knob

somewhat

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as

oil

adjustment,

contact

cleaning.

in

the

manufacturer's

materials.

be

closed

also

contains

be

cleaned

Use a

if

necessary.

components,

neither

or

cleaning

to

the

after

cut-out

and

press

on

above

control

value.

operation

not

after

cut-out

and

press

drops

a

single-pole,

closes

made

"low"

action

this

operating

pressure

nor

settings.

The

during

soft

other

practical

contacts,

fact

that

under

control

tripping

setting.

the

scale

the

will

The

be

set

pressure

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setting.

the

or

stops

below

on

with

the

setting

takes knob knob

oil

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ex-

should

The

If

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normal

trouble-

as

often cloth

than

nor

be

at

to to

sure the

Chapter

to

open

control

5-Adiustment

the

main

is

"hot"

even

power

though

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supply

the

Maintenance

switch,

burner

since

switch

is off.

periodic

A

established

at

least

verify

safety failure main

flame, conditions These

Checking

Close

the

main

fuel

The

pilot

prepurge

detected,

the

main

to

see

that

The

programmer

which

time

lock

out.

Turn

the

after

allowing few

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moments.

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re-establish

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Leave

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burner

on.

The purge energized should ner

ignition

trip

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ignition Turn

the

after

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few

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With

the

main

burner

Relay

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Turn

the

after

allowing

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verified

placed replaced.

safety

to

test

once a month

shut

to

ignite

the

and

upon

should

tests

will

also

Pilot

flame

gas

pilot

supply.

system

period.

the

fuel

burner

pilot

valves

there

the

will Since

is

lockout

switch

the

Reopen

main

failure

gas

pilot

fuel

pilot

will

period.

drop

but

The

there

out

within 4 seconds

trial

lock

out

about

trial.

burner

switch

the

Re-establish

Loss

of

burner

in

fuel

2K

should

is

extinguished.

the

post

purge.

30

relay

lK.

burner

switch

the

Re-establish

OPERATIONAL

operation

and

tested

into

service

Periodic

check

the

down

pilot,

be

checked

verify

shutoff

Turn

be

valve

will

an

ignition

will

thermal

to

lighl

shut

supply.

light

main

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Flame

normal

supply

drop

The

seconds

thermal

of

the

when

or

checks

procedure

complete

or

safeguard

oftener.

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upon

failure

loss

of

flame.

on a scheduled

fuel

failure

cock. Also

the

burner

energized

there

is

no

will

be

not

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spark

complete

switch

off.

will

Reset

element

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gas

pilot

fuel

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cock

open.

Turn

the

upon

completion

fuel

valve(s)

be

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The

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30

seconds

off.

Reset

element the

main

operation,

to

extinguish

out

within 4 seconds

The

blower

lock

out

later

off.

Reset

element

main

TEST

various

the

controls

boiler

whenever

should

system

Tests

lock

Each

valve

should

out

to

ignite

of

tightness.

shut

off

switch

at

the

end

pilot

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de-energized

energized.

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the

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switch

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shut

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Flame

Shut

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the

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switch

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to

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fuel

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off

main

motor

switch

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should

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initially

a

control

be

made

be

upon

the

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basis.

the "on''. of

the

to

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and Check flame.

cock

the

switch

pre-

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2K

bur-

of

the

switch

for a

the

flame.

after

runs

trip

switch

for a

be

there-

is

5-7

Chapter

after

5-Adjustment

in

accordance

program. The

operating allowing increase upon crease burner valve

until

the

shut

can increases. cutoff

pressure

the

burner

steam

pressure setting fire

Water be by burner limit

the

again control

as

control

temperature,

operating

manually

shuts

control.

desired

when

for

Observe

operations

Check water

Proper

be week

the

cut-off

operation

checked

thereafter.

formation Check

for precautions lodge

under a valve

Promptly

GENERAL

There

are

steam

the

load,

it

firing

off

be

closed

Observe

as

down.

or

the

burner

for

at

increasing

down

Observe

settings

burner

the

ignition

to

make

proper

(and

at

time

on

flame

tight

and

correct

F.

relatively

with a planned

limit

control

pressure

burner

may

be

rate

to

raise

point.

or

the

Open

vent

If

throttled

steam

operating

the

steam

restarts.

desired

operating

on a hot

less

than

thru

the

at

the

restarts.

desired

temperature

and

sure

operation

pump

operating

of

the

flame

of

starting

Refer

to

safety

shut-off

of

strainers,

seat

any

conditions

Oil

few

and

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steam

load

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gauge

limit

header

and

Check

water

full

load,

the

firing action thermometer

point

Check

programming

that

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and

setting

control,

failure

and

all

fuel

foreign

preventing

causing

BURNER

adjustments

maintenance

be

checked

temperature

Depending

to

manually

pressure

the

pressure

to

check

control

valve

to

release

check

the

high-low

pressure

boiler

that

may

be

rate

until

of

the

operating

to

of

cut-out

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modulating

range.

control

are

correct.

of

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device

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valves.

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material

tight

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to

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verify

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used).

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may

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made

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properly as 4

to

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setscrews

cover

typical

the

made

located

properly

burner

to

and

burner

drawer,

see

that

all

tightened.

drawers

however, a check

all

components

holding

and

devices

Figures

show

5-3

and

pertinent

are

such

5-

dimensions. The

burner spected adjusted surrounding casionally that

might

laden

atmosphere. relation portant

drawer

for

evidence

combustion.

the

for

any

be

to

the

and

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of

nozzles

carbon

caused

The

opening

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residue

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in

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maintained.

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improperly

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any

clogging

or

oil

nozzle

tube

in-

tubes

oc-

lint-

IS

Im-

in

DIFFUSER Proper

tained on have affected. of

BURNER Efficient

zles. ness at is

a

clogged gauge partially

positioning

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that

it.

Remove

accumulated

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the

fins.

oil

The

nozzles

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any

time

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oil

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attempt

NOZZLES

burner

deliver a spray

proper

the

flame

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one

worn.

Even

indicate

nozzles

the

diffuser

or

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change

operation

mixing

becomes

or

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flow

the

requires

of

with

the

"stringy

of

the

pressure,

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pattern

gap

clean

extreme

air

stream.

or

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nozzles

oil

pressure

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reduce

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if

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fine-

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or

oil

If

it

is

delivery. The

nozzles

pear

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or

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the

strainer

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economical

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tip

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to

with a wood

metal

the

oil

they

replace

to

avoid

grooves.

ap-

30° 30° 45° 45°

Low

Nozzle

Spray Angle

HV HV HV HV

PLP PLP PLP PLP PLP

CBH

Boiler

Size

25 2.5 30° 30 3.0 30° 40 4.5 50 A 50 60 70 80

100

NOTE: Nozzle size is rating

8.3

4.0

5.0

6.0 45°

7.0 45°

8.3 45°

FIGURE

5-8

Fire

Number

899-93 899-26 899-31 899-60 899-12 4.0 899-18 5.0 899-35 899-61 7.0 899-39

at

100

Part

PSI

High

Fire

25-50A)

Spray Angle

HV

HV HV HV PLP PLP PLP PLP PLP

SIZES,

Nozzle

50-100)

Part

Number

899-23 899-93 899-26 899-26 899-12 899-18 899-35 899-61 899-39

LOCATION

(CBH

Intermediate

(CBH

Size

30°

2.0 30°

2.5 30°

3.0 30°

3.0 45° 45° 45°

6.0 45°

45°

8.3

oil

pressure. Flow rate increases with pressure.

5-2.

NOZZLE

Size

2.0 30° 30°

2.5

3.0 30° 30°

4.0 45°

5.0 45°

6.0 45°

7.0 45°

8.3

AND

High

Nozzle

Spray Angle

HV HV HV HV

PLP PLP PLP PLP PLP

Fire

Part

Number

899-23 899-93 899-26 899-20 899-12 899-18 899-35 899-61 899-39

FIRING

Max. Input

BTU/Hr.

1,045,000 1,255,000 1,675,000 2,095,000 15.0 2,095,000 15.0 2,510,000 2,930,000 3,350,000 4,185,000

RATE

Max.

Firing

GPH

12.0

18.0

21.0

24.0

30.0

Rate

7.5

9.0

Chapter

5--Adjustment

and

Maintenance

Nozzles tremely firing city 2 for

The delivery burner

atomizing is sized marking

The approximately the pressure smoke be later justment.

IGNITION Maintain

ignition Figures

Inspect bustion file. feed chipping. this bon keep

may important

order.

and

spray

proper

capacity

rate

is

greatly

nozzles

oil

pressure

regulator

occurs

adjusted

section

5-3

electrode deposits

Inspect

through

can is

an

the

designed

oil

increased.

compared

setting

the

electrode(s)

the

If

any

cause

electrical

insulating

be

of

different that

Nozzles

angle

location stamped

with

oil

pressures,

are

installed

required

175 psi. Oil

in

the

may

at

open

downward

covering

SYSTEM

proper

or

5-4

show

tips

and

insulators

are

present

grounding

conductor,

they

can

be

stamped

of

nozzles.

on

side pressure to

use

the

Do

not

to

the

fuel

be

slightly

damper,

to

oil

gap

for

the

for

signs

dress

of

for

of

portion

capacities

are

replaced

identified

on

them.

of

nozzle

at

100 psi. Since

considerably

capacity

assume

on

the

burner

for full

pressure

oil

pump

higher

the

clear

the

burner

and

dimensions

best

ignition

correct

of

as

required

the

electrodes

evidences

replace

ignition

so

it

of

electrode

and

it

in

proper

by

the

See

chart

represents

higher

of

the

that

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basis

of

input.

burner

pressure

combustion

pitting

the

is

adjusted

and

or

lower.

fire.

settings.

or

with

of

cracks

items,

voltage.

necessary

input

should

See

of

results.

and

is ex-

capa-

5-

the

nozzle

is

by

final

If

the

ad-

the

com-

a fine

the

or

since

Car-

to

wiped

clean removing

Check Also see and

light

The

cleaned remove thoroughly dry cap gasket. cover the

the

OIL Problems

traced fuel closed head

The pump even the been

limit

these operation verified,

if

ignition

electrodes

Oil

fuel

with

screw

Tap

gasket.

strainer

basket.

PUMP

to

lines,

valves, a high

of

pressure

gears

pressure

set.

can

units

any

is

present.

carbon

that

Strainer

oil

at

this

compressed

attributed

other

lack

oil.

Collapse

indicate

without

it

or

cables

all

connections

are

strainer

regular

screen

by

immersing

being

careful

strainer

Slip

pliers

and

twist

Re-assemble

causes

of

gauge

are

pumping

to

deliver

to

which

are

designed

is

generally

Ammonia

soot.

for

cracks

tight.

screen

intervals.

air.

cover

to

fuel, clogged

vacuum

(Figure

of

the

worn

undue

must

each

in

To

not

gently

into

the

counterclockwise

in

reverse

the

pump

such

as

and

oil

to

the

integral

nozzle

internal

to

wear.

advisable

in

the

between

be

It

is

month

solvent

remove,

to

lose

to

cross

can

broken

filters,

or

even

1-1)

reveals

building

the

spray

parts,

give

long

If

this

will

insulation.

transformer

removed

advisable

and

blowing

loosen

the

loosen.

on

the

to

order.

generally or

restricted

stuck

an

excessive

that

up a steady

nozzles

regulator

below

although

periods

situation

to

replace

aid

in

and

to

clean

cover

copper

Check

top

of

remove

be

or

the

and

at

has

the

set

of

is

the

FIGURE

5-3.

OIL

BURNER,

........

3/B"

~~(\aEv----

SPARK

IGNITED-CBH

~q=

50-100

__

~~

3/B"

5-9

Chapter

pump. returned rather

If

the

vacuum

pump suction

5-Adjustment

It

is

recommended

to

the

than

replacement

oil

supply

gauge

is

helpful

line

and mally a vacuum Vacuums oil Excessive as valves, reading

tings,

vacuum evidence

If

the pressure may not damage

reducing Seal

the

In

an

whine

results

soon the tion,

higher

separation

readings

kinked

or

even a frozen

look

or

pump.

gauge

of

oil

supply

gauge

be

used

too

great.

or valve

leakage

return

line.

initial

may

from

as

the

pump

condition

it

may

for

restrictions

to

If

seal

may

start-up a pump

be

air

persists

indicate a leak

factory

is

below

installed

in

checking

aids

in

reading

than

or

in

erratic

can

clogged

air

On

should

is

above

installed

determine

the

head

leakage

should

also

noticed.

in

the

is

able

and

Maintenance

that

for

complete

of

individual

the

level

at

the

pinpointing

should

this

can

lead

or

indicate

lines,

sticking

oil line.

leaks

in

the

gravity

read

being

the

in

fed

zero.

present.

level

the

that pressure can

be

installed

be

caused

noise

This

is a

oil

line

and

to

clear

after a long

in

removed

pumps

be

reconditioning

parts.

of

the

pump,

suction

declining

port

condition

problems.

not

exceed

to

problems

delivery.

restrictions

or

If

there

lines,

valve

of

the

of

the

Nor-

10".

such

closed

is no

fit-

installations

If

not,

this

of

the

pump,

pump

the

head

is

over

bypass

of

oil is

10 psi.

port

occur. A pressure

in

this

instance.

by

restrictions

in

the

condition

should

the

line

period

the

suction

form

of

cease

of

air.

opera-

line.

in

of

that

as

a

in

a

is

a

If

OIL

PUMP

The V -belt

vicing should and

proper apply damage

BELT

driving

and

no

preservatives

be

used.

tension

excessive

to

the

pump

On a combination

practice

for

necessary merely pump

to

extended

to

be

and

remove

periods,

do circulated belt

life will

removed. COMBUSTION Each

boiler

is

adjusted

factory,

ment, may maximum

Periodic also

The

however

installation,

require

further

operating

rechecks

recommended.

burner

system of a combustion has

been

in

operation

warm Proper

use measures (C02),

boiler.

air-fuel

ratio

of a combustion

the

content

oxygen

(02)

the

oil

pump or

Belts

normally

should

tension

fired

the

since

shaft

unit

belt

be

bearings.

when

although

this.

If

left

back

to

be

extended

ADJUSTMENT-

prior

to

circumstances

or

operating

adjustment

efficiency

of

adjustments

should

efficiency

be

adjusted

analysis

sufficiently

should

gas

by

and

be

analyzer.

percent

carbon

requires

dressing

compounds

stretch

maintained.

this

can

it is

an

acceptable

gas

is

being

it

is

not

absolutely

connected,

the

tank.

if

the

OIL

shipment

caused

load

conditions

to

and

settings

on

after

long

to

established

This

instrument

of

carbon

monoxide(CO)

no

ser-

with

use

Do

not

result

in

used

oil

will

However

belt

from

the

by

ship-

assure

economy.

are

the

basis

the

unit

assure

by

the

dioxide

in

is

a

5-10

1-7/8"

PACKING

GLAND

FIGURE

PILOT

GAS

INLET

5-4.

OIL

AND

GAS

APPROX. 17-318" SET SO DIFFUSER

FLUSH

WITH

END

OF

IS

BURNER,

GAS

BURNER

PILOT

IGNITED,

HSNG.

SPACER

CBH

50-100

Chapter

5-Adjustment

and

Maintenance

the

flue gas. Efficiency is centage setting

when present. burner cess pressure cent of be detectable

Turn this size determining guide visible flame amount

Determine exists ing nozzles. require suggested not

Take a sample known COz required flow. See this

Recheck

fected

linkage

of

from a

there

It

to

air

to

or

excess

12

to

13% is

operated

the

rate

for

ot

the

for

additional

is

overly

of

as

mentioned

that

be

obtained

to

reading.

chapter.

low fire

by

adjustment

C02

present

standpoint

is no

is,

however,

operate

compensate

burning air

is

desirable.

with

percentage

burner

several

flame.

efficiency,

tentative

bright,

combustion

that

In

the

setting

be

in

good

Based

adjustments

the

section

high

fire

G.

GENERAL There

made

should

properly as inspect due

Check figure 5-4)

insulator. voltage. ting

for

tween

GAS

The

justing

The

flame

are

relatively

to

the

be

made

located

setscrews

the

to

improperly

the

gas

and

Cracks

Check

and

dress

insulation

transformer

PILOT

size

of

the

gas

flame

and

to

burner

are

burner

pilot

also

the as cracks.

FLAME

the

gas

flow

must

be

measured

in

the

of

efficiency is

measurable

with a reasonable

properties

considered

an

air-fuel

of

to

high

minutes.

Color

setting.

combustion

rumbles

air

the

proper

in

the

some

oil

pressure

if a desired

with

an

of

flue

working

on

to

on

to

determine

adjustments.

may

GAS

few

to

see

and

that

properly

drawer

adjusted

electrode

for

can

cause

tip

of

required.

See

and

pilot through

be

sufficient

seen

by

percentage

more

for

minor

normal. A C02

The

burner

ratio

carbon

fire

and

Observe

alone

although

If

air

will

atomizing

preceding

instances,

be

flue

open

gas

with

order

this

analysis,

increase

air

damper

be

required.

BURNER

adjustments

drawer,

that

all

holding

tightened.

for

combustion.

for

any

cracks

grounding

electrode

Check

that

electrode

ADJUSTMENT

flame

the

flame

by

the

flue gas.

practical

variations

of

oil. 15

monoxide.

is a

it

smoke

is

or

have

reduced

damper.

whether

If

however, a check

all

evidence

proper

the

all

is

pilot

to

The

reached

of

oxygen

to

set

amount

to

20

should

that

indicates

let

it

operate

the

color

poor

means

can

serve

or

haze

required.

emits

sparks

to

be

reduced.

oil

pressure

section

conditions

below

gas

analysis

an

instrument

and

determine

make

or

decrease

adjustment

it

was

so,

additional

that

components

devices

Periodically

of

damage

setting

in

the

porcelain

of

ignition

for signs

ignition

connections

are

tight.

regulated

gas

regulator.

ignite

the

detector

ideal

of

in

range

never

as

If

cover-

may

can

such

of

cable

by

main

but

per-

the

ex-

the

per-

at

and

of

the the

the

can

any

air

in

af-

be

are

(see

pit-

be-

ad-

an

is

extremely rich Too

To

check

the

rear mately control ment

A

preferred

a

micro-amp

measured

suitable

DC

The the

flame

ing

plug the

plus

ness

tab

( 1)

(2)

(3)

( 4)

NOTE:

(5)

CAUTION:

(6)

large

flame

can

cause

small a flame

the

pilot

sight

port. A flame one-half the

flame

to

the

gas

method

reading

with

a good

multi-meter

rating.

meter

is

connected

safeguard harness (red

meter

and

the

minus

before

inserting

To

measure damper shut-off line.

Connect above.

Turn

burner through the

ignition posite to Relay ignites.

If

ten

the

2K

the

pilot

seconds,

Repeat

On

an

the

fuel "bleeding" this

with periods than

to

the

pilot

tempts,

system.

When

the

flame

The

pilot

this

opening.

Keep

sight

tective Never while

To

make

the

gas

no

longer

switch

cock. Close

the

TEST

the initial

risk

pilot

is

not

required.

sooting

can

flame,

of

the

size,

pilot

of

setting a flame

of

the

with

control.

(Cleaver-Brooks

lead)

(black

the

and

the

micro-ammeter

switch

normal

area

index

should

flame

turn

lighting

starting

lines

time.

repeated

with

prolonged

does

check

pilot

detector

flame

eyes

tube

shield

remove

the

final

regulator

be

seen

of

cause

visually

that

diffuser

make

the

regulator.

flame

quality

to a jack

to

position

may

intervening

all

flame

main

micro-ammeter

a zero

Use a

to

the

meter

plug

adjust

low.

Fully

the

cock in

on.

pre-purge

of

the

notch,

not

can

sufficiently

set

pull

is

not

off

attempt.

attempt,

be

It

is

better

short

light

components

is

from

then

opening

or

the

burner

adjustment,

through

An

the

flame

ignition

encircles

is

necessary

signal.

to

in

red

lead)

in

the

Let

timer

to in

established

the

empty

fuel

established,

the

be

and

suitable

until

problems.

observe

satisfactory.

is

to

This

25

micro

the

amplifier

meter

884-72).

tab

of

to

the

meter

pilot,

open

the

as

the

burner

cycle.

dial

the

timer

stop

the

when

burner

portions

and

to

accomplish

lighting

purge

introduction.

after

several

of

burner

observed

away

wear a pro-

flame

is firing.

slowly

the

sight

overly

detector.

it

thru

approxi-

adjust-

obtain

can

or

amp

connect-

Connect the

har-

the

black

jack.

turn

the

pilot

main

outlined

When

is op-

switch

timer.

the

pilot

within

switch.

require

trial

periods

the

pilot

remove

plate.

thru

from

glasses.

detector

close

flame

tube.

To

a

be

a

of

the

gas

go

of

If

at-

the

can

5-11

Chapter

5-Adjustment

and

Maintenance

Then flame

slowly providing

observed.

This

adjustment

time

limit

seconds

shuts

down, element manually from

step

(7)

When a suitable the

after

in

reset

of

the

safety

the

allow

the

it.

3.

detector.

must

detector

safety

micro-ammeter.

( 8)

(9)

tween reading tuates, that and

Reset position

If

the

that

main

two

must

recheck

flame

the

to

flame established, with

instructions

(10)

The

micro-amp signal flame burner flame rate and

If

should

signal

flame

at

positions.

in

the

there

high,

are trouble-shooting bulletin.

The

gas

plate

should

of

damage adjusted Routine which cement obstruct The

diffuser Figure angle

of

GAS

burner

maintenance

can

and

the

5-4.

the

housing

be

periodically

that

might

or

be

done

asbestos

holes

should

Do

not

fins.

PRESSURE AND

INFORMATION

Because and regulate produces a steady, highest yet pressure ded regulator

casional pressure

of

the

supply

the

combustion

prevents

has

and

periodic

is

modification

by

variables

system,

pressure

overfiring.

been

holding

the

supplier

open

the

full

sight

be

accomplished

switch

is

removed.

several

moments

switch

Replace

the

flame

Observe

The

reading

and

five

micro-amps

be

steady.

the

adjustment.

detector

lens

is

clean.

timer

the

NORM

has

proceed

switch

not

to

elsewhere

reading

also

be

checked.

for

pilot

alone,

together

low,

and

Readings

range

indicated

any

deviations,

section

surrounding

checked

be

caused

by a

poor

seal

should

include

with a mixture

pulp.

Use

in

the

face

be

positioned

attempt

in

both

of

it the

to

the

will

dependable

efficiency

at

Once

established,

checks

the

made

pressure

in

fuel

may,

regulator

tube

coverage

or

approximately

If

for

the

to

cool

detector

is

obtained,

the

reading

should

If

the

reading

is

properly

from

position.

been

do so

in

accordance

in

the

of

the

main

Observe

pilot

the

main

intermediate

should

in

paragraph

refer

in

the

for

by

an

improperly

to

the

this

of

care

not

of

the

gas

as

change

the

FlOW

properties

be

necessary

gas

to

a level

flame

rated

it

to

at

that

performance

this

should

veri(y

at

this

composition

times,

require

until

within

the

30

the

control

thermal

and

then

and

repeat

replace

on

the

be

be-

and

the

fluc-

Make

sure

seated

the

TEST

previously

manual.

flame

the

and

main

burner

firing

be

steady

to

the

technical

diffuser

any

signs

refractory.

resealing

refractory

to

clog

or

housing.

shown

gap

or

of

gas

to

that

yields

optimum

be

recor-

that

the

level. Oc-

or

re-

is

7.

in

a

adjustment Since furnished tions the

manufacturer

Pressure

The

gas

tity

of

at

a pressure-loss posed

The

pressure

ner

train regulated must full

input.

The

pressure altitude, pressure

Minimum

to

the

gas

by

others,

and

adjusting

supplied

gas

demanded

pressure

due

by

the

burner

required

for

pressure".

be

adjusted

and

type

requirements.

For Rated

return

rated

requirement

(Required

Boiler

Size

(H.P.)

25 30 40 50

A 50 60 70

80 100 8.5 100A 9.5 100S

The

pressures

FT. above tudes, factor

Feet

natural

sea

multiply

from

Altitude

Above

gas

level.

Table

Sea

1000 2000 2500 3000

the

burner

pressure

regulator

detailed

procedures

should

must

high

to

provide

by

the

enough

the

frictional

system

at

boiler

The

achieve

be followed.

unit,

and

the

output

gas

this

varies

of

gas

train.

TABlE

Net Regulated

listed

the

Boiler

at

Gas

Train

Standard

and

Approved

FM

Train

4.5

4.5 5.0

7.0 7.5

4.5

5.0 6.0

5.5

9.5 13.0

are

based

and

elevations

For

installation

selected

pressure

2.

TABlE

Level

to

peak

itself

adjustment

recommended

not

only

but

to

overcome resistance

the

control

entrance

is

pressure

with

Refer

to

1

Gas

Pressure

Output

Entrance)

on

1000

up

at

by

2

Correction

Factor

1.04

1.13

1.18

1.22

efficiency. is

usually

instruc-

the

must

also

valves.

to

the

termed

regulator

to

boiler

Table

FIA

Approved

Train

5.0

5.5

7.5

ll.5

13.0

BTU/CU.

to

700

higher

the

by

quan-

be

the

im-

bur-

"net

assure

size,

1 for

feet

alti-

proper

4000 1.33

5000 6000

1.44

1.57

7000 1.70

8000

9000

1.84

2.01

5-12

Gas

flow

The

volume

cubic

feet

The

!{as

output FT.) provide

To hour

FT.) See

depends

of

the

obtain

of

into

Table

Horsepower

this

gas,

Pressure

The

flow

figured

on a "base''

mospheric

Meters "line" each tor vert

cubic

for

the

generally

or

this

quantity quantity pressure.

To

express

meter

reading necessary the

proper

Conversely: reading of rate answer

gas

by

should

required

the

indicates pressure deliver

the

pressure.

Regulator

Inlet

Pressure

psig

1

psig

2

psig

3

psig

4

psig

5

psig

6 7

psig

8

of

!{as

and

is

determined

flow

rate

on

gas

supplied.

information.

the

required

divide

the

required

3 for

input

Boiler

25 30 40 50

60 70 80

100

Correction

rate

outlined

or

14.7

supply

foot

pressure.

is

measured

pressure

which

the

would

volume

into

to

multiply

pressure

to

determine

be

for

proper

the

which

must

equivalent

Pressure

Factor

1.05

1.11

1.18

1.25

1.32

1.39

1.45

1.52

flow

required

the

heating

The

number

the

heating

burner

requirements.

TABLE

in

pressure

psi.

measure

must

be

indicated

be

obtained

cubic

feet

the

factor

in

order

input,

pressure

number

pass

number

TABLE

Correction

is

measured

by a meter

for

supplying

3

Maximum

the

gas

The

and

known

by

the

measured

at

meter

obtained

what

to

provide

divide

correction

of

through

of

4

Regulator

Inlet

Pressure

9 10 11 12 13 14 15

maximum

value

of

cubic

value

input

BTU/Hr.

1,046,000 1,255,000 1,674,000 2,092,000

2,511,000 2,929,000 3,34 7,000 4,184,000

is

in

cubic

pressure

the

correction

in

order

meter

from

base

pressure

index

from

the

meter

the

desired

cubic

the

cubic

factors

psig psig psig psig psig psig psig

in

terms

reading.

boiler

(BTU/CU.

utility

feet

can

per

(BTU/CU.

(BTU/HR.).

Input

section

usually

at-

feet

at

which

fac-

to

con-

into

the

at

"base"

an

actual

it

reading

by

Table

index

the

volume

flow

factor.

feet

at

This

line

meter

feet

at

base

Pressure

Factor

1.59

1.66

1.72

1.81

1.86

1.93

2.00

of

is

at

is

4.

to

As

an

boiler

is

equipped

BTU

natural pressure ments

can

Chapter

example:

installed

with a standard

of

5-Adjustment

gas

is

3 psig.

be

determined

assume

at

available

The

Pressure

Correction since gas

pressure.

WC

altitude

gas

pressure

for

the

2,000

has a bearing

The

standard

at indicates a correction Multiplying lated This

is should can

be

input

gas

requirement the be

adjusted.

made

needed

these

initial

later,

for

results

pressure

burner

flow

Since

the

gas

flow

rate ditions supply mine the "correct" factor

BTU/HR BTU/CU.

of

pressure

the

gas

for 3

flow,

flow

into

this

Input

FT.

correction

through

rate

the

answer

psig

by

(Table 4 ).

2,929,000 1,000

2,929

1.18

This

is

the

CFH

(at through requirement be

Checking

Your developed from revolution knowledge observation

Lacking a chart "clock

the

delivered.

gas

the

meter

the

(1)

Turn be

( 2)

Set

(3)

Note for 3

meter

of

Gas

supplier to

determine

of

the

of

the

period.

gas

off

served

burner

meter

minutes.

so

2,929

flow

based

10

flow

of

meter"

all

other

by

at reading

that

2,000

feet

gas

pressure

as

feet

altitude

gas

sea

level

factor

in a calculated

of

approximately

to

Slight

if

additional

necessary,

rating.

is

based

must

the

meter

dividing

burner

by

input

applying

CFH

OR

2,929

CFH

atmospheric

THEN

2482

line

pressure)

that

the

CFH

(at

can

generally

the

cubic

on

the

cubic

feet

rate

after a relatively

this

nature

as

follows:

gas

the

meter.

high

fire.

and

a 70

above

train;

and

with

an

and

follows:

must

on

the

train

(Table 1 ).

of

1.13

for

which

to

obtain

on

standard

be

of

the

BTU

(Table

the

(Cubic

(At

"base"

CFH

which

equivalent

base

furnish a chart

feet/hour

number

dial.

This

it

appliances

record

Maintenance

horsepower

sea

level;

that

1,000

incoming

flow

require-

be

made

net

regulated

requires

5.0"

Table

2,000 feet.

net

regu-

5.7"

we.

the

regulator

adjustment

the

con-

made

for

3 psig.

Deter-

content

3)

and

correction

feet/Hour)

14.7 #

pressure)

must

pass

full

input

pressure)

reading

of

seconds

provides

short

is

possible

that

may

consumption

is

gas

2

gas

the

of

will

per

a

to

5-13

Chapter

(

5---Adjustment

4)

The

following

quired Input

(BTU/CU.

feet

for 3

( 5)

Apply tor

to

this

(6)

To

illustrate:-

previous BTU/HR---;-

input

in cu. ft.

2,929,000---;- 1000---;-

pressure)

146.5

---;-

cu ft. (line

(7)

If

the

agree

with

mula

adjust

crease

NOTE:

The all

practical adjust supplier correction tion specific gas

used.

COMBUSTION

Gas

input creasing stream justment ner

at

wide

open. In

the required linkage the

valve

plete

turns.

sion

is

It

is

not nection final

setting

ment

of

valve

opens

an

overly

tween

air

ratio

If

it

greater

Points

complete should

or

of

the

to

high

event

proceed

by

backing

is closed.

released.

practical

points

the

rich

the

two

can

opens

air

flow

to

remember its

travel

adjustment

decreasing

the

fire

Adjust

damper rapidly,

formula

gas

input

(BTU/HR)

FT.)

---;-

minutes.

any

necessary

answer

example,

BTU/CU.

1.18

(pressure

pressure)

input

timed

the

rating

the

gas

or

decrease

information

purposes

controls

can

factors

BTU

content,

gravity,

ADJUSTMENT-

pressure

regulator.

regulator

and

with

linkage

or

as

out Then

the

to

list

or

of

the

shou-ld

provide a coordinated

and

compared fire will firing

positions.

cause

sooting

too

slowly

should

are

full

travel

its

required

and

Maintenance

will

for a 3

20 =

Gas

pressure

to

obtain

using

circumstances

compute

FT.---;- 20 = 3

OR

20

= 146.5 cu. ft.

correction)

for 3

indicated

pressure

flow

as

given in

sufficient

for

gas

if

necessary

that

take

exact

temperature,

is

accomplished

the

pressure

should

the

gas

regulator

follows.

the

low fire

run

screw

connecting

specific

setting

angles

the

gas

to

occur

during

This

of

the

then

the

extinguish that

the

and

that

arc

without

provide

minute

period:

Heating

input

correction

the

desired

as

follows:

minutes

by

regulator

required.

this

section

to

input.

Your

furnish

into

considera-

base

pressure,

etc.,

GAS

of

gas

Any

required

be

done

with

butterfly

adjustments

Initially

stop

screw

out

two

rod

so

that

of

the

arms.

valve.

the

If

air

transition

improper

fireside

surfaces.

proportionally

the

flame.

motor

the

arm

valve

excessive

the

re-

Value

in

cubic

fac-

rate.

from

minute

(base

= 124.5

does

not

the

for-

to

in-

is for

set

and

gas

exact

of

the

by

in-

down-

ad-

bur-

valve

are

set

the

so

com-

ten-

the

con-

The

move-

the

gas

damper,

be-

fuel-

must

arm

stretching the

swivel

less

distance

arm

travel,

hub

or

away

This

low fire

tive

until

tion

is

established.

After

operating

time

to positioning it

progresses pressure ment

is damper, extinguish Determine failure

At wide

shaft.

is

high

just

before

fire

open

Set

touching

Determine reading rections

are increase the

pressure clockwise wise

to

decrease

When ther

With

the

adjustment

proper necessary must

be

justments When

burner

the

down, necessary linkage. terfly of

Any ing are

To

valve

one

turn

adjustment

of

the

made,

affected.

The

appearance indication flame lucent

Proper firing bustion the (C02), the

will

yellow.

setting

must

gas

content,

oxygen

flue

of

the

over

ride

joint

in

the

motor

it

will

travel.

move

the

connecting

from

it

if

decreased

setting

proper

should

gas

pressure

at

low fire for a

assure a warm

switch

is

too

not

it

is

the

toward

low

properly

possible

flame.

and

to

"high''.

high

or

if

that

Immediately

correct

co-ordinated

repeating

position,

as

and

the

as

outlined

necessary

or

decrease

indicated

lock

the

valve

actual

the

by

high

in to

regulator.

to

increase

pressure,

pressure.

high

fire

gas

flow is

of

the

regulator

gas

flow,

to

obtain a desirable

done

with

the

air

with a combustion

high

fire

air/fuel

re-light

to

re-adjust

assure

is

always

of

override

recheck

of

its

vary

of

be

analyzer.

by

(02),

and

the

that

low

the

stop

must

not

springs.

to

determine

or

color

efficiency

from

transparent

the

air/fuel

established

This

percentage,

and

carbon

gas.

springs.

arm

To

be

for

boiler,

Observe

fire.

the

butterfly

increased

condition attempt.

butterfly

the

slot

fire

arm.

gas

flow

another obtain gas

pressure

Turn

its

established,

any

further

damper.

gas

ratio

check

low

fire

position

same,

screw

for

cause

If

linkage

that

of

the

gas

since

ratios

by

the

instrument

of

The

closer

that

is

to

the

hub

increase

rod

travel

regarded

sufficient

turn

In

on

stop

closer

high

the

valve with air

turn

causing

valve

the

screw

the

is

required.

as

fire

opera-

period

damper

burner

event

the

flow

burner

should

end

until

valve

to

tenta-

move-

may

flame

of

from a meter

section.

the

required

adjusting

or

counter

by

adjusting

If

cor-

input,

screw

clock-

no fur-

is

required.

adjustment

flue

gas

analysis

Check

all

ad-

analyzer.

is

set,

shut

low

fire.

It

may

stop

screw

or

of

the

but-

allow a minimum

over-travel.

extensive

stretch-

adjustments

high

fire is

flame

is

not

an

efficient

blue

to

trans-

at

all

rates

use

of a com-

measures

carbon

monoxide

dioxide

(CO)

the

of

as

gas

air

off.

be

its

it

the

be

the

not

an

gas

of

in

5-14

Chapter

&-Adjustment

and

Maintenance

Burner percentage theoretical gas this or excess authorities be detectable

Subject amounts mended

10-1/2%

readings

LOW The

be closed assuring ignition damper closes upon fore, reaching

The motor during direction

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efficiency is

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carbon

monoxide

air

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and

operated

percentage

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of

that

be

of 2 to

with

excess oxygen,

C02

measured

C02

present

11.7%.

when

there

(CO). A

of

course,

an

air-fuel

regulations

readings

attained

4%.

by

the

amount

in

the

flue

C02

percentage

As

shown

for

in

is no excess oxygen (02)

definite

required

the

ratio

of

carbon

pertaining

it

of

with

burner

percentage

by

most

should

that

indicates

monoxide.

to

is

generally between corresponding

gas.

natural

Chart

local

specific

recom-

9-1/2

or

The

5-5

of

gas

never

and

02

H. SWITCH AND CAM ADJUSTMENT

FIRE

low fire

when

completion

must

low fire

terminals B and

adjust

1.

Remove

SWITCH -ALL

switch

to

complete

that

damper

takes

place.

motor

drives

the

motor

be

actuated

its

closed

switch

the

closing

of

the

CLOSE

the

switch:

motor

/ \

(LFS),

is

The

to

resumes

of

pre-purge.

position.

circuit

stroke

cover.

used

programmer

in

low fire

switch

open

during

just

prior

is

connected

W.

The

(motor

arrow

12

I/

11

BOILERS

on

all

position

opens

pre-purge

its

low fire

The

switch

to

switch

shaft

on

outside

Fust

V!S!IJI,.

'.:

boilers,

circuitry

when

position

the

damper

to

damper

makes

moves

of

I I

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of

must

before

the

and

there-

B-W

in

the

case).

Stack

Haze

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Per

c~t

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60

5J

FIGURE

02

111

40

Per

CP.nl EltCP.SS A1r

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Fit~

30

Gas

20

5-5.

10

FLUE

FOR

GAS

ANALYSIS

NATURAL

CO---

GAS

Disconnect switch

2.

Insert a screwdriver

cam

(white

the

motor.

a

proximately

3.

Move moving arrow switch degrees

cam.

cam

on

the

should

on

power

plastic) Each

20

degrees

the

correct

in

the

outside

make

motor

supply

before

in a slot

located

slot

in

the

of

near

motor

number

direction

of

the

at

approximately 8 to

closing.

IMPORTANT!

The

switch

closer

should

not

than 5 degrees

be

from

adjusted

ends

stroke.

4.

Repower which

the

motor

switch

and

makes.

check

necessary.

HIGH (CBH or

A Q607 A the that 40 switch, the

The to purge. is programmer wiring

The the While also

FIRE

25-40

HIGH

damper

actuates

and

50A

when

CBH

high

prove

Its

nearly

diagram

following

switch

particularly

serve

a)

BEFORE ting the scale shown

b)

Release

c)

Loosen two

cam

movement.

OIL

and

FIRE

switch

motor,

the

high

oil

fired

insurance

50-100

fire

switch

that

the

terminals

open

and

de-energizes

for

directions

prior

as a guide

attaching

bracket,

scale

so

is

approximately

in

Figure

the

both

cam

lobes

(silver

VALVE

50A)

SWITCH

(single

serves

fire

boilers;

requirements

boilers.

(HFS)

air

damper

should

just

sequence

to

its

attachment

useful

for

depress

that

the

5-6.

scale

lock

cam

locking

so

that

colored)

Tighten

SWITCH

(CBH

microswitch)

as

the

oil

valve

or

See

Figure

is

used,

opens

make

when

before

the

damper

timing

are

based

during

the

final

the

zero

and

switch

scale

at

replacement, adjustment.

mark the

loosen

screws.

only

will

cause

the

differential

screw.

d)

The

mally

the

index

switching

open

motor

mark

action

leads

(red

reaches

its

as a reference

desired

and

open

blue)

position.

adjusting

in

the

cam

equals rotation.

of

degrees

of

the

motor

case.

to

of

the

Readjust

50-100)

attached

auxiliary

on

the

as

the call

1-1.

when

during

the

timing

motor.

of

the

on

to

the

to

the

lock

and

on

index

thumb

the

operational

switch

is

for

to

point,

the

switch

center

ap-

by

OPEN

The

10

operate

motor

point

switch

CBH

25-

high

fire

for it,

on

required,

pre-

damper

of

the

See

control.

adjusting

motor.

they

moun-

rotate

the

black

mark

nut.

Align

the

lever

cam

the

nor-

close

Using

the

push

the

of

at

if

to

as

5-15

Chapter

scale

approximately Release

e)

Turn

lever operational cam click in cam's

f) No

make that and that switch.

g)

Tighten

h)

Mount

red

(HFOV)

shown yellow

be

i) Check

actual

5--Adjustment

lock

down

the

scale

cam

until

is

exactly

cam

at

this

point

the

switch.

locking

cam

and

the

operational

the

screw.

differential

the

break

differential

thumb

the

switch

and

blue

leads

or

to

the

on

your

lead

is

not

insulated

out

to

the

operation

operating

and

Maintenance

and

turn

70°

(motor

lock.

the

cam

over

the

lobe.

Slight

should

Tighten

is

desired

of

the

cam

lobe

cam

has

screw.

on

the

to

the

high

fire switch

boiler

wiring

required

prevent

short of

conditions.

the

scale

stroke

roller

of

outer

corner

movement

produce

the

contacts,

(brass

lobe

are

no

motor.

oil

valve

diagram.

and

its circuits.

the

switch

Readjust

clockwise

is 75°).

the

switch

of

an

audible

operational

between

so

be

colored)

aligned

effect

on

Connect

circuit

(HFS)

end

should

under

the

cam

the the

the

sure

so

the

as

The

if closing used high is two-thirds

HIGH CBH

When switch switch

damper The

first circuit. air

damper

The

following

the

switch While also

serve

a)

BEFORE bracket, scale is 5-7.

necessary

at

the

for

proving

fire

position

not

critical

and

FIRE

25

SWITCH

THRU

insurance

on

the

25

(two

micro-switches)

motor.

switch

The

second

is

open

directions

prior

particularly

as a guide

attaching

depress

so

that

close

to

the

to

assure

desired

that

the

during

and

it

full

motor

-

40

AND

50A

requirements

thru

40

and

is

used

for

switch

is used

during

are

to

its

attachment

useful

during

for

final

switch

the

scale

the

zero

mark

index

mark

oil

valve

point.

air

If

damper

pre-purge,

should

travel.

call

50A sizes, a

is

attached

the

high

to

pre-purge.

based

to replacement, adjustment.

to

lock

on

as

shown

opening

the

make

for a

fire oil

prove

on

the

and

the

black

and

switch

reaches

setting

between

high

fire

Q607B

to

the

valve

that

the

adjusting

damper.

they

mounting

rotate

the

scale

in

Figure

is

SCALEPLATE

(BLACK

DIFFERENTIAL

LOCKING

SCALE)

SCREW

CAM

ROLLER

SWITCH

FIGURE

CAM

-----:

5-6.

Q607A

AUXILIARY

SWITCH

(SINGLE

INDEX

MARK

OPERATING

(SILVER)

DIFFERENTIAL

CAM

(BRASS)

THUMBNUT

SCALE

LOCK

MICRO-SWITCH)

CAM

5-16

Chapter

5--Adjustment

and

Maintenance

b)

Release nut

c)

Proceed tion ting

d)

Place Make

screw is on

the

scale

e)

Loosen two

cam

movement. screw.

f)

Depress cam over lobe

the

and

with

to

get

on

switch

the

sure

switch

plate

both

cam

(silver

the

roller

the

outer

when

scale

the

top

steps

the

high

No. 1.

second

that

the

cam

is

set

cam

lobes so

colored)

Tighten

scale

of

the

corner

the

scale

lock.

set

of

'c'

thru

fire oil

set

the

operational

opposite

is

near

locking that

will

lock.

No. 2

indicates

Remove

cams.

'i'

of

valve

of

cams

side

to

operate

zero).

screws. Align

only

cause

the

differential

Turn

switch

of

the

operational

the

preceding

(HFOV)

on

the

cam's

of

the

(when

the

operational

switch

cam

so

lever

60°

or

thumb

locking

shaft

that

is

exactly

more

sec-

set-

shaft.

as

the

lever

cam

the

cam

of

motor damper

the

leads wiring required prevent a short

g)

Check

tual

necessary oil

valve

the

high

is

open.

HIGH CBH

Oil fired

FIRE

50-100

CBH adjustable end

of

the

motor.

See

travel.

opening

into

the

diagram.

and

its

the

operation

operating

cam

opens

fire

switch

OIL

boilers

cam

actuated

jackshaft

Figure

1-6.

This

switch during circuit

The

end

should

circuit.

of

the

conditions.

adjustments

at

the

desired

makes

VALVE

in

SWITCHES

sizes 50

switches

connected

Their

purpose

is

used

pre-purge.

as

indicated

yellow

be

switches

to

assure

point

when

thru

located

to

Connect

on

lead

is

insulated

under

Make

that

and

the

damper

-

100

have

at

the

damper

is

to

energize

prove

your

not

to

ac-

any

the

that

two

the

SCALEPLATE

(BLACK

OPERATING

LOCKING

DIFFERENTIAL

OIL

(BRASS)

VALVE

SWITCH

(HFOV)

SCALE)

SCREW

CAM

(

INDEX

MARK

THUMBNUT

DIFFERENTIAL

LOCKING

SCREW

CAM

ROLLER

HIGH

FIRE

SWITCH

(HFS)

CAM

FIGURE

5-7.

Q607B

SCALE

AUXILIARY

LOCK

SWITCH

(TWO

MICRO-SWITCHES)

5-17

Chapter

the

(HFOV-2)

The

position point of movement of combustion plained

actuates.

The way termediate to smoother high the amount open a

point is an cam when reposition

The tuated the position provide

In position possible check replaced, correct. checked

5-Adjustment

intermediate

variables

of

actuation

damper

opening

by

first

between

fire,

providing

fire

high

of

at

approximately

when

no

incomplete

improper

must

the

second

just

basis

or more

the

event

to

for

The

I.

Since

the

able

only damper correct ficient that the gas-fired normally

are

Normally, slightly travel. the

a

the

justment

Turn

combustion.

transmit

air

required,

With

screw

slight

damper

the

ratio

damper

open. A stop

haze

(HFOV-1)

oil

valves.

involved

the

cams

by

is

directly

travel

may

switch

oil

change-over rates fire,

be

valve

cam

as

of

proper

make

occasionally

on a particular

be

set

to a greater depending needs.

detailing

air

oil

of

linkage

cams

their

set

Cam

the

(AS-1) is

low

and

high

valve

to

an

increased

and

vice

the

air

damper

into

the

sufficient

combustion

air/fuel

guided

damper

or

of a component

ratio.

by

opens.

to

slightly

valve

switch reaches

a

combustion

adjustment

less

and

original

switch

sure

that

screw

for

If

air

open

between

versa.

mid-range,

air

holding

AIR DAMPER

rate

at

which

within

is

unit)

need

to

screw

damper

the

of

motion

(and

are

further

proceed

at

low

the

allow

appears

until

narrow

primary

fuel

to

The

from

to

the

set

at

adjustment.

as

fire

screw

burner

the

damper

in

the

haze

in

this

positioning

and

Maintenance

and

the

preclude

degree

position

function

actuated

fire.

and

boiler.

is

The

observing

smoke

retard

(AS-2)

at

this

replace

position;

actuation.

wiring

tightness.

specifying

of

angle

to

burner.

or

lesser

job

conditions

can

of

This

causes

the

second

firing

the

As

it

moves

allows

The

but

present

or

smoke

positioning

the

or

haze

valve

should

its

open

analysis,

may

be

point.

replacement,

them

but

If

connections

the

cam

ADJUSTMENT

fuel is

air

the

firing

position.

delivered

limits,

means

to

insure

arms

and

the

gas

butterfly

factory

follows:

the

damper

limits

at to

the

stack.

disappears.

switch

setting

of

obtaining

connecting

damper

and

If

the

low

further

Gradually

high

since

their

the

amount

Damper

amount

best

be

the

switch

to

close

mid-

the

nozzle

rate

for a

low

and

towards

an

increasing

valve

should

definitely

so

that

there

caused

of

fire

or

stack

is

noticed,

opening.

be

position.

damper

required

as

near·

be

sure

a

switch

should

is

adjust-

of

the

most

motor

valve

should

adjustments

is

cracked

amount

rate,

back

close

until open

Lock

the

to

high

fire

the

and

ex-

in-

the

at

by

the

ac-

On

to

note

as to

are

be

air

the

ef-

rod

to

on

not

of

off

ad-

fire.

it

is

a

Turn

the

close

the Re-adjust tion

where

ment

screw

Consider correct. flue

Adjust damper cycles

the

much sufficient

The

linkage

Periodically tightness casionally cone

The and

The build vessel. boiler The portance ted and prevent

lation area. pound

this

ches flange the

remove

wrench

A

Final

gas

analyzer.

the

movement

to

high

air

flow is

air

following

adjustment:

(a)

The

its striction

(b)

The

is

to

(c)

The

when To away

(d)

Final dinated per

(e)

Over-travel extend

type

safety

deserves purpose

up

The

is

installation

in a vertical

Code

build

of

Apply

to

can

distort

on

connected

mounting

side

in

drip

pan

high

fire

adjustment

air

damper

the

screw

to

the

haze

disappears.

in

this

position.

these

settings

adjustment

linkage

may

amount

damper

full

closer

the

amount

its

decrease

from

adjustments

motor.

of

oil lubricant.

J.

valve

over

size,

determined

to

its

required

foreign

only a moderate

male

the

elbow

and

occurs.

fire

and

coordinated

extinguish

will

factors

motor

travel

can

cause

the

swivel

hub,

the of

connecting

opening

the

movement

linkage

its

spring

check

for

setscrews

swivel

joints

SAFETY

is a

attention

of

the

valve(s)

the

design

rating

of a valve

service

position

drains

up

of

material

threads

the

seats.

flats

provided.

valve,

bolts

down

outlet

outlet.

or a flexible

screw

until a slight

open

the

damper

Lock

to

be

only

should

the

Observe

back

the

cause a smokey

can

must

range

damage.

less

damper

joint

hub.

should

of

should

to

proper

to

be

arms

so

to

low

with

the

flame

serve

be

able

of

75

joint

in

distance

opening

is

closer

move

result

the

damper

not

fullest

with a graphite

stretch.

adjustment.

prevent

VAlVES

very

important

accordingly.

is

to

prevent

pressure

and

number

by

the

ASME

is

of

life. A

back

valves

valve

so

that

can

be

pressure

around

amount

and

avoid

Use

only

use a new

evenly.

by

discharge

properly

overtightening

flat

When

gasket

Do

using a pipe

connection

to

slightly

haze

appears.

to a posi-

the

adjust-

approximately

made

using

that a smooth

the

burner

to

be

fuel flow.

while

changeover.

as

to

degrees. A re-

the

it

will

the

be

required

slippage.

safety

of

the

of

valves

Boiler

primary

must

and

the

of

jawed

installing

not

as

sure

that Too

an

guides

complete

motor

arm

travel.

increases

to

the

hub.

ball

joint

in a coor-

and

dam-

Check

or

sili-

device

pressure pressure

on

Code.

be

mounpiping

piped

accumu-

valve

seat

pipe

com-

wren-

and

draw

install

between

a

it

in-

in

to

Oc-

a

im-

to

as

a

or or

5-18

the

valve

and

the

escape

Figure

arranged

bear Do

working require work

Follow

spector

frequency

lever based spector, cordance

Boiler

Avoid

even Safety to

When a pop

pressure

allowing

mal

Do

of

side

hold

purge

area

Frequent

seat

This

down

ment.

manufacturer

Avoid

safety

recommended.

desirable

valve

Steam

economy,

possible.

Should

tion

terminals 1 and 2 of

that

ing. replaced. should

To setscrews bonnet.

1-7.

upon

not

paint,

parts

any

properly.

the

regarding

or

by

on

and/or

and

excessive

one

valves

assure

service.

not

hand

the

stamped

of

the

valve

accumulated

and

will

time

Repair

having

valve

longevity.

is

K.

the

by

applying

the

main

If

the

it

remove

The

discharge

and

supported

the

valve.

oil,

or

otherwise

of

the

lubrication

recommendations

valve

of

testing,

raising

the

with

Pressure

opening

that

to

the

it

to

operate

disc.

then

usage

disc

cause

of

and

expensive

wastage

the

recommendation

the

valve

sections

operation

can

should

they

test

is

set

open

and

set

pressure

When

in

an

foreign

allow

of

the

to

become

the

boiler

of a valve

or

his

the

operating

set

pressure.

An

will

assure

to

should

MOTORIZED

valve

fail

test

shut

off

actuator

The

actuator

be

disassembled.

the

actuator,

that

hold

the

pipe

is

recommended.

piping

so

safety

or

inspection

either

steam

manufacturer,

VI

Vessel

provide a means

be

operated

are

in required, pressure

reseat

the

valve

hand

open

position

the

valve

safety

wire

valve

to

for

must

authorized

even

better

generate

must

that

its

cover

valve. A valve

protective

of

by

the

pressure,

of

and

VII

Code.

of

the

only

good

raise

of

the

as

with

exerted

operating,

material

to

valve

drawn

leak

valve

repair

be

done

representative.

pressure

A 10%

greater

seat

and,

be

avoided

GAS

to

operate,

leads

of

the

proper

the

actuator.

cock is

fails

is

loosen

actuator

to

not

closed

operate,

field

the

collar

be

weight

any

interior

coating

your

boiler

and

testing.

use

of

the should

your

boiler

and

of

the

safety

of

often

working

the

operating

safety

it

would

less

than

on

the

be

long

enough

from

snap

will

cause

or

steam

and

necessitate or

only

too

differential

tightness

for

the

whenever

VALVE

check

its

voltage

Make

prior

it

repairable

two

5/32"

to

the

See properly does

not

or

does

not

in-

The

lifting

be

in-

in

ac-

ASME

valve

as

leakage.

enough

order.

valve,

in

nor-

75%

under-

sure

and

to

the

seat

shut.

the

cut.

replace-

by

the

near

the

and

sake

opera-

certain

to

test-

must

be

nor

allen

valve

to

is is

of

to

Chapter

After

replacement,

shut

off

to

determine

the

valve

colored The

closed ponent.

has a visual

indicator;

auxiliary

indication

L.

GAS

Foreign disc

assembled, assembly

damaged

is A

when

zing

and tube that

assembled. the

Coils

from valve.

insulating

stalled

The pletely rear Normal pense tory. spection condition

unexpected repairs.

Frequent recommended. type of

intervals

best

are

Rear Door

The

baffle

castable

Burned the trouble,

PILOT~FUEL

matter

can

cause

however,

to

during

in

proper

low

hum

coil is or a chattering clean

plunger

thoroughly.

plunger

Take

plunger

may

be

the

line.

Check

washers

in

proper

Cleaver-Brooks

installed

head,

the

maintenance

and

prolongs

Preventive

will

of

wash-coating

mortar,

light

cream,

will

determined

opened

rear

door

tiles

and

refractory

or

discolored

door

does

but

5--Ad.iustment

cycle

that

yellow -shut;

switch

SOLENOID

between

leakage.

care

be

sure

that

the

removal

order.

or

buzzing

energized.

noise

assembly

Do

not

tube

and

care

not

tube.

replaced

Be

sure

coil

position

or

order.

M.

REFRACTORY

boiler

refractory.

inner

door

requires

the

maintenance

keep

the

refractory

and

unwanted

High

temperature

diluted

for

may

with

is

used

vary

with

by

the

inspection.

is a

steel

lined

with

(See

paint

not

necessarily

be

an

the

valve

it

opens

indicator,

normally

is

replaceable

VALVES:

OIL-VENT

the

valve

Valves

must

be

internal

and

will

normally

If

valve

develops

check

and

use

any

solenoid

to

nick,

without

to

retaining

operating

operator

of

for

operator

shell

removing

turn

and

make

is

shipped

This

and

little

through

and

down

refractory

water this

purpose.

operating

containing

insulation

Figure

on

the

indicate

indication

and

Maintenance

with and

observe

red -open.

used

as a valve

VALVES

seat

are

readily

used

during

parts

that

re-assembly

be

for

proper

interior

oil.

Make

are

tight

dent

off

power

sure

springs

consists

the

furnace

time

life

of

periodic

informed

will

guard

time

and

surfaces

bonding

to

the

consistency

Re-coating

loads

when

material

5-8).

outer

of

the

fuel

closes.

the

as a com-

and

seat

disdis-

are

not

audible

loud

buz-

voltage

plunger

sure

when

re-

or

damage

the

valve

to

the

that

any

are

rein-

with

com-

of

the

liner.

and

ex-

the

refrac-

of

the

against

major

air-dry

and

are

the

heads

horizontal

and

surface

refractory

other

con-

If

in-

is

of

5-19

Chapter

ditions

(a) (b) (c)

5---Adjustment

such Leaking Improper

Door evenly

(d)

The blocked

(e)

Repainted paint.

Therefore, re-working:

(a)

Check

(b)

Check tecting

(c)

Check cracks,

(d)

Check ends

(e)

Check

as:

gaskets.

retaining

tightened.

air

line

or

before

condition condition

the

breaks,

for

of

baffle

tightness

seal.

bolts

to

the

loose.

with

other

assuming

of

tadpole

horizontal

chipped

cracks

tile.

of

and

Maintenance

insufficiently

rear

than

that

tadpole

insulating

gasket.

baffle

corners,

in

castable

door

bolts.

sight

tube

heat

refractory

gasket.

cement

tile

etc.

refractory

or

un-

may

resistant

requires

pro-

for

large

be

at

(f)

See

that connections with

an

It

is

normal

develop

indicates refractory degree

expected

when

thin

improper

materials

with

to

examined

approximately

close

at

high

that

are

relatively

clean

them

and mortar. able

Any

refractory

in a similar

After

opening surface Clean fiber the shell.

of

the

brush

mating

Remove

the

surface

surfaces

air

line

are

air

hose.

for

refractories

"hairline"

design

expand changes show

minor

at

in

low

1/8''

temperature.

large

fill

with

gap

that

and

the

fashion.

the

rear

door

with a scraper

of

the

to

avoid

of

all

dried

to

sight

tight.

If

exposed

cracks.

or

and

temperature

cracks

temperature.

across

may

If

(1/8"

high

may

show

baffle

door,

refractory

damaging

the

baffle

out

tube

is

clear

necessary,

This

to

by

blow

hot

no

workmanship.

contract

they

should

due

to

contraction

Cracks

be

expected

there

are

any

to

1/4"

in

temperature

between

tile

should

clean

off

the

or

wire

carefully

the

surface.

tile

and

the

sealing

and

clear

gases

to

means

Since

to

some

be

up

to to

cracks

width)

bonding

the

cast-

be

filled

flange brush. with

Clean boiler

material.

a

BOILER

FlANGE

GASKET

CLIPS

841-507

INSULATING

CEMENT

872-26

TADPOLE

GASKET

ROPE

BAFFLE

SEAL

5-20

SIGHT

AIR LINE

TUBE

FIGURE

5-8.

REAR

DOOR

OPEN

Chapter

&--Adjustment

and

Maintenance

Wash-coat

tory

prior

The

upper insulating ner

door. A thin with a brush face.

If

the

baffle ment, sentative Department ing

refractory.

Front

The

castable

cracks ever, pansion

A

brush Minor

cutting they

Should remove Inspect Reinforcing used. Vee Part

Mix sistency. with Trowel patched. bottom ness apply in

Allow use

to

Furnace

Maintenance the

ing

or

are

Should replace may ted nace

If

contact

or

major

Inner Door

front

insulation

may

these

when

thin

wash-coat

is

helpful

repairs

out

are

clean

the

existing the

The

Block

Number

the

material

Mixing

no

portion

this

If

of

equal

horizontally

layers

avoid

fingertips.

replacement

until

to

air-dry

of

boiler

rapid

Unerr

entire

high

temperature

detected.

segments

the

break

so

that

and

liner.

obstruct

the

lower

to

closing.

half

of

the

material

tile

write

for a

repair

inner

develop

will

affected

entire

retaining

wire

recommended

Mix

mixture

replacing

door

to

is

consists

This

entire

out

it

will

similar

wash-coat

is

helpful

or

the

your

to

copy

or

door

generally

the

boiler

mixture

in

can

be

and

installation

material

suitably

and

is

872-162).

with

should

either

and

the

protecting

back

the

required

as

long

required,

drying

Face

should

of

the

refractory.

should

not

the

is

necessary,

local

after a period

maintaining a hard

accomplished

then

pins

into

complete

apply

of all

bonding

fuse

half

of

the

rear

door

contains a lightweight

to

that

used

mixture

in

maintaining a hard

refractory

the

Cleaver-Brooks

of

bulletin

replacement

is

lined

material.

tend is fired.

areas,

patching

and

insulation

available

water

be

wetter

any

the

and

as

fire

of

the

occasional

joints

be

liner

be

removed

to

burner

requires

Cleaver-Brooks

C10-4101

with a lightweight

Thin,

to

close

applied

by

making

as

require

clean

replace

attached

in

50

to a troweling

completely

or

drier

areas

that

insulation

mixture

shroud.

forth

across

thickness

possible.

as

slowly

material.

wash

or

cracks

mortar

done

as

burn

away

Any

refractory

as

the

bottom

flame.

refer

to

Chapter 7 and

door

refrac-

in

the

in-

applied

of

gently

replacement,

to

may

is

than

With a trowel

If

with a trowel

soon

gently

replace-

repre-

Service

cover-

rear

"hairline"

time,

due

to

with

surface.

enlarging

certain

required.

bare

metal.

if

necessary.

also

known

lb.

bags

uniform

another.

are

being

begin

to a thick-

the

is

reached.

immediate

as

possible

coating

by

apply-

as

cracks

or

fall

as

detec-

of

the

sur-

door

how-

ex-

or

that

be

as

(CB

con-

at

door

of

out,

that

fur-

order

proper

ing

refractory

the

furnace refractory sure

new

furnace

It

is

recommended marked, proper are

desirable. shave a portion

If

a fill piece is

fit.

this

piece

Allow immediate and

intermittently

N.

Whenever

a

spection, hardening be

replaced. graphite certain The

flange

any

hardened

Check

seal.

Replace

condition, prior

to

positioned.

If

it

is

tube

sheet Place a new (

853-924)

with

furnace

NOTE:

Generously

ture

of entire around shown adjacent

When protect

tween The

insulating

the

front

tion

when

When

closing

and

tightened

replacement

and

covered

cement

liner

metal

removed

amount

at

the

refractory

use

DOOR

the

head

and

Coat

mixture

that

all

of

the

condition

liberally

closing.

necessary

area

piece

on

the

cement

Earlier

ments

serve diameter bars

be

used.

apply a seal,

insulating

rear

door

the

inside

in

Figure

to

the

door

the

tadpole

the

refractory

head.

closing.

the

thoroughly

by

or

other

seating

for

of

Generally

from

of

firmly

soundness.

that

and

refractory

one

required,

bottom

to

air

boiler

if

possible.

ClOSING

front

or

gaskets

brittleness.

the

before

gasket

cement,

if

tack

as

is

pulp Make

evenly

retaining

door

should

of

necessary.

coat

Make

sure

to

replace

to

remove

of

1-1/2"

lip

of

the

or

models

welded

a

gasket

rope.

removed

cement circumference. diameter

5-8.

Also

baffle

closed,

gasket

surface

seal

sure

door,

to

materials.

the

liner foreign

the

tile

then

it

will

or

more

cut

of

the

dry

as

is

required

rear

door

should

Doubtful

gasket

closing

scale,

the

rope

If

it

with

that

the

all

diameter

baffle

an

adhesive.

had

several

across

It

is

and

consisting

and

of

coat

tile.

the

pulp

and

is

not

that

bolts

should

avoid

Remove

clean

that

to

remove

material

to

the

steel.

be

dry

fitted,

reinstalled

cement.

be

necessary

tile

it

to

fit

furnace.

long

as

fire

AND

suggested

1-1/2"

is

with

the

rivets

be

clean

etc.

used

the

rope

an

the

rope

rope,

old

sealing

tile.

the

retainer

water,

Place

the

head

the

tube

will

to

form a seal

and

the

needed

gaskets

cocking

SEAUNG

opened

be

gaskets

as a baffle

insulating

wire

rope

Hold

steel

tube

diameter

of a pulp

be

exist-

portion

all

to

Inspect

match

with

Thin

joints

to

obtain

and

install

possible.

at

low

for

checked

should

an

oil

door.

Make

are

in

place.

and

free

is

in

good

is

properly

brush

material.

it

in

bar

sheet

for

that

around

the

gasket

sheet

compress

tube

sheet.

or

used

are

in

run

in

door

of

old

in-

the

to

a

If

rate

infor

and

of

pulp

the

place

seg-

to

5/8"

these

rope

mix-

the

pulp

as

area

to

be-

on

posi-

snug

and

5-21

Chapter

5-Adjustment

and

Maintenance

damaging

and center overtighten. top

and door in

operation

any NOTE:

gasket.

alternate

bolt

bottom,

is

secured

expansion.

Proper avoid loss

0.

The

position

the

air

intake

the

output should same 1/32". used

Check tightened for

deposits can

cause a decrease

unbalanced

If

motor connected, proper models front

the

impeller

capacity

not

rub

time

Spacing

to

obtain

occasionally

to

was

before

is

counterclockwise

of

the

P.

Soot

and

non-combustibles

and

if

allowed transfer sumption. moisture form metal.

Clean-out intervals fuel, efficiency. A used, accumulation gas

Tube and end. removed. removed

Refer on

to

Soot

absorbent

corrosive

should

depending

internal

can

be a guide

temperature.

cleaning

rear

doors.

All

loose

Any

from

to

Section N of

properly

Start

between

until

both

Continue

tightening

and

re-tighten

sealing

leakage

of

heat

fORCED

of

the

impeller

housing

or

contact

the

clearance

washers

desired

the

motor

of

dust

condition.

replaced

make

sure

starting

boiler.

housing.

fiRESIDE

to

the

water

and

acids

be

boiler stack

of

soot

is

accomplished

Tubes

soot

the

furnace

closing

tightening

top

center

are

drawn

tightening

bolts

gas

tight.

the

bolts

of

doors

of

combustion

and

operating

DRAfT

vanes

is

extremely

of

the

fan.

the

air

must

of

various

clearance.

to

see

that

shaft.

or

dirt

since

in

air

capacity

or

if

motor

that

impeller

operation.

when

Notice

the

ClEANING

are

accumulate

and

other

deposits

and

may

which

will

performed

upon

load, temperature, temperature

to

clean-out

deposits

may

be

and

accumulations

or

other

and

this

chapter

front

and

at bolt up-tight.

sequence

alternately

After

boiler

to

compensate

is

efficiency.

fAN

with

important

The

impeller

housing

not

be

thicknesses

fan

Examine

these

or

leads

Rotation

viewed

direction

effective

will

reduce

increase

can

attract

deteriorate

at

regular

type

and

thermometer,

intervals

will

raise

by

opening

brushed

deposits

tube

sheets.

for

rear

heads.

top

center

and

bottom Do

not

along

until

is

back

for

essential

gases

and

relation

vanes

but

at

the

more

than

are

is

securely

the

vanes

build

ups

lead

to

an

were

dis-

rotation

on

most

from

the

arrow

insulators

fuel con-

moisture

quality

combustion

from

should

instructions

on

heat

be

very

fireside

frequent

since

an

the

flue

front

either

be be

to

to to

is

to

of

if

The

vent

stub

and

stack regular to spected

The

any circumstances a protective quired.

Electric

Manufacturers specifications bearings followed.

Ball The having

tors.

closure, and

tors

Complete be

the

housing

and tom) grease motor

filler the the

grease. thoroughly

The

one

locally tributed

Control

Apply a non-gumming

lubricant, to

cant

required of

Solenoid

lubrication.

intervals.

perform

fireside

extended

for

See

this

damage

should

lay-up

Section

Q.

Motors

of

for

and

their

bearing length

The

ambient

involved.

accomplished

new.

below

and

not

hole drain motor

lubricant

of

Gulf Humble

Texaco

Phillips Fiske

Standard/Mobile

all

pivot

in

parts.

equipped

of

grease

which

available.

well

added

rating

duty,

temperatures

renewal

Thoroughly

around

bearings). free

may

running,

until

hole.

for 10

The

filler

cleaned

used

the

good

nationally

Oil

Bros.

Linkage

such

points

and

intervals

valves

time a bearing

atmospheric

by

the

clear

Before

to

as

wipe

and

Commercial

work.

The

and

be

thoroughly

of

the

J in

lUBRICATION

electric

lubrication

recommendations

motors

will

of

the

motor,

of

grease

forcing

wipe

filler

Remove

drain

have

add

grease

replacing

20

minutes

and

before should

commercial

Some

are:

-Precision

-Andok

-Multifak

-1

B +

-Ball Lubriplate

-Mobilux

dripless

graphite

and

moving

excess.

to

maintain

motorized

should

repaired

boiler.

Chapter

motors

depend

conditions,

are

out

those

and

hole

accumulated.

new

drain

they

be

lubricants

Bearing

or a silicone

Repeat

firms

stack

cleaned

Depending

coating

and

are

can

upon

type

but

a few

can,

when

the

portions

drain

the

drain

of

grease

starts

the

to

expel plugs are

clean

grades

Grease

B

No. 2

RB

No. 2

high

parts.

freedom

valves

as

2.

old

No. 2

be

should

vary

care

pre-lubricated.

any

to

drain

cleaned

are

available

be

required.

prior

upon

may

be

in

their

of

motor

should

run

without

many

of

motor

humidity,

of

the

necessary,

grease

of

plugs

(above

plug

(bothardened With

through come

out

plug

any

excess

should

replaced. and

equal

of

grease

that

are

No. 2

temperature

derivative

Work

lubri-

application

of

motion

require

at

in-

to

re-

be

fac-

en-

fac-

with

the

the the

of

run

be

to

dis-

at

no

5-22

CHAPTER 6

This

section properly been

running

listed

in assumed familiar time.

The briefly simplify correcting may

If

refer programming pointing parent. other studying bulletin. will down systematic the

which

ing a routine

an

simple

If

continuity lamp. isolated be minal box. terminal

as

be

the

burner

to

controls

make

time

normal

performance

obvious

to

an

obvious

Each

done

boards

Refer

assumes

installed

for

the

heading

that

the

with

both

points

locating

found

this

problems

Familiarity

the

Knowledge

and between

identification.

under

possible

the

trouble,

elsewhere

will

trouble

relay

in

contents

troubleshooting

or

checks

sequence

may

condition,

correct.

condition

of

the circuit corrected.

in

the

to

the

A. BURNER DOES

1.

Main

disconnect

A. B. NO IGNITION C.

D. E. F. DAMPER

that

and

adjusted

some

time

of

each

operator

burner

each

causes,

source

once

in

not

start,

shooting

bulletin

that

may

with

the

system

of

the

delays

of

possibly

circuits

appropriate

schematic

can

the

actual

to

determine

deviates

often

is

not

with a voltmeter

can

be

Most

control

switch

TROUBLES

f§URNER

GAS

lOW lOSS

the

prior section.

has

become and heading

suggestions

of

trouble.

it

has

this

or

section

for

assistance

not

the

programmer

may

this

manual

system

much

be

operation

from

eliminate

one

apparent,

checked

circuitry

terminals

cabinet

Wiring

NOT

open.

PilOT

FIRE

OF

unit

and

to

It

manual

are

been

manual.

operate

be

obtained

and

easier.

prevented

the

normal.

overlooking

that

is

and

checking

or

the

Diagram

START

DOES

FlAME,

FlAME

MOTOR

has

been

that

it

the

trouble

is

further

thoroughly

by

set

down

or

clues

Methods

identified,

properly,

and

to

in

pin-

readily

and

its

controls

Costly

against

stage

Follow-

relatively

check

or

the

fault

on

the

entrance

OOTING

NOT START

BUT NO

BUT NO HIGH FIRE

has

this

to of

the

ap-

and

by

the

by

at

the

test

can ter-

for

MAIN

2.

Blown connections.

3.

Combustion setting

a) b)

c)

d)

4.

Limit grammer

a)

b)

c)

5.

Motor

If

6. seconds

1.

Lack

a) b) c) Loose

d) e)

2.

Spark

a)

b)

FlAME

fuses,

Refer

to Check L2

(terminal

If

relay

does

not

grammer

Check closed (see

circuit

terminal Pressure operating Water

1)

Check vided,

Fuel

pressure

defective.

burner

starts,

check

of

spark Electrode Improper

shorted

Inoperative

Check

but Lack valve, Inoperative valve

FlAME

tripped

control

manufacturer's

for

power

board 4 and·

lK

pulls

start,

terminal

that

appropriate programmer

not

completed -no

3

or

temperature

control

below

manual

on

and

the

required

low

must

high

but

air

B. NO

grounded

electrode

terminal

ignition

appropriate no

flame

of

fuel

-

empty

tank,

pilot

overloads,

safety

check

switch

between

in,

but

8

reset

water

be

within

pressure

shuts

proving

bulletin terminals

the

for

relay

bulletin)

is

level

control

down

IGNITION

or

porcelain

setting

or

ignition

transformer

program

no

gas

broken

solenoid

loose

electrical

requires

5) blower

power

contacts

power

above

pressure,

button,

settings

switches

after

switch

cable;

relay

line,etc.

or

low

setting

re-

Ll

and

motor

at

pro-

are

to

pro-

of

if

pro-

of

low

a few

circuit.

cracked

cable

contacts

closed

fire

oil

6-1

Chapter 6---Trouble Shooting

c)

3.

4.

Insufficient noid

Low

fire

a)

Damper defective

b)

Damper

Check

valve.

switch

interlocks

or

no

Check

open

motor

switch

jammed

and

not

12

5.

Timer

and

1.

Insufficient

2.

Gas

3.

Oil

4.

Inoperative

l.

Pressure control

2.

Damper

3.

Inoperative

4.

Defective

5.

Binding

6.

Check

switch

timer

C.

(CB20

stopped

PilOT

MAIN

pilot

flame

fired

unit:

a)

Manual

b)

Main

c)

Low necessary)

fired

a)

Oil valve,

b)

Pump c) No fuel d)

Inoperative e)

Check

a)

If

flame amplifier

b)

Flame structed

c)

If

energized,

If

no

D.

BURNER STAYS IN

appropriate

gas

or

high

unit:

supply

or

loss

inoperative;

oil

programmer

relay

2K

lights,

detector

or

relay

2K

check

voltage

or

temperature

setting

positioning

damper

high-low

or

loose

cock

valve

gas

cut-off

solenoid

nozzles

does

check

detector

pulls

check

linkage,

or

in

FlAME,

FlAME

inoperative

of

defective,

for

switch

motor

fire

relay

voltage

power

or

circuit

CB40)

"pre-purge"

to

at

closed,

linkage

to

in

BUT NO

closed

pressure

by

obstruction,

suction

belt

broken

valve

and

lines

not

pull

flame

detector,

lens

dirty

in

but

fuel

voltage

contacts.

lOW

above

in

wrong

(See

control

cams,

contacts

gas

pilot

relay

terminal

slipped

binding

relay

TEST

(reset

switch

or

in

when

contacts,

sight

tube

valve

at

terminal

(See

bulletin)

FIRE

high-low

position

Section

setscrews,

sole-

cam,

terminal

position

closed

slipping

pilot

ob-

isn't

7.

fire

F)

etc.

if

E.

5

1. Loss

2.

3.

4.

5.

6.

7.

8.

1.

2.

3.

4.

5.

SHUTDOWN OCCURS DURING

FIRING

or Defective Flame Lens

dirty

If

the

programmer

ped,

check

or

blower

If

the

a)

Check

b)

Check

c)

Visually

contacts,

d)

Check (CB-40)

e)

Lockout

1)

Improper

a)

Slipping

b)

Damper

c)

Fluctuating

1)

2)

Interlock

Damper Linkage

Motor pre-purge

Motor

a)

Check

a)

Damper tion

b)

High-low operative

c)

Check

a)

Loose

b)

Faulty

does

inoperative

stoppage

fuel

detector

or

motor

lockout

Stuck

air-fuel

Temporary Temporary

device

F.

DOES

positioning

loose

or

appropriate

electrical

damper

of

valve;

weak

sight

lockout

the

limit

switch

fuel

lines

flame

detector

check

appropriate

(refer

to

blower

switch

contacts

ratio

linkage

stuck

open

fuel

inoperative

DAMPER

NOT

or

jammed

riot

drive

close

on

not

operate

positioning

fire

control

motor

fuel

supply

loose

electrical

or

defective

tube

obstructed

switch

circuit

motor

malfunctioning

supply obstruction drop

controls,

has

tripped;

and

valves

program

and

(lean

in

control

fire)

gas or

MOTOR

OPERATE

switch m wrong

to

open

or

burner

contacts

connection

shutdown

contacts

on

demand

switch

improperly

transformer

connection

has

interlock,

timer

and

all

interlocks

in

fuel

pressure

defective

position

close

(See

bulletin)

in

wrong

set

(See

bulletin)

not

trip-

relay

manual)

supply

during

posi-

or

in-

6-2

CHAPTER 7

PARTS

FURNISH ORDERING your boiler, be sure to include on your order the

serial Your

number

quired. Also

method of shipment.

quired.

ment, such as

may not be shown in

sure to give

accessory for which

WHERE

ment

your Cleaver-Brooks representative or from

Brooks of

tario.

RETURNING

COMPLETE

PARTS -When

number

order should

and

If

parts

of

the

name

state

the

parts

are

an

electric motor, pump, etc., which

the

complete

TO

ORDER

for CB Boiler should be ordered from

Canada,

Ltd., P.O. Box 458,

PARTS

INFORMATION

boiler from

state

and

quantity

Indicate

required for accessory equip-

the

parts

name

the

parts

PARTS-

FOR

ORDERING

AND

ordering

the

Cleaver-Brooks

description of

desired;

date

reference

plate

are

required. Repair

REPAIR-

parts

name

the

and

material

material,

data

or replace-

Stratford,

Parts

PARTS

WHEN

for

plate.

part

re-

specify

is re-

be

from

the

Cleaver-

On-

to be

INSTRUCTIONS

LIST

repaired representative or Cleaver-Brooks of 161 Lorne Ave., Center. A repairs to your representative or Cleaver-Brooks. returning please remove fittings or accessories from the comply with shipping regulations

of with your

If

repair sentative reasons for directions prior to returning

(Be sure to show all

should

and

component, properly

the

package a packing slip identifying

you desire to

or exchange, please contact your repre-

parts

orders

be directed to your Cleaver-Brooks

Canada

Stratford,

purchase

giving complete details should be mailed

company's

return

or

the

Parts

the

return

the

and

Ontario,

order or a letter authorizing

drain

name.

parts

for reasons other

Center in

and

await

the

serial

number

correspondence.)

attention

and

clean part, to

and

include inside

Stratford

permission

material.

of your

Ltd.,

Parts

Prior to

the

part

than

stating

and

unit

on

SERIAL NO.

IT

IS RECOMMENDED THAT YOUR LOCAL CLEAVER-BROOKS

REPRESENTATIVE

REPLACEMENT PARTS.

Usage Column indicates

designation is given, ranges. "HW"

"LP"

"HP''

Indicates

"Hot

"Low

"Horsepower''

BE

CONTACTED

parts

apply

Water"

Pressure"

that

apply

to

all

FOR

PROMPT SUPPLY OF

CLEAVER-BROOKS

to a

particular

models in

unit.

all

horsepower

If

no

7-1

Chapter

7-Parts

List

Usage sizes

Column

and

series

indicates

covered

NUMBER

"H.W." "L.P.'' "POWER''

parts

that

apply

to a particular

by

this

manual.

CLEAVER-BROOKS

FUEl

SERIES

100 No. 2 Oil 200 700

SHOWN

25 = 25 30 40 = 40 50A

50 60 = 60

70 = 70 80 = 80 100 = 100

30

=

=50 =50

Indicates Indicates Indicates

H.P. H.P.

H.P.

IN

USAGE

)

{

)

t

HOT LOW HIGH

CBH SERIES

DESIGNATIONS:

SIZES:

COLUMN

These

sizes

PRESSURES

WATER

PRESSURE

UNIT

unit.

If

FUEL

No. 2 Oil

Gas

INDICATES

have

36"

have

48"

UNIT

no

designation

BOILERS

or

Gas

Diameter

i.e. 15 lbs.

i.e. 150 lbs.

is given,

HORSEPOWER

Shells

Max.

Pressure

Max.

Pressure

parts

apply

to

all

BOILER

PART

899-23

899-93 899-26 899-20 899-12 899-18 899-35 899-61 899-60 899-39

25 30 40 50

50 60 70

80

100

NO.

SIZE

A

NOZZLE

SELECTION

QTY.

2 2.0

2 2.5

2 3.0 1 8.3

3 4.0 3 5.0 3 3 3 8.3

Nozzle, 2.0 Nozzle, 2.5

Nozzle, 3.0

Nozzle, 4.0 Nozzle, 4.0 G Nozzle, 5.0 G Nozzle, Nozzle, 6.5 Nozzle, 8.3 G Nozzle, 8.3 G

SIZE

GPH

GPH GPH

GPH

6.0

GPH

6.5

GPH GPH

DESCRIPTION

GPH GPH GPH GPH

PH PH

6-.0

GPH GPH

PH PH

CHART

30°

Monarch,

30°

Monarch,

30°

Monarch,

30°

Monarch,

45°

Monarch, Monarch,

45° 45°

Monarch,

45°

Monarch,

30°

Monarch,

45°

Monarch,

QTY.

1 1

.1

1 1

w/Strainer

w/Strainer w/Strainer w/Strainer w/Strainer w/Strainer w/Strainer w/Strainer w/Strainer w/Strainer

SIZE

2.5

3.0

4.5

4.0

3.0

GPH GPH GPH GPH GPH

7-2

Chapter

7-Parts

List

Part

No.

32-442

32-443 32-746 32-742 853-209

32-516

32-518 32-848

32-1149

32-572

32-1564 853-152 853-394

853-924

841-494 841-551 841-507

275-128

275-129

275-122 275-126 275-123

275-127

435-62 435-66 435-23

435-79 435-42 94-179 904-36 57-68

57-171 57-30 90-226

90-227

8-884 899-11 899-52 100-100 851-77 134-59 134-58 134-52

Req.

3 1 1 1

5

3 1

1

1 1 1

6

24 12 12

1 1

1 1 1

1

2 2

1

2

1 1

1 1 1

1

1 1

1

3

1 1 1

1

Gasket, Gasket, Gasket, Gasket, Gasket, Gasket, Gasket, Gasket, Gasket, Gasket, Gasket, Gasket, Gasket,

Gasket,

Rivet, Rivet,

Split, Split,

Fastener,

Diffuser Diffuser

Diffuser

Nozzle,

Electrode Electrode Electrode,

Electrode,

Ignition

Grommet,

Pipe,

Gas

Pipe,

Gas

Pipe,

Gas

Scanner

Bracket, Body,

Body,

Mica,

Nozzle, Nozzle, Nozzle

Porthole Spider, Spider, Spider,

Description

Head, Door Burner Burner Handhole, Head, Dry Burner Burner Dry Damper Handhole,

Front & Rear

to

Dry

Oven Housing Drawer

2-3/4 x 3-1/2

Front & Rear

Oven

to Drawer Housing

Oven

to

Housing

3-1/4 x 4-1/2

Tadpole -Front

Rope,

1-1/2" -Rear

9/64 x 3/4 1/4 x 7/8

Rear

Head

Burner

Feed-Thru

Gas

Gas Gas

Gas

(See

Pilot

Pilot Pilot

Pilot

Chart)

Insulator

Electrode

Pilot

Tube

Scanner

Tube

Pilot

Dual

Burner Burner Burner

GASKETS

to

Head

Door

to

Head

Tube

Sheet

Baffle

Gasket

BURNER

Baffle

PARTS

25-50A

50-100

38"

25-50A;

50"

50-100

36"

25-50A;

48"

50-100

Inner

Door

Front

25-50A 25-50A

700

Series 50-60-70 80-100 50-60-70

700

Series 80-100 &700

Series

25-SOA 50-100 25-50A

700

Series 50-100 50-100 100

Series

25-50A

700

Series 50-100 50-100

25-50A

700

Series

50-100

700

Series

25-50A 25-50A

50-100

25-50A 25-50A 25-50A

Usage

Baffle

100 200

100

200

100

200

200 700

200

200 700

200

100

200

700

Series &

Series

&

Series

&

Series Series

&

Series Series

&

Series Series Series

7-3

Chapter

7-Parts

List

Part

No.

134-67

134-55

134-66

90-280

32-1731

40-177 40-179

40-221

40-227

832-107

832-118

817-16 817-110 817-111 817-415 817-109 817-900 836-45 817-251 817-204 817-234 832-764 817-400 817-1050 817-1244 817-399 817-378 828-27 904-60 894-3268 836-429 836-742 894-2812 832-235 836-209 836-210 836-261 836-211 817-436 292-47 292-99 292-126 836-384 817-774

817-1935

Req.

1

3

1

1 1

1

1 1 1

1 1

1 1 1

1

1 1 1 1

1

1 1 1 1 1 1

1

1 1

1

Spider,

Spider, Spider,

Air

Gasket,

Housing, Housing, Housing, Housing,

Burner

Burner Oil

Cooling

Air

Burner, Burner, Burner, Burner,

ELECTRICAL

Transformer,

6000

Sec. V

Transformer,

10,000 Sec. V Control, Control, Control, Control, Control, Control, Switch, Control,

Control, Control, Coil, Control, Control, Control,

Pressure, Pressure, Pressure,

Mercury,

Pressure,

Pressure, Pressure,

Potentiometer

Temperature, Temperature, Temperature,

Well Well

Clip Grommet Motor, Switch,

Switch, Motor,

Damper,

Auxiliary, Auxiliary,

Modulating,

Transformer,

Potentiometer, Switch, Switch, Switch,

Switch,

Ignition

Switch,

Burner Damper Oil-Gas Air

Cable, Cable,

Cable, Micro, Gas

Gas

Line

Tubing

Cooling

Oil Gas Oil Gas & Oil

Ignition,

0-15 5-150 10-300 lb, 0-15 lb, 5-150 10-300

for

0-15 lb,

10-300

M436A

Q607

Damper

MH

Positioning

Selector

Pressure

12" 18" 15"

YZ-2RD-A2

Pressure,

Description

BURNER

Assembly

Tubing

and

Oil

CONTROLS

115 V /60 Cycles,

115 V/60 Cycles,

lb,

MH

lb,

MH

lb,

MH

lb,

MH

L404A

and

MH

5-150

lb,

MH

lb,

MH

for L91 A

100-240 High

Limit,

160-260

A

Q607B

M941C

Motor,

30112

MHC645A1

C645A

C645B

PARTS

AND

L404A

L404C

L91A

degrees

L4008E

degrees

115/25V,

(cont.)

COMPONENTS

F,

L4008A

F,

T991A

60

Cycles

50-100

50-100 50-100

50-100

200

100

Series

700 100 &

Series

100

Series

100 &

Series 25-50A 25-50A 50-100 50-100

Gas

Pilot

L.O.

Pilot L.P. Power

Power

to

Over

L.P.

Power

to to

L.P. Power Power

Hot Hot Hot For For For

And

For

to

Over

Water Water

Water L4008A T991A 817-399

817-378

894-2812

Combustion

Low

Gas

Pressure

High

Gas

Pressure

Usage

&

Series

&

150

150 250

150 lb.

150

& E

Wells

Air

Switch

lb.

lb. lb.

lb.

7-4

Chapter

7-Parts

List

Part

No. Req.

833-2200 1 833-2201 1 833-2204 1 833-2205 1 817-1801 1 817-1742 1

833-2209 1

833-1964 1 833-1965 1 833-1967 1 833-1166 1 833-1921 1 833-1814 1 832-160 1 817-139 1 832-747 1 832-748 1

833-2222 833-2223 833-2045 833-2046 833-1157 833-1168 833-1883 833-1936 833-2224 833-2047 833-2225

1 1 1 1 1 1

1 1

1 1 1

PROGRAMMING

Control, Control,

Programmer,

Programmer, Amplifier, Amplifier Cell,

Lead

Flame

Purge

The

order

Control, Control,

Detector,

Extender -(Plug-in

following

or

preceded

Programmer,

Programmer, Amplifier, Control, Control, Control, Cell,

Flame Tube, Tube,

The controls exchange

Control, Control, Control, Control, Control, Control, Control, Control,

Programmer, Programmer, Programmer,

Lead

Detector, Electron, Electron,

following

available

basis only.

CB-20 CB-40 CB-2-1A CB-4-1A CB-1 6009C 6080C CB-3

Amplifier,

Purge

Extender

Infra-red,

Infra-red

Sulfide

Assembly

are

Infra-red,

Sulfide,

Assembly, 12AX7 12BH7

are

(FR) (FR)

(FR)

(FR) (FR)

(FR) R7248A R7258A

(FR)

Description

CONTROLS

CB-20 CB-40

R7248A1020

(Ampli-check)

(Infra-red)

C7015A

Module)

used

on

special

the

above.

CB-2-1A CB-4-1A

R7258A

6009C CB-3 6080C

Fireye

A

factory

rebuilt

on a trade-in

(FR) (FR)

AND

R7248B

104662D

COMPONENTS

For

Usage

CB

20 &

CB-40

Includes

Lens,

For

CB3

CB-20,

Cell,

Cable,

Etc.

CB-40

CB-2-1A & CB-4-1A

CB1, 6009,

& 6080C

CB-40

CB-2-1A, CB-4-1A

948-70 3 832-1000 1 880-81 1 948-195 1 832-1064 1 901-366 1 901-367 1 901-586 1 923-96 1 923-93 1 853-514 1 529-11 1 171-28 1 32-350 1 32-351 1 29-442 1 825-42 1 940-2447 1 854-23 1

Valve,

Coil,

Solenoid,

Kit,

Spare

Valve,

Coil,

Solenoid, Pump, Pump, Pump,

Strainer,

Gasket, Strainer,

Basket, Gasket, Gasket, Flange, Valve, Valve,

Snubber,

Solenoid,

Parts

Solenoid,

Oil,

Sundstrand

Oil,

Sundstrand

Oil,

Webster 112832 112842

Strainer

Fuel,

Double, Cover,

Bolt,

CBCO

Pump

Adapter Needle, Check,

Horizontal,

Gauge

FUEL

OIL

115/50-60,

115/50-60

115/50-60,

115/50-60

H4EA-200 H5F

22R626A1BE4

Cover, 110441

CBCO

1/8"

NPT x 1/4"

COMPONENTS

1/8",

826281

1/4",

8262C232W

A-200

ODC

3/8"

For

948-70

For

948-70

For

948-195 25-30 40-50A 50-100 For

901-366 For

901-367 For

901-366, 901-367 50-100 For

529-11 For

529-11

50-100

7-5

Chapter

7-Parts

List

Part

No.

Req.

940-278 1

832-208 1

918-93 1 940-947 1 945-139 1 945-143 1 940-4539 1 940-4544 1

940-231 1

948-53 832-1066 1 880-117 1

883-14 883-11 82-27 882-15

287-5

318-1 2-96 2-65 287-18 2-66 287-30 287-24 287-19

12-8

1

Valve, Coil,

Solenoid,

Solenoid, Regulator, Valve,

Diaphragm, Actuator, Actuator, Valve Valve

NOTE:

Body, Body,

Check

nameplate

Valve, Valve, Coil, Kit,

Gas Solenoid,

Solenoid,

Spare

GAS

VALVES

1/2",

115

Gas

Pilot,

Gas

Valve, V 4005A

Gas

Valve, V 4055D

2",

V5055A

2",

V5055C

actuator

when

ordering a replacement.

Butterfly,

1",

115

Parts

Description

AND

115/60, K3A

V.

1/2"

Maxitrol

2",

115/60, V

or

valve

2"

N.O., 8215A53

V.

COMPONENTS

4005

48F

Gas For

25-50A

w/"Proof

"Valve

Vent

For

Usage

Pilot

940-278

of

Closed

Valve 948-53 948-53

Closure"

Indicator"

LINKAGE

1

Ball

Joint

Ball

1

1 2 1 1 1 1

1

1 1

2

Joint, Spring, Arm, Arm, Coupling, Arm, Arm, Arm, Arm, Arm, Arm, Arm, Cam,

90°

Over Spring Over

Ride

Drive Damper Damper Damper Damper Damper Gas

Butterfly

Gas

Butterfly

Oil

Valve

Ride

Holding

Shaft Motor & Gas Motor & Gas Shaft

Shaft

Counter

Shaft

Valve

Switch

Linkage Linkage

50-100 25-50A 50-100 25-50A 50-100 50-100 25-50A 50-100

817-99 817-85 817-389 817-778 817-779 836-44 836-93

836-46

853-268 853-555 1 822-13 836-323 1 836-303 853-546 851-199 851-137 853-115 2 825-92 825-132 825-134

7-6

1 1 1 1

1 1 1

1

1 1

1

3

1 1

Head, Head, Head, Head, Head, Switch, Switch,

Operating Operating Operating Operating Operating

Mercury, 3 Wire, Mercury, 3

SA-150M-124

Switch,

Gasket, Gasket,

Mercury, 2 Wire,

Float

Head, Switch, No. Switch, Switch, Gasket, Glass, Glass, Gasket, Trycock, Set, Set,

Mercury,

Assembly,

Head

Gage, Gage,

Gage

1/2" Water Water

WATER

Mechanism, Mechanism, Mechanism,

Mechani~m.

Mechanism,

Wire,

Housing,

For

42 & 64

11

Pump,

5M

5/8" x 9-1/2" 5/8" x 7-l/8"

Glass,

5/8"

Gage Cock Gage

Cock

LEVEL

McD&M McD&M McD&M McD&M McD&M

Auto Manual

SA-150-125

150-14

SA42-125

CONTROLS

150M 150 194M 42-C-HD 64-C-HO

Reset,

SA-150-124

Reset,

HD

Power

L.P.

Only & HW

Power

For

817-85

For

817-99

For

150 & 42

Controls

For

150

For

64

For

64

For

194

For

194 Power L.P.

Power

L.P.

to

150

Over

Controls

Control Control

to

150

PSI

150

PSI

Chapter

7-Parts

List

Part

No.

894-637 1 894-668 894-772 894-638 894-669 894-775 1 894-804 1 894-996 1 894-1322 1 894-743 894-741 1 894-776 894-744 1 894-742 894-777 1 894-1228 1 894-807 1 894-1231 1 894-1155 1 894-1154 1 894-1652 1 894-3180 894-3181 1 894-3196 1

192-107 1 192-108 1 192-109 1 192-112 1 192-68 1 192-69 1 192-104 1 192-66 1

192-67 1

Req.

1 1 1 1

1

BLOWER

Motor, Motor, Motor,

3/4 3/4 3/4

HP, HP,

HP, Motor, 1 HP, Motor, 1 HP, Motor, 1 HP, Motor, Motor, Motor, Motor, Motor, Motor,

1-1/2 1-1/2 1-1/2 1-1/2 1-1/2

1-1/2 Motor, 2 HP, Motor, 2 HP, Motor, 2 HP, Motor, 3 HP, Motor, 3 HP, Motor, 3 HP, Motor, 3 HP, Motor, 3 HP, Motor, 3 HP, Motor, 5 HP, Motor, 5 HP, Motor, 5 HP,

NOTE:

When sure motor.

Impeller Impeller Impeller Impeller Impeller Impeller Impeller Impeller Impeller

NOTE:

Above

installed feet giving

Description

MOTORS

115/230/1/60/3600 208/220/440/3/60/3600 575/3/60/3600

115/230/1/60/3600 208/220/440/3/6/3600 575/3/60/3600

HP,

115/230/1/60/3600

HP,

208/220/440/3/60/3600

HP,

575/3/60/3600

HP,

115/230/1/60/3600

HP,

208/220/440/3/60/3600

HP,

575/3/60/3600 115/230/1/60/3600 208/220/440/3/60/3600 575/3/60/3600 115/230/1/60/3600 208/220/440/3/60/3600 575/3/60/3600 115/230/1/60/3600 205/220/440/3/60/3600 575/3/60/3600 200/3/60/3600 230/460/3/60/3600 575/3/60/3600

ordering a replacement

to

furnish

impellers

or

for

complete

at

altitudes

50

cycle

nameplate

are

standard.

higher

motors

information.

AND

data

than

consult

IMPELLERS

motor

of

For

be

present

boiler

3000

factory

25-30 25-30

25-30 40 40 40

50

A

50 A

50

A

50

60-70

80 80

80

100

25

30

40

50

A

50

60

70

80

100

Usage

869-170 869-172 809-168 809-105 921-30

921-460

921-393

921-342

921-140

Nut,

1 1 1 1 1

1

Impeller,

Nut,

Impeller,

V

-Belt, V-Belt, Sheave,

1A

Groove

Sheave,

1A

Groove

Sheave,

1A

Groove

Sheave,

1A

Groove

Sheave,

1A

Groove

4L340 4L510

Motor,

Oil

5/8" 3/4"-16

2.5 P.D.,

5.0 P.D.,

Pump,

-18

1/2"

5/8"

4.7 P.D.,

6.0 P.D.,

Bore,

7/16"

Bore,

25 50A,

25

50

25

50

A

50

25

50

thru

50 thru thru

thru

40

thru 50A 100

40

100

50A

100

7-7

Chapter

7-Parts

List

Part

No.

Req.

91-75 91-67 91-68 91-69 91-72 91-73 91-74 91-88 91-99

91-71 914-86 1 914-147 1 841-721 841-648 1

850-82 850-476 850-109 850-122 850-243 1 850-293 850-265 850-266 937-28 937-59

817-641

* * * * * * * * * *

1

1 1 1 1

1 1 1 1 1

1

BLOWER

Washer, Washer, Washer,

Washer,

Washer, Washer,

Washer, Washer, Washer, Washer, Ring, Ring, Key, Key,

Gauge, Gauge, Gauge, Guage, Gauge, Gauge, Gauge, Gauge, Thermometer, Thermometer,

Remote

Well

1/8" Spacing, .005 Spacing, .015 Spacing, .030 Spacing, .005 Spacing, .015 Spacing, .030 Spacing Spacing Spacing

Snap,

Snap, Impeller, Impeller,

2",

0-200

2",

0-300 Gas, 4-1/2", 4-1/2", 3-1/2", 3-1/2", 3-1/2",

Bulb

Description

MOTORS

Thick

No. 5100-75 No. 5100-78

3/16 x 3/16 x 5/8 1/4 x 1/4 x 7/8

GAUGES

0-20 Oz. &

0-200 0-30 0-200 0-60

0-30 3", 3-1/2",

AND

PSI PSI

PSI

PSI,

PSI

200-700°F.

100-300°F.

AND

IMPELLERS

THERMOMETERS

0-35"

& 0-30

0-70

In.

60-260°F.

Ft.,

60-260°F.

& 0-30-ln.

(cont.)

50A, 50

25

thru

25

thru

25

thru 50A, 50 50A, 50 50A, 50 25

thru 50

A

50

thru 25

thru 50A, 50 25

thru 50A, 50

50-100

25-50A Stack

For

937-59

Usage

thru

100 40 40 40

thru

100

thru

100

thru

100 40

100

40

thru

100 40

thru

100

Temperature

94-133 1 94-134 1

94-131 5 94-132 6

94-219 1 94-220 1

94-152 872-47 1 872-26 872-162 94-115 7 94-172 465-103 1 465-299 465-121

7-8

Refractory,

Refractory, Refractory,

8

-

Refractory, Cement, Cement, Cement,

1

Tile, Tile,

9

Door,

1

Door,

1

NOTE: consult Cleaver-Brooks

Refractory Insulating

Vee-Block Rear Rear

Front Front Front

For

your

Oven

Furnace Furnace

Oven

Furnace

Baffle Baffle

Inner Inner Inner

complete

local

Parts

REFRACTORY

Liner Liner

Liner

(50 lb.

Mix

Cleaver-Brooks

Drum)

(50 lb.

rear

door

Department.

Bag)

refractory

service agency

replacement,

or

25-50A 100 25-50A 200 &

700

25-50A 100 25-50A 200 &

700

50-100 100 50-100 200 &

700

50-100

Bulk-Order

25-50A 50-100 25-40

A

50 50-100

the

Series

All

Series

by

Pounds

Chapter

7-Parts

List

Part

No.

814-8 814-7 550-42 851-26 853-213 317-57 317-58 104-399

104-449 958-48 958-49 51-160 868-194

868-94

Req.

1 1

1

2

1 1 1 1

1

1 1

1

Brush, Brush, Window, Glass, Gasket, Cover, Cover, Yoke, Yoke, Yoke, Yoke, Nut, Capscrew, Capscrew,

Flue, Flue,

Pyrex

Sight Handhole, Handhole,

Handhole Handhole Handhole Handhole

Head

1-7/8" 2-3/8"

Observation

Glass

2-3/4" x 3-1/4" x

Bolt,

5/8" Head Head

Bolt,

IMPORTANT

Description

MISCELLANEOUS

3-1/2" 4-1/2"

5/8" x 4" 5/8" x 4-1/2"

NOTICE

25-50A 50-100 Rear

Door

For

550-42

For

550-42

25-5.0A 50-100 25-50A

50-100 15 50-100 50-100

Power Power

Usage

PSI

& H.W.

(U.S.) (Can.)

The

manufacturer's

and

Programming

along control below.

CONTROL

CB-20

CB-40

CB-3

4580 5022

6080, 6580

with

this

bulletin

Order

MODEL

bulletin

Control

operating

is

required,

from

your

CLEAVER-BROOKS

for

the

installed

manuaL

the

In

model

Cleaver-Brooks

BULLETIN

C9-767

C9-768

C9-758

-

particular

on

your

the

event

and

form

representative.

NO.

Flame

boiler

Safe

is

supplied

Guard

that a replacement

number

is

listed

MANUFACTURER'S

BULLETIN

NO.

-

C-60 C-14 C-30

7-9