Cleaver-Brooks CBW Operation, Service And Parts Manual

$30.00 U.S.

Compliments of Power Mechanical, Inc.

Used Boilers

Rental Boilers

CLEAVER-BROOKS

CBW

PACKAGED BOILERS

MODEL

Manual Part No. 75.0-150

Milwaukee, Wisconsin

Boilers and Accessories for the Complete

Service and Parts Coast

53201

to

Coast

Boiler Room

CLEAVER-BROOKS

MODELCBW

PACKAGED BOILERS

Operation, Service, and Part Manual

100 thru 400 HP

Fuel: Gas, Light Oil, Heavy Oil or Gas Combination

Cleave

Please direct purchase orders for replacement manuals

to your local Cleaver-Brooks representative

Manual

Part

No.

750-150

Printed

in

U.S.A.

DO NOT OPERATE, SERVICE, ALL

APPLICABLE SECTIONS

WARNING

OR

REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND

OF

THIS MANUAL.

DO NOT

ALLOW

OTHERS TO OPERATE, SERVICE,

OR

REPAIR THIS EQUIPMENT UNLESS

THEY

FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

TO

FA.ll..URE

FOLLOW

VERE PERSONAL INJURY

TO:

This operating manual presents information that will help to properly operate carefully. The unit will provide good service and continued operation 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 mechanical devices supplied as part techniques and maintenance procedures must be followed at all times. Although these componesnts afford a

protection and safety, operation

firing

Any him/her

It

replace intelligent thinking and reasoning and this manual for proper operation. maintain, service, or repair

Owners, Operators and/or Maintenance Personnel

No

attempt should be made to operate the tmit until the principles

of

fuel.

"automatic" features included in the design do not relieve the attendant

of

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

is solely the operator's responsibility to properly operate and maintain the equipment. No amount

On

ALL APPLICABLE WARNINGS

OR

DEATH.

of

the owner

the other hand, a thorough understanding

this equipment. ·

to

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

and

engineered to give long life and excellent service on the job. The electrical

of

the unit were chosen because

of

equipment

is

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

is

AND

INSTRUCTIONS MAY RESULT IN SE-

and

care for the equipment. Study its contents

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

not intended to relieve the operating personnel

of

this manual

is

required before attempting to operate,

of

the components are

of

equipment.

of

written instructions can

high degree

of

and

of

the responsibility

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

Operating controls will normally daily or monthly tesing, assuming that normal operation will continue cal operation and

It

activities

Most instances for the operator to periodically check his/her low water controls and to follow good maintenance and testing practices. connecting 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 such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.

of

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

fi.mction

and

damage and, in most cases, these conditions ca nbe traced directly to carelessness and deficiencies in testing

maintenance.

is recommended that a boiler room log or record be maintained. Recording

and

recording

of

foreign substances that would impede float ball movement.

of

a qualified water treating company or a water consultant

of

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

of

any unusual operation will serve as a valuable guide

major boiler damage are the result

of

water to the low water devices. Float bowls

of

the pressure vessel is

of

any mud, sludge, scale or corrosion.

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

for

long periods

of

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

extreme importance. Waterside surfaces should be inspected frequently to

of

electric controls and safety devices which vary consider-

~e

and we have found that some operators become lax in their

indefinitely. Malfi.mctions

of

daily, weekly, nonthly and yearly maintenance

to

any necessary investigation.

of

these controls must be inspected frequently to check for

to

recommend the proper boiler water treating practices

of

controls lead to uneconomi-

of

any conflict or inconsistency between

Cross·

Safety precautions and Abbreviations

1.

Safety Precautions

It

is

essential to read and understand the following safe.ty precautions before attempting eqmpmenL

Failure

to equipment, serious personal injury

A complete understanding

_bef<:;~re

equtpmenL The equipment should be

who have a working the equipment.

to heed these precautions may result in damage

of

this manual

attempting to- startup, operate

o~rated

knowledge and understanding

to operate the

or

death!

or

main tam the

only by personnel

!WARNING

This symbol indicates a potentially

hazardous situation which, avoided, could result in serious personal

in· or death.

CAUTION!

This symbol indicates a

ardous could result

situation which,

in damage to the equip

ment.

~tentially

if

not avoided,

if

is

required-

not

haz-

BTU

·c

CFH

Cu.

Ft.

DC

OF

FM

FT

of

..

GPM Hd

'HT

HTB

HZ

IRI

Lb

LWCO

:MFD

MR

NO

British Thermal Unit Degrees Celsius Cubic Feet per Hour

· Cubic Feet Direct Current Degrees Fahrenheit Factory Mutual Feet Gallons per Minute Head Height High Turndown Burner Hertz Industrial Risk Insurance Pound Low Water Micro Farad Manual Reset

Number

Cutoff

Note: This symbol indicates information that

is

vital to the operation

ment.

2.

Abbreviations

Following acronyms, and symbols

AC

AR

ASME

ASThfD

BHP

is

an exP.lanation

Alternating Current Automatic Reset American Society

Engineers American Society

Dimensions

Boiler Horsepower

of

used

in this manual.

of

this equip-

the abbreviations,

of

Mechanical

of

Tables, Measures,

ii

pH

PPM PR

PSI

SAE T TC

11

v

we

WSI

Measure

base

Part Number Parts Per Million Program Relay Pounds Per Square Inch (Gauge) Society Tern perature Temperature Control Temperature Gauge Volt Water Column Watts

of

the degree

of

a sol uti

of

Per Square Inch

on

Automotive Engineers

of

acid

or

THE

Combustion air enters through the air inlet. The forced draft fan forces air through the rotary air damper and diffuser into the combustion chamber. The main combustion chamber or main firetube constitutes pass one. A combustion turnaround section directs the gases into the second pass tubes. The turnaround section with water, giving the design name third pass at the front

THREE

(CBWlOO

PASS

CONSTRUCTION

through

of

the boiler and finally exit out the vent at the rear

200

Boiler Horsepower

is

contained within the pressure vessel, completely covered

"WETBACK." Gases are directed from the second to the

iii

OF

A TYPICAL

CBW

Shown)

of

the boiler.

BOILER

Table

of

Contents

CHAPTER 1

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION •

A

B.

C.

D.

E.

F. G.

H.

I.

The

Boiler

The

Burner Control Controls Common to Steam Controls Hot Water Controls Controls for Gas Firing Controls Common to Oil Fired Boilers

(lncfuding

Additional Controls For Heavy Oil

and

Control System

and

Component Function

aJI

(AJI

Fuels)

(AJI

combination) ·

J. Controls for Combination Burners Only

K CombustionAir L . Automatic Ignition M. N.

0. P.

Q. Modulating Firing

Atomizing Air Oil Fuel Flow - Ught Oil Oil Fuel Flow - Heavy Gas Fuel Flow

Boilers

Fuels)

Oil

1-1

.1·1

1-2 1·2 1-3

1-4 1-6 1-8 1-8

1-10 1-13 1-16 1-16 1-16 1-16 1-18 1-18 1-21

1-22

CHAPTER 2

THE PRESSURE VESSEL

A

B. C.

D.

E.

F. G. H.

I.

J.

2-1

• • • •

General Construction 2-2 Water Requirements 2-2 Water Treatment 2-6 Cleaning Boil-out Washing Out SlowdownPeriodic Inspection 2-13 Preparation for Extended Lay-up

II

e • • • • a • • • • • • e • • 2·1

of

a New Unit 2-8

Steam Boiler

2-1

2-7

2-10 2-10

2-14

CHAPTER

3

3-1

SEQUENCE OF OPERATION • • • • • • • • • • • • • • • • • • •

A General

CHAPTER

STARTING

4

B.

c.

D.

AND

OPERATING INSTRUCTIONS • • • • • • • • •

A General Preparation

B.

C. D.

E.

F.

G. Firing Preparations For

H.

I.

Circuit and Interlock Controls Sequence Flame

For

Start-Up -

ControiSe~ngs-

Steam And Gas Pilot Atomizing Air 4-4 Firing Preparations for No. 2 Oil (Sseries Firing (Series 400-600)

(Series 200-400-700) 4-8 Start-up, Operating and Shutdown

-

AJI

Control Operational Test and Checks

of

Operation - Oil

Loss Sequence 3-9

AJI

Fuels

Hot

Water

1 00-200) 4-5

Preparati~n

Fuels 4-9

For No. 6 Oil

gas

3-1

Or

Gas 3-7

4-1

3--1 3--6

4-1

4-2 4-3

4-6

4-11

CHAPTER

ADJUSTMENT PROCEDURES

5

A

B.

c.

D.

E.

F. G.

H.

5-1

• • • • • • • • • • • • • • • • • .

Gene

raJ Unkage-Modulating and Air Damper Modulating Motor Modulating Motor Switches Low Fire and High Fire Burner Operating Controls - General 5-5 Modulating Pressure Control (Steam) 5-7 Operating (Steam) High

Umit

Pressure Control (Steam)

Motor

Pressure Control

5-1

5-2

5-3 5-4

5-5

5-8 5-8

I.

J.

K

L

M.

N.

0.

P.

a.

R.

s.

T.

u.

v.

w.

X.

Y.

z.

AA.

88.

cc.

DO.

Modulating Temperature Control (Hot

Water) Operating Umit Temperature Control (Hot

Water)

High

Umit Temperature Control

(Hot

Water)

Low

Water Cutoff Devices (Steam Combustion Air Proving Switch

Atomizing Air Proving switch

Gas Gas Gas Low High Fuel General Fuel Burner Drawer Adjustment

Oil

Low High Low Electric (400 Steam (No.6 Series Hot

400

( Steam (400

and

Hot

Water)

Pilot Flame Adjustment Pressure Fuel Gas

Gas

Oil

Pressure

Oil

Combustion Adjustment 5-19

Drawer Switch

Oil

Temperature Switch

Oil

Temperature Switch (Optional) 5-24

Oii_Pressure

Oil

and

Oil

Oil)

Water

and

Heater Pressure Regulator

and

Flow Information 5-12

Combustion Adjustment

Pressure Switch 5-17

Pressure Switch

And

Temperature -

Switch (Optional)

Heater Thermostat

600

Series -Steam)

Heater Thermostat

(400

and

600

Steam)

Oil

Heater Thermostat

600

Series)

600

Series-

Steam)

5-8

5·8

5-9

5-9 5-9 5-10

5-15

5-18

5-23 5-23 5-23

5-24

5-25

CHAPTER 6

6-1

TROUBLE SHOOTING

A

B.

c.

D. E. F.

CHAPTER 7

INSPECTION AND MAINTENANCE

A

B.

G.

D. E. F.

G.

H.

I.

J.

K

L

M. N.

0.

P.

a.

A.

s.

T.

• • • • • • • • • • • • • • • • • • • • • •

Burner

No Ignition

Pilot Burner Stays Shutdown Occurs During Firing

Modulating Motor

General Fireside Cleaning Water

Water

EJectriccU Flame Oil Gas Motorized

Sole~oid

Air

and Forced Safety

Fuel Adjusting The

Refractory

Opening

Lubrication

Oil

Electric,

Combustion

Does

Flame,

Level

Gauge

Safeguard Control

Bumer Maintenance

Control

Cam

Valves

Oil

Air

Heaters -

Not

Start

But

No

Main

In

Low

Fire 6-4

Does

• a • • a a e • e e • G • e e

Controls

Glass

Controls 7-4

Gas

Valve(s)

Valves

Damper,

Spring

Draft

Fan

Metering

and

Relief

Pump

and

And

Closing Doors

Steam,

Unkage

Valve,

Valves

Lubricating

Hot

Water

Flame

Not

Operate

8-1

7·1

7•1

System

6-2 6-2 6·3

6-4

6-5

7-2 7-3 7-3 7-4

7-6 7-7 7-9 7-9 7-9

7-12 7w12

7-13

7-13 7-15 7-16 7-20 7·20

7-22 7-22

CHAPTER 8

PARTS ORDER/UST INSTRUCTIONS

•.•.•.•••••.••

8-·1

8-1

CHAPTERl

GENERAL

CHAPTER 1

DESCRIPTION

AND J?RINCIPLES

OF

OPERATION

GENERAL

DESCRIPTION

PRINCIPLES

A The Boiler B.

C.

D. E. F. G.

H. Controls For

I.

J. Controls For Combination Burners

K. Combustion Air L. Automatic Ignition

M. Atomizing N.

0. P.

Q. Modulating Firing

AND

OF

The Burner And Control System Control And Component Function Controls Common To All Boilers Steam Controls (All Fuels) Hot Water Controls (All Fuels) Controls For Gas Firing (Including Combination)

Co~trols

Oil Fuel Flow - Light Oil Oil Fuel Flow - Heavy Oil Gas Fuel Flow

OPERATION

Oil Fired Boilers

For Heavy Oil

Air

NOTE:

The general information directly Models in sizes ranging from 100 through 400 boiler horsepower for the following fuels:

750-150

If

your boiler

CB-HA

ment control system, refer to CB-

Hawk. Installation, Operating,

and Servicing Manual No.

133 for information regarding

controls discussed in this section.

to

Cleaver-Brooks

WK™

is

equipped with a

boiler

in

this manual applies

manage·

750-

"CBW''

Boiler

Series Series Series Series Series

NOTE:

100 - Light Oil (No. 2) 200 - Light Oil (No. 2) Or Gas 400 - Heavy Oil (No. 6) Or Gas

600700-

Although the Series 400 burner

to bum No. 6 oil, the burner will

handle grades well modifications. While this manual contains peninent infonnation on

Heavy Oil (No. 6) Only Gas Only

or

600

is

designed and designated

4 and 5 equally

with

some

possible

CHAPTER 1

..

1

CHAPTER!

GENERAL

DESCRIPTION

AND

PRINCIPLES

OF

OPERATION

No. 6 fuel oil, all references this fuel should plicable

The boiler and related equipment installation, by others, of stallation also should conform codes governing such equipment. lation, the proper authorities having jurisdiction are to boilers in the equipped with optional equipment, Risk Insurers (I.R.I.), Factory Mutual other insuring underwriters requirements.

is

to

be

the National Board

be

consulted, permits .obtained, etc. All

A.

The "CBW" Boiler of

welded steel construction and consists pressure vessel, burner, burner controls, forced draft

fan,

damper, air pump, refractory and ap-

propriate boiler trim.

to

in compliance with the standards

above

THE

is

be

considered ap-

all grades

of

series

of

heavy oil.

Fire Underwriters. In-

to

state and local Prior to instal-

comply,

to

BOILER

a packaged :firetube boiler

to

when

Industrial

(FM), or

of

a

Burner (Oil)

Burner (Gas)

Air Damper . . . . . . . Rotary Type

Steam Trim . . . . . . . ASME Code

Water Trim . . . . . . . ASME Code

The horsepower rating

by

the numbers following the fuel series. Thus,

CBW700-200 indicates a gas fired 200 HP boiler.

B.

.......

......

THE

(Low Pressure)

Air Atomizing

Non-premix

Otificed Type

(Electrically Modulated)

of

the boiler

BURNER

is

indicated

AND

Rated Capacity . .

Operating Pressure .Steam 15-250 psig,

Hot Water . . . . . . .

Fuel . .

Ignition

Firing . . . . . . . . . .Full Modulation

; . . . . . . . .Oil

.100 through 400)-IP

or higher if.specified

.30-250 psig

higher if specified

or

or Combination

.Automatic

Through Operating Ranges

or

Gas

CONTROL

The oil burner ing (nozzle) type. The gas burner premix orifice type. The burners are ignited spark ignited gas pilot. The pilot rupted type and

is

flame

NOTE:

The burners equipped to burn oil and gas include

equipment for each distinct fuel.

uses only one type

selector switch

burner.

It

number, shown on the nameplate, any correspondence

established.

is

important that the burner model and serial

is

of

is

A Series 100 boiler equipped with a light oil pilot though a gas pilot frequently

used.

is incorporated in a combination

SYSTEM

the low pressure, air

is

extinguished after the main

Since the burner

of

fuel at a time, a gas/oil

or

parts order.

atomiz~

is

of

the non-

of

the inter-

is

usually

be

included

by

al-

is

in

CHAPTER 1-2

750-150

CHAPTER I

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

Regardless operates with full modulation (within operating range) through potentiometer-type positioning controls, and the burner returns to minimum firing position for ignition. High pressure boilers (above 15 psi) can be low pressure and high pressure modulation optional equipment. This enables the boiler to operate at lower pressure during off-load hours,

but at a somewhat reduced steam output ent upon lower steam pressure and steam nozzle sizing.

The flame safeguard and program relay include a flame detector flames and to shut the burner down ofloss of

the control provides a . pre-purging period, proving of

continued blower operation to postpurge the boiler controls shut down the burner under low water conditions, excess steam pressure or high water tern

perature.

The safety interlock controls include combustion and atomizing air proving switches and, ing upon the fuel and insurance carrier requirements, controls that prove the presence adequate fuel pressure plus temperature proving controls when

of

which fuel is used, the burner

its

wired for both

depend-

to supervise both oil· and gas

in

the event

of

flame signal. The programming portion

of

the pilot and main flame, and a period

of

all unburned fuel vapors. Other safety

depend-·

heated fuel oil

is

used.

rated

as

of

fuel oil through a cam operated metering valve. Fuel input and air are thus properly proportioned for most efficient combustion.

Filtered primary air for atomizing fuel oil furnished independently

air pump. The burner control circuit operates on 115 volt, single phase

so equipped) alternating current. The forced draft

is

fan motor vice at the available main power supply voltage.

Indicator lights signaling load demand, fuel valve, low water, and flame failure conditions are standard equipment.

In addition to the standard basic controls

plied,

specific requirements

local code. Refer prepared by Cleaver-Brooks for your specific

installation to determine the specific controls the burner and limit control circuits. The function of

individual components

ter and the electrical sequence

Chapter

generally operated on 3 phase ser-

other devices may be required to meet

to the Wiring Wiagram (WD)

3.

C.

CONTROL

COMPONENT

of

combustion air

60 hertz (or

of

an insurance carrier or

is

outlined

SO

hertz when

in

this chap-

is

covered

AND

FUNCTION

by

sup-

is

an

in

The sequence through shut-down

in

relay interlock devices, which are cuitry to provide safe operation and help to protect against incorrect operating techniques.

All "CBW" model boilers sembly attached may be swung open for inspection and tenance.

Combustion air blower located delivery damper motor. This same motor regulates the flow nected to the gas butterfly valve and the flow

750-150

conjunction with the operating, limit and

of

burner operatiop from start-up

is

governed

to

the front head. The entire head

is

provided

in

the front head. Combustion air

to

the burner

gas fuel through a linkage system con-

is

under the control

by

the program

wired into the cir-

·have the burner asmain-

by

a centrifugal

of

the

of

The term "control" covers the more important valves and components, including but not limited

to electrical controls or those monitored by the

The

program relay.

familiar with the individual functioning controls before he can understand the boiler's operation and procedures outlined

Identify and locate each item using the figure callout.

The actual controls furnished with any given

boiler will depend upon the type

it

is

equipped and whether steam boiler. Refer to the applicable group or groups listed which apply to the particular boiler.

operator

must become

in

the manual.

of

fuel for which

it

is

a hot water or

CHAPTER

of

all

1--3

CHAPTER!

GENERAL DESCRIPTION

AND

PRINCIPLES OF OPERATION

LIMIT

ERATING, HIGH

LATING PRESSURE CONTROLS

AND

WATER AND PUMP CONTROLS

COLUMN

GAS

CONTROL

VALVE

[FIGURE

OIL

FUEL

CONTROLLER

1-1

I TYPICAL STEAM

Boilers having optionally ordered features may have control components not listed here.

D.

CONTROLS COMMON

ALL

BOILERS

TO

(1) Forced Draft Fan Motor (Fig. 1-1): Drives the forced draft fan directly air. Also referred

to

provide combustion

as a blower motor.

(2) Forced Draft Fan Motor Starter (Fig. 1-7): Energizes the forced draft fan (blower) motor.

OIL

RELIEF VALVE

BOILER-

LIGHT OIL FIRED]

(3) Forced Draft Fan (Fig. 1-10): Furnishes all

of

air, under pressure, for combustion

pilot fuel

and main fuel, and for purging.

( 4) Ignition Transfonner (Fig. high voltage spark for ignition

1-1

): Provides a

of

the gas pilot or

the light oil pilot.

(5) Modulating Motor (Fig. 1-1): Operates the rotary air damper and fuel valves through a cam and linkage system to provide proper air fuel ratios under all boiler load conditions.

CHAPTER 1-4

750-150

CHAPTER!

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

OIL

STRAINEfl

OIL

SUPPLY

PFESSUAE

GAUGe

WATER

FIEUEF

VALVES

HOTWA~

OILHEATER

BVP..a&VAL\IE

0Pe=IA11NG

TEMPeRATURE.

HIGHUMIT

T'EJIIFIEAA

MOOULA11NG

'T"EMP'ERA

CONTROLS

HOT

WATER

OIL

.

EI009"1"EF!

WATER

PUMP

HEATER

COIL

NOTE:

~TO

FOR

•

TURE

AND

TUAE

WATER

'T"EMPERA

GAUGE

STREAM

FIGURE 1-8

TUAE

COMPONENTS

[FIGURE 1-2 I TYPICAL HOT WATER BOILER WITH HEAVY

(6) Low Fire Switch (Not Shown): An internal auxiliary switch, cam actuated by the modulating motor shaft, which must be closed the air damper and fuel metering valve are

to

indicate that

in

the low fire position before an ignition cycle can occur.

(7)

Burner

Switch

(Fig.

1·7): A manually

operated start·stop switch for directly starting

of

and stopping operation

(8)

Manual*Automatic Switch (Fig. 1-7): When set at "automatic," subsequent operation command

of

the

modulating governs the position accordance with load demand.

750-150

burner.

control, which

of

the modulating motor

When

is

at the

set at

in

OIL

HEATER]

"manual," the modulating motor, through the

manual flame control, can desired burner of

the manual position

firing rate.

be positioned at a

The

primary purpose

is

for testing and setting

the air-fuel ratio through the entire firing range.

(9) Manual Flame Control (Fig. 1-7): A manually

operated potentiometer that permits the

ing

of

the modulating motor to a desired burner firing rate when the manual·automatic switch set on manual.

subsequent setting

It

is

used primarily for initial or

of

fuel input throughout the

position-

is

frring range. It has no control over the firing rate when the manual-automatic switch

is

set on

"automatic."

CHAPTER

1..5

CHAPTER!

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

(10) Modulating Motor Transformer (located in

the mod motor): Reduces control circuit voltage

Aq

(115V operation

(11) Indicator Lights (Fig. 1-7): Provide visual information on operation

Flame Failure

Load Demand

Fuel Valve (valve open)

Low Water

(12) Program Relay and

trol (Fig. starting, operating and shutdown period junction devices. This includes, sequence, the operation ignition system, fuel valve(s), and the damper

motor. The sequence includes air purge periods

prior to ignition and upon burner shutdown.

The flame monitors both oil and gas flames and provides

protection signal.

to required voltage (24V

of

the modulating motor.

of

the boiler

Flame Safe Guard Con-

1~

7): Automatically programs each

with

operating limit and interloc,k

in

a timed and proper

of

the blower motor,

detector

in

the event

portion

of

the loss

of

Aq

for

as

follows:

in

con-

this control

of

a flame

of

pilot proving period. A standard equipped boiler has a detector.

(14) Combustion Air A pressure sensitive switch actuated

sure from the forced draft fan. Its contacts close

to

prove the presence valves cannot satisfied.

(15) Alarm (Not

operator

is

alarm

Stack Thennometer (Fig. 1-1): Indicates the

(16) temperature

(17) Diffuser (Figs.

circular plate located at the furnace end

burner drawer, which imparts a rotary swirling

motion to combustion air immediately prior to its entering· the furnace, thus providing for thorough and efficient mixing with the fuel.

(18) Rotary Air Damper (Figs. This damper provides accurate control

bustion air load demands. cylinders with openings. The outer The

inner is rotated, modulating motor, the openings where they overlap.

E.

·lead sulfide (infrared sensitive)

Proving Switch (Fig. 1-1):

by

air pres-

of

combustion air. The fuel

be energized unless this switch is

Shown): Sounds

of

a condition requiring attention. The

available

in

STEAM

as

optional equipment.

of

the vented flue gases.

1-4 and 1-10): This

proportion to fuel input for various

It

consists

to vary the effective size

of

under

CONTROLS

to

notify the

1-4 and 1-10):

of

two concentric

is

stationary.

control

of

com-

of

is

the

of

a

The control mal operation It

must be manually reset following a safety

shut~own

porated on every start that will prevent burner operation

in

the event anything causes the flame relay to

h~ld

in during this period.

(13) Flame Detector (Fig. 1-1): Monitors gas oil pilot and energizes the programmer's flame

relay in response

to monitor main flame (oil

CHAPTER 1-6

re~ycles

or

caused by a loss

is

an internal checking circuit, effective

automatically during nor-

following a power interruption.

of

flame. lncor·

or

to

a flame signal. It continues

or

gas) after expiration

(ALL

(1) Steam Pressure Gauge (Fig. 1-1): Indicates

in

the pressure

(2) Operating Limit Pressure Control (Fig. 1-1):

Breaks a circuit

rise

of

boiler pressure above a selected setting.

is

adjusted to stop

preselected pressure setting.

the boiler.

to

FUELS)

stop the burner operation on a

It

or

start the burner at a

750-150

CHAPTER I GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

(3)

High Breaks a circuit to stop the burner operation rise adjusted sure above the operating limit control setting. This control

reset.

Limit

of

pressure above a selected setting. It is

to

stop the burner at a preselected pres-

Pressure

is

normally equipped with a manual

Control (Fig. 1-1 ):

on

water

cutoff

a

equipment) requires manual resetting in order start the burner after a

(7)

Low

(Fig. 7-1): Gives instructions and information for

operation

point. Manual reset type (optional

low

water condition.

Water Pump Control Instruction Plate

of

low water devices.

to

(4) Modulating Pressure Control (Fig. 1-1): ses the changing boiler pressures and transmits this information to the change the automatic switch is

Low

(5) 1-1): This float-operated control responds to the water level in the boiler. It performs two distinct functions:

(a) water level drops below a safe operating

level and energizes the low water light in the control panel; it also causes the low water alarm bell ring. Code requirements require a manual reset. type. cutoff. This type requires manual ting to start the burner after a low water shutdown.

(b) Starts and stops the feed water pump

(if

operating level.

burner's

Water

Stops the

used) to maintain water at the proper

Cutoff

fuing

modulating

firing rate

set

on

and Pump Control (Fig.

(optiOI~al

·

when

automatic.

of

the burner

equipment) to

of

some

the manual-

models

of

low water

Sen-

motor to

if

the

re8et-·

CAUTION!

Determine auxiliary pump

control stallation equipment's avoid

(6) Auxiliary Low Water

(Optional Equipment): This control breaks the circuit to stop the burner operation in the event

the boiler water drops below the master low

damage

that

low

and

·the

water

main

cutoffs

are level

throughout

operating

to

the

equipment.

Cutoff

and

after

in-

the

life

to

(Not Shown)

(8) Water Column (Fig. 1-1): This assembly houses the low water and includes the water gauge glass, gauge

shutoff

(9) Water Column Drain Valve (Fig. 1-1): The water column drain valve is provided so that the water

regularly

ing piping and

free

nished with the auxiliary low water cutoff (

tional equipment) for the

(10) Water Gauge Glass Drain Valve (Fig. 1-1):

This valve

(11) Test Valve (Fig. 1-1): This valve allows the

boiler

routine boiler inspection.

(12) Safety Valve (Fig. 1-1):

valve(s)

design pressure

rating and number

mined by the

valves and their escape piping

1-9) are to code requirements. of must discharge piping and code-required drains can be properly piped sure an accumulation

the amount avoid overtightening as this

Use provided. valve use a new gasket and draw the mounting bolts outlet valves by using a pipe outlet

cocks, and trycocks.

column

of

sediment. A similar drain valve is fur-

to be vented during filling, and facilitates

is to prevent pressure buildup

primary importance to its service life. A valve

be

mounted in a vertical position

valve

of

only

down

and its

to assist in maintaining cross-connect-

to keep the float bowl clean and

is

provided to flush the gauge glass.

of

ASME

be installed to conform to the

to prevent build up

seat

pipe compound to male threads and

flatwjawed

When

evenly. Do not install

cutoff

the pressure vessel.

of

valves

Boiler Code.

The

of

area.

Apply

installing a flange-connected

and pump control

gl~

piping

same

installation

foreign material around

wrenches

can

be flushed

purpose.

The

purpose

on

a boiler is deter-

The

shown

of

a valve

of

back

only

a moderate

can

dis

toft

on

or

remove side

or

wrench

of over The

safety

in (Fig.

ASME

so

pres-

the seats. the flats

in

op-

the the

size

is

that

the

750-150

CHAPTER 1·7

CHAPTER!

GENERAL

DESCRIPTION

AND

PRINCIPLES

OF

OPERATION

A drip pan elbow

tween the valve and the escape pipe mened (see Fig. 1-9). The discharge piping must be

properly arranged and supported so that its

weight does not bear upon

Do

not paint, oil,

or working parts

not require any lubrication

to work properly.

or

a flexible connection be-

is

recom-

~e

valve.

or

otherwise covery any interior

of

the safety valve. A valve does

or

protective coating

!WARNING

Only properly certified personnel

such

manufacturer's sentative the

heed

serious

F.

HOT

as

the

should

safety

certified

adj~st

or

valve

repre-

repair

boiler safety valves. Failure

this

warning could result in

personal

WATER

injury

or

death.

CONTROLS

to

(5) Modulating Temperature Control (Fig. 1-2): Senses changing boiler temperature and transmits this information change the burner's frring rate when the automatic switch

low

(6) circuit to stop the burner operation level in the boiler drops below a safe operating level, activating the low water light and optional alarm bell

(7) Auxiliary

(Optional): Breaks the circuit operation below the master low water cutoff point.

(8) Relief Valve(s) (Fig. 1-2): Relief valve(s) relieve the boiler design pressure (or a lower pressure, nated). Relief valves and their discharge piping are requirements.

Water Cutoff (Fig. 1-2): Breaks the

if

the boiler

low

if

the water level in the boiler drops

to

be installed

to

the modulating motor to

manual-

is

set on automatic.

if

the water

is

so equipped.

Water Cutoff (Not Shown)

to

stop the burner

of

pressure higher than the

if desig-

to

conform

to

ASME code

(ALL

(1) Water Temperature Gauge (Fig. 1-2): Indi-

water temperature in the boiler.

cates

(2) Water Pressure Gauge (Fig. water pressure in the boiler.

(3) Operating Limit Temperature Control (Fig. 1-2): Breaks a circuit on a rise setting. a preselected operating temperature.

(4) High Limit Temperature Control (Fig. 1-2): Breaks a circuit rise adjusted temperature above the operating control setting. The high limit temperature control normally equipped with a manual reset.

of

boiler temperature above a selected

It

is adjusted to stop

of

temperature above a selected setting. It

to

stop the burner at a preselected

i=UELS)

1-2): Indicates

to

stop the burner operation

or

start the burner at

to

stop the burner operation on a

is

!WARNING

.Only properly certified personnel

the

such as

turer's

should adjust relief valves. Failure

warning

personal

G.

CONTROLS

relief valve manufac· ·

certified

representative

or

repair

the

to heed

could

injury

result In serious

or

death.

FOR

boiler

this

GAS

FIRING

Depending upon the requirements surance carrier

gas

flow control system,

of

some, the Dimension Diagram (DD) prepared by Cleaver-Brooks for your specific installation. A typical gas train

or

other governing agencies, the

or

gas train, may consist

all,

of

the following items. Refer

is

shown

in

Fig. 1-3.

of

the in·

to

CHAPTER

1...S

750-150

CHAPTER!

PRESSURE

GAS

PILOT

SHUTOFF COCK

LON

PRESSURE

GAS

PILOT

REGULA

GAS

SWITCH

TOR

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

GAS

PILOT

PRESSURE

GAUGE

PILOT

SOU:N040 VALVE

PRESSURE

REGULATING

VALVE (UTlUTIES)

[FIGURE

..

GASFLCIN

YAIRFLON

*PRESSURE

REGULATlNG VALVE

MAIN

GAS

VALVE

HIGH

GAS

PRESSURE

1·3/

TYPICAL GAS TRAIN],.

SWITCH

SHUTOFF

COCK

BUTTERFLY

VALVE

GAS

PILOT

~ENOIOVALVE

ROTARY

DAMPER

AIR

*FURNISHED

CLEAVER-BROOKS

ON

SPECIAL

750-150

~ul

METER

(UT1UT1ES)

MAIN

GAS

SHUTOFF

COCK

ORDER

BY

ONLY

[FIGURE 1-4 I SECONDARY AIR

FlOW

GAS

PRESSURE

WITH GAS TRAIN]

PILOT REGULATOR

CHAPTER 1-9

CHAPTER!

GENERAL

DESCRIPTION

AND

PRINCIPLES

OF

OPERATION

(1) Gas Pilot Valve: A solenoid valve that opens

to

during the ignition period

It

pilot. The sequence controlled by the programming relay. A second gas pilot valve may be required by insurance regulations.

(2) Gas pilot valve valve vent gas to the atmosphere, should any be present in The valve closes when the pilot valves are energized.

(3) Gas ing valve.

(4) Gas Provided flame.

(5) Gas flow

(6) Gas Pressure Gauge: Indicates gas pressure

to the pilot.

(7) Gas Pressure Regulating Valve: Reduces in-

coming gas pressure ment

(8) Butterfly Gas Valve: The pivoted disc valve gas modulating cam flow to the burner.

closes after main flame

of

energizing and de-energizing

Pilot Vent Valve: When a secorid gas

is

required, a normally open vent

is

installed between them. Its purpose

the pilot line when the pilot valves are closed.

Pilot Shut

or

closing the gas supply to the gas pilot

Pilot Adjusting Cock (Fig. 5-10):

to

Pilot Aspirator (Fig. 5-10): Improves the

of

gas to the pilot.

of

between

is actuated by connecting linkage from the

...off

Cock: For manually open-

regulate the size

to

5"

to

10" W

to regulate the rate

admit fuel

is

of

the gas pilot

suit the pilot's require-

..

C.

to

the

established.

is

to

in

this

of

gas

(11) Main Gas Valves: Electrically actuated shut-

off

valves that open simultaneously to admit gas

to the burner. The downstream valve

with a "proof

into the pre-ignition interlock circuit.

(12) Main Gas solenoid valve installed between the two main gas valves should any be present

the gas valves are de-energized. The vent valve closes when the gas valves are energized.

(13) Low Gas tuated switch that

line pressure Should the pressure drop below this setting, the switch contacts will open a circuit causing the

main gas valve(s) from starting. This switch with a device that must be manually reset after

being tripped.

(14) High Gas Pressure Switch: A pressure

tuated switch that

gas

line pressure Should the pressure switch contacts will open a circuit causing the

gas

main

from

starting~

with a device that must be manually reset after

being tripped. (15) Leakage Connection: The body

valve has a plugged opening that

ever it

for possible leakage across the closed valve.

of

closure" switch that

Vent Valve: A normally open

to

vent the gas to the atmosphere

in

the main gas line when

Pressure Switch: A pressure ac-

is

closed whenever main gas

is

above a preselected pressure.

to

close,

or

prevent the burner

is

closed whenever the main

is

below a preselected pressure.

riSe

above this setting, the

valve(s)

is

necessary or desirous to conduct a test

to

close or prevent the burner

This switch

is

equipped

is

connected

usually equipped

ac-

usually equipped

of

the gas

is

used when-

An

(9) Gas Modulating Cam (Fig. 5-6): of

a series contour spring, providing for adjustment input at any poirit in the modulating range.

(10) Main Gas Cock: For closing the main fuel gas supply downstream the main gas line pressure regulator. A second shut-off cock, downstream valve(s), may be installed shutting

for leakage across the main gas valve.

CHAPTER

of

adjustable allen-head screws and a

m~nually

of

to provide a means

off

the gas line whenever a test

1-10

assembly

of

gas

opening and

of

the main gas

of

is

made

H.

CONTROLS

OIL

FIRED

QNCLUDING

The following items are applicable

or gas and oil fired boilers. Additional controls for No. 6 oil are listed in Section

COMMON

TO

BOILERS

COMBINATION)

to

all oil fired

I.

75()..150

CHAPTERl

OIL

BURNER

PRESSURE

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

OIL

MODULATING CAM

GAUGE

OIL

PRESSURE

REGULATOR

OIL

RETURN

SUPPLY

+ TO MAIN

OIL

[FIGURE 1-5 I OIL CONTROL VALVE

OIL

MODULATING

OIL

METERING

OIL

BURNER PRESSURE GAUGE

SOLENOID

VALVE

ASSEMBLY-

CAM

VALVE

PACKING GLAND

OIL

PRESSURE REGULATOR

OIL

FOR LIGHT OIL]

RETURN PRESSURE GAUGE

OIL

FUEL

THERMOMETER

OIL

RETURN

750·150

OIL

ORIFICED

VALVE

TO

MAIN

SOLENOID

OIL

VALVE

BACK PRESSURE

MANUAL

VALVE

BY·PASS

SUPPLY

VALVE

[FIGURE 1-6 I OIL CONTROL VALVE ASSEMBLY- FOR HEAVY OIL]

CHAPTER

1-11

CHAPTER!

GENERAL

DESCRIPTION

(1) Oil Dra'(ver Switch (Fig. 4-1): Opens the limit circuit if the oil drawer burner gun in

the forward position required for burning oil.

is

not latched

(2) Atomizing Air Proving Switch (Fig. 1-1): Pressure actuated switch whose contacts are

closed when sufficient atomizing air pressure

is

from the air pump

present for oil firing. Oil valve(s) will not open or will not remain open unless the switch contacts are closed.

(3) Air Pump Module (Figs. 1-1 and 7-8): This

assembly provides the compressed air required

to atomize the fuel oil for proper combustion.

is

started automatically by the programmer's se-

quence.

It

includes the components described

It

below.

AND

PRINCIPLES

OF

OPERATION

(f)Lube Oil Level Sight Glass (Fig. 7-8): Indicates the level

of

lubricating oil in the

air-oil receiver tank.

(g)Lube

Oil Cooling Coil (not shown):

Cools the lubricating oil before it enters

the air pump. A fan driven by the air pump motor circulates the cooling air over the coil.

(h)Lube 7-8):

Oil Fill Pipe and Strainer (Fig.

Used when adding oil

to

the air-oil

receiver tank.

(a)Air motor drives the air pump and cooling fan. The motor stopped simultaneously

Pump Motor (Fig. 7-8): This

an

air

is

started and

with the forced

draft fan motor.

(b)Air atomization

(c)Air Filter (Fig. 7-8):

Pump (Fig. 7-8): Provides air for

of

fuel oil.

An air inlet

strainer to clean the air supply prior to entering the air pump.

(d)Check Valve (Figs. 1-11 and 1-12): Prevents lubricating oil and compressed air from surging back through the pump and air filter when the pump stops.

(e)Air·oil Receiver Holds a supply

of

air pump and separates the

the atomizing air before delivery

Tank

(Fig. 7-8):

oil for lubricating the

1 ube oil from

to

the

oil nozzle.

(4) Atomizing Air Pressure Gauge (Fig. 1-1):

Indicates the atomizing air pressure at the burner

gun.

(5) Low

Oil Pressure Switch (Optional): Switch contacts open when fuel oil pressure drops below a selected pressure. The switch will interrupt the

of

limit circuit upon loss

sufficient fuel oil pres-

sure for correct combuStion. (6) Oil Solenoid Valve (Fig. 1-1): Opens when

energized through contacts

in

the programmer and allows fuel oil flow from the oil metering valve to the burner nozzle. A light oil fired burner uses two valves operating simultaneously.

(7) Fuel Oil Controller (Figs. 1-1 and 1-5): An

assembly

combining

into a single unit the gauges, regulators and valves required for regulating the flow have the following integral parts. these, the controller burner has additional components described

of

fuel oil. All controllers

In

addition to

used

on a No. 6 oil fired

in

Section I.

(a

)Oil Metering Valve: The valve metering stem moves the orifice area to regulate the supply fuel oil to the burner nozzle with boiler load variances.

to

increase or decrease

in

accordance

Stem move-

of

CHAPTER 1-12

750-150

CHAPTER

I GENERAL DESCRIPTION AND PRINCIPLES

OF

OPERATION

ment motor through linkage and the oil ing cam.

(b)Oil Modulating consisting head screws and a contour spring ing for adjustment in

( c )Oil Burner Pressure Gauge: pressure valve.

(d)Oil Pressure Regulator: For ment valve.

(8) Fuel oil from the storage tank and delivers it under pressure to the burner system.

(9)

Oil Relief Valve (Fig. 1-1): Maintains a constant oil supply pressure to the fuel oil controller by

bypassing excess fuel oil.

(10) Fuel Oil Strainer (Fig. 1-1): Provided prevent foreign matter from entering the burner system.

is

controlled by the modulating

Cam:

of

a series

of

the modulating range.

of

the fuel oil at the metering

of

the oil pressure at the metering

Oil Pump (Not

An

of

adjustable allen-

oil input at any point

~hown):

meter-

assembly

provid-

Indicates

adjust-

Transfers fuel

to

L ADDITIONAL

FOR

NOTE:

Oil Heater Switch (Fig. 1-7): Manually

(1) provides power to the oil beater system.

(2)

Oil Heater (Electric) (Figs. 1-2 and 1-8):

Used for heating sufficient fuel oil for low fire

flow during cold starts before steam or hot water

is

available for heating. The heater must

turned

time that the fuel oil transfer pump

(3)

Oil Heater (Steam/Hot Water) (Figs. 1-2 and

1-8): Heats fuel oil through the medium

or

hot water. The electric heater

steam heater, but

water heater.

will operate at boiler pressure.

furnished on high pressure boilers are also

operated at less than 15 psi. This

through use

(4) Electric 1-8): Senses the fuel oil temperature and gizes or de-energizes the electric oil heater maintain the required temperature

Items 6 and 7 are applicable only

on a hot water boiler.

off

during extended boiler lay-up, or any

of

Oil Heater Thennostat (Figs. 1-2 and

HEAVY

is

Steam oil heaters on 15 psi boilers

a steam pressure regulator valve.

CONTROLS

OIL

be

is

stopped.

of

steam

is

housed

housed separately on a hot

Steam oil heaters

is

accomplished

of

in

the

to

be

ener-

to

the fuel oil.

(11) Gas the various components.

(12) Light a light oil. pilot provided to control the flow nozzle. It

tacts.

after main flame

(13) Back Pressure Orifice (Fig. 1-1): A

tion located

downstream

back pressure

750-150

Pilot: See Section G for description

Oil Pilot Valve (Not Shown): When

is

furnished, a solenoid valve

of

fuel to the pilot

is

energized through programmer con-

It

is

de-energized to shut

is

ignited and established.

in

the oil return line immediately

of

the fuel oil controller

(100 and 200 series only).

off

pilot fuel flow

restric-

to

create

of

is

Steam Oil HeaterThennostat (Fig. 1-8): Sen-

(5)

ses the fuel oil temperature and controls the

of

opening and closing

maintain the required temperature

(6) Hot Water

This control

the fuel oil temperature and control the starting and stopping hot water to the pre-heating assembly the required temperature

(7) Booster Water

stopped by the hot water thermostat

the flow heater

to

Oil Heater Thennostat (Fig. 1-2):

is

used on a hot water boiler

of

the booster water pump to supp I y

of

hot water through the hot water oil

maintain the temperature

the steam heater valve

of

the fuel oil.

to

maintain

of

the fuel oil.

Pump (Fig. 1-2): Started and

to

of

the fuel oil.

CHAPTER 1·13

to

sense

regulate

CHAPTER I

GENERAL DESCRIPTION AND

PRINCIPLES OF OPERATION

(8) Oil Heater

~team

Valve (Fig. 1-8): A normally closed solenoid valve opened by the steam oil heater thermostat to allow the flow the steam heater to maintain the temperature

of

steam to

of

the fuel oil.

Steam

(9) Prevents oil contamination

Heater

Check

Valve

of

the waterside

(Fig. 1-8):

of

the pressure vessel should any leakage occur in the oil heater.

PLUG-IN AS

GAS-OIL

OIL

AIR

MODULES

REQUIRED

SELECTOR

HEATER

SWITCH

PUMP

SWITCH

PURGE

FOR:

SvVlTCH

(10) Steam Heater Pressure Regulator (Fig. 1-8): Adjust to provide reduced (usually less than 15 psi) steam pressure to the heater to properly maintain the required fuel oil temperature. This regulator and the pressure gauge are not nished on

15

psi units.

Fl.Afv1E

SAFEGUARD

AND

PROGRAM

LOCKOUT

BUTTON

fur-

SvVlTCH

RESET

SWITCH

LOCKING

CHAPTER 1-14

LEDGE

SCREW

I

MANUAL

FLAME

CONTROL

[FIGURE 1·7 I TYPICAL CONTROL PANEL]

750-150

CHAPTER!

GENERAL

DESCRIPTION

AND

PRINCIPLES

OF

OPERATION

(11) Steam and prevents the loss heater. Condensate must of

discharge.

(12)

Check

Trap

(Fig. 1·8): Drains condensate

of

steam from the steam oil

be

piped

to

Valve

(Steam Heater Discharge)

a safe point

(Fig. 1-8): Prevents air entry during shutdown periods vacuum within the

(13)

when

cooling

steam

Oil Supply Pressure

action heater.

Gauge

may

(Figs.

create

1·2

and 1-8): Indicates fuel oil pressure in the oil heater and supply pressure

to the fuel oil controller's

pressure regulator.

(14)

Low

Oil Temperature Switch (Figs. 1-2 and

Thermostatic

1-8): burner from starting,

firing

if

the selected fuel oil temperature

switch

or

that

prevents

stops the burner from

is

lower

the

than is required for proper oil burner operation.

(15) High (Optional): fuel temperature.

Oil Temperature

The

oil

temperature

The

Switch

switch contacts

rises

(Not

Shown)

open

when the

above a selected

switch will interrupt the limit circuit in the event the fuel oil temperature rises above the selected point.

(16) In addition to the components controller mentioned in Section

·

of

the fuel oil

H, the following

are used with a heavy oil fired burner.

(a)Fuel temperature

Oil Thermometer: Indicates the

of

fuel oil being supplied to

the fuel oil controller.

(b)Back

ment downstream Also regulates the rate

Pressure· Valve:

of

the

oil

side

of

For

the adjust-

pressure

on

the

the metering valve.

of

return oil flow.

(d)Manual By-Pass Valve: Provided as a

saver

time

in establishing oil flow. operi, it permits the circulation through During

a

closed.

(e)Orifice may

the

supply

operation, this

Oil Control Valve:

be

opened prior to

and

return

valve

start·up

When

of

l-ines.

1IlJ.W.

The

valve

to aid in

oil

be

establishing fuel oil flow through the controller. Prior valve

~

to

the initial light off, this

be

closed. Its disc has an orifice to permit a continuous circulation of

hot fuel oil through the controller.

(17)

Air

valve

Purge Valve (Not Shown):

opens

simultaneously with the closing

The

solenoid

of the oil solenoid valve at burner shutdown, allowing compressed air nozzle and adjacent piping.

to purge oil from the burner

This

oil

is

burned by

the diminishing flame, which continues burning for approximately 4 seconds after the oil solenoid valve closes.

Air Purge Orifice Nozzle (Not Shown):

(18) Limits purging air

to

the proper quantity for

expelling unburned oil at normal delivery rate.

(19)

Air

Purge

Shown): Filters the purging air

that

(20)

might

plug the air purge orifice nozzle.

Air

Purge

Orifice

Check

Nozzle

Filter·

of

any particles

Valve (Not Shown):

(Not

The

check valve prevents the fuel oil from entering

the atomizing air line.

Air

(21)

Purge

controls operation

Relay (Fig. 1-7):

of

the air purge valve.

When

energized,

(c)Oil Return Pressure Gauge: Indicates

on

the oil pressure

the return side

fuel oil controller.

750-150

of

the

CHAPTER 1-15

CHAPTER I

J.

CONTROLS

COMBINATION

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

FOR

BURNERS

ONLY

(1) Gas-Oil Switch (Fig. 1-7): Burners equipped

to

bum

either oil

~el..

each

propnate Interlocks and controls for gas

operation.

mechanical functions

The selector switch engages the ap-

K.

COMBUSTION

or

gas include equipment for

Chapter 4 details

of

each fuel system.

the

AIR

or

oil

required

At

the beginning governed by the program relay, the pilot solenoid valve and ignition transformer are

ly

energized.

The ignition transformer supplies high voltage current for the igniting spark. A gas pilot has a single electrode and a spark arcs between the tip of

the electrode and the wall

ing

it..

A light oil pilot has two electrodes and the

arc

is between their tips. The pilot solenoid valve and the transformer are de-energized after the main flame

Fuel for the gas pilot

~ain

or

a1r

flows

to provide an adequate flame.

is

~om a ta~

10to

of

the ignition cycle, and

simultaneous-

of

the tube surround-

ignited and established.

is

supplied from the utility's

and

(bott~e)

m1xes

supply. Secondary

w1th

the pilot gas stream

Air for combustion "secondary" air) fan (Fig. operation, air pressure

· head and thorough mixture with the fuel for proper

bustion. The supply

is

governed by automatically throttling the out-

put

of This furnishes the proper amount correct ratio at all firing rates.

L.

Oil type ically by an electric spark.

A series pilot fired with light oil fuel. All as

well insurance equipped with a gas burning pilot. In the case a combination burner, the gas pilot ignite either the main gas flame Either pilot serves the same function and unless exception used interchangeably.

1-1 0) mounted in the boiler head. In

is

forced through a diffuser plate for a

the fan by regulating the rotary air damper.

of

AUTOMATIC

or

gas burners are ignited by an interrupted

pilot..

The pilot flame is ignited automat-

100 burner usually

as

a series 100 burner complying with

underwriters

is

taken

of

fuel (often referred to

is

furnished by the forced draft

is

built up

of

secondary air to the burner

air to fuel for efficient combustion

in

the entire

of

air for the

com-

IGNITION

is

equipped with a

other

burners,

requirements,

is

used

or

the oil flame.

in

the text, the term pilot

as

are

of

to

is

Insurance regulations may require two gas pilot

is

ignited

to

be-

in

of

is

as

solenoids with a normally open vent valve

~een

ptlot valves open, and opens when the gas pilot

valv~

the pilot hoe the gas pilot valves.

Fuel for a light oil pilot that supplies oil under pressure for the main flame. A solenoid actuated valve controls the flow energized simultaneously with the ignition trans-

~ormer

IS

and established.

Air for atomizing the fuel oil (often referred

"primary

air-oil receiver tank and delivered under pressure through a manifold block to the oil burner nozzle.

The atomizing air mixes with the fuel oil just

prior to the oil leaving the nozzle.

Atomizing air pressure pressure gauge on the burner gun.

them. The vent valve closes when the gas

sh~t

to

ve~t

gas should any be present

dunng

of

oil to the pilot nozzle. This valve

at the beginning

de-energized after the main flame

M

ATOMIZING

air") is pumped by the air pump into the

the de-energized period

is

provided from the line

of

the ignition cycle and

AIR

is

indicated by the air

CHAPTER 1-16

750-150

CHAPTER!

GENERAL

DESCRIPTION

AND

PRINCIPLES

OF

OPERATION

NOTE:

PAESSUFE

FOR

HOT

FEFERTO

[FIGURE

OIL

SUPPLY

WATER

FIGURE

GAUGe

COMPONENTS

1·2

1-8/

OIL

STEAM

SOLENOIOV

HEATING

STEAM

PRESSUFE

OIL

INLET

FROM

GAUOE

~~=C~~l===~~aSTEAM

1..-'-_._-"""'"'"..,..,_

TANK

HEA

NOTE:

ASSEMBLY

AU

CONOENSA

TRAP

MUST

TO A SAFE

POINT

(STEAM)]

__

LOW

BOflERS

TE

BE

WASTED

STEAM

FEGULATOR

-i.-.f

__

PRESSURE

ONLY

FROM

STEAM

AND

OF

DISCHARGE.

PRESSURE

STEAM

SHUTOFF

VALVE

INLET

PIPED

Air pressure from the pump also forces sufficient oil from the tank cate them and also tion for the pump vanes. delivered

to the tank contains some lube oil;

however, most and filters

in the tank before the air passes

to

the pump bearings to lubri-

to

provide a seal and lubrica-

As a result, the air

of

it is recovered through baffles

to

the

burner. Some

of

the primary air also is

oil pressure regulators

is

This

explained in Chapter 4.

of

used

to

assist the

the fuel oil controller.

SIJIIfii(.Jtf

F'RCII

a::lNS't'RUCTia.

[FIGURE

VALVE

ro

aUIU'IHC

1·9/

RECOMMENDED SAFETY

sro.M

~T

INSTALLATION PROCEDURE]

750-150

CHAPTER 1-17

CHAPTER!

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

The oil flows through a fuel oil strainer provided

to

prevent any foreign material from flowing through the control valves and nozzle. The fuel oil controller contains in a single unit,a metering

to

is

created

regu-

valve, a regulator, and a gauge required late the pressure and flow adjustable regulator controls the pressure. To

in this regulation, back pressure

assist by an orifice nozzle located in the oil return line immediately downstream ler.

of

oil to the burner. The

of

the fuel oil control-

[FIGURE

N.

1·1

0 I SECONDARY AIR FLOW

CIA

GRAM]

OIL FUEL

FLOW-

The programming relay energizes or

gizes the solenoid oil valves to permit or cut oil flow to the burner. Two valves, operating simultaneously, are used. These valves are closed when de-energized. They cannot be opened (energized) unless the combustion air proving switch and the atomizing air proving switch are closed.

·ficient combustion air pressure from the forced draft fan and pressurized air from the air pump.

The oil flow movement ing valve, which varies the flow to meet load demands. The metering valve and the air dam per are controlled simultaneously at all times modulating motor to proportion combustion air and fuel for changes

These are satisfied, respectively,

to

the burner is controlled

of

the metering stem

in

load demand.

0.

OIL FUEL FLOW -

HEAVY

in

OIL

de-ener-

off

by

suf-

by

the

the oil meter•

by

the

UGI-ITOIL

The oil fuel flow system is shown in schematic diagram in Fig. 1-11.

arrows and the pertinent controls are called out.

is

Fuel oil pump that delivers part

burner. Excess oil tank through the fuel oil relief valve and oil return line. Normally, the pump operates only while the burner ing switch or automatic pump operation can

CHAPTER 1-18

delivered into the system by a supply

is

in operation, although often a position-

is

provided so that either continuous

Oil flow is indicated by

of

its

discharge

is

returned

to

the oil storage

be

obtained.

to

the oil

The oil fuel flow and circulating system

in the schematic diagram in Fig. 1-12. The tinent controls are called out and the oil flow indicated

Fuel oil oil supply pump, which delivers part charge to the oil heater. The remainder oil returns oil relief valve and oil return line.

The combination electric and steam oil preheater

is

controlled by thermostats. The electric oil

heater thermostat energizes the electric heater

by

arrows.

is delivered into the system by the fuel

to

the oil storage tank through a fuel

is

shown

per-

of

its dis-

of

the fuel

. 750-150

is

CHAPTER!

~A

oo---

STRAINER

swiNo

CHECK

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

·

NOZZL.E

PRESSURE

VAlVE

AIR

GAUGE

LUBE

OIL

STRAINER

ATOMIZING

PROVING

SWITCH

AIR

ATOMIZING

FEED

CONTROLLER

OIL

METERING

VAlV

~OIL

0

~=================='

MODULATING

CAM

0 D

BACK

FUEL

AIR

PRESSURE

CONTROl

OIL

TUBING

0

750

..

150

OIL

RETURN

PRESSURE

ORIFICE

==========================~~~~~

PRIMING

TEE

VACUUM

GAUGE

NOT

SUPPUED

CLEAVER-BROOKS

BY

SHUTOFF

VALVE

FUEL

OIL

STRAINER

BACK

rl~====~~

FUEL

SUPPLY

C'

01

PUMP

(FIGURE 1·11 I SCHEMATIC DIAGRAM FOR LIGHT OIL FLOW]

0

......_.....

CHAPTER 1-19

CHAPTER!

STRAINER

@II

NOTE: DIAGRAM SHOWS COMPO·

NENTS USED WITH STEAM

ATO~S.

FOR CORRESPONDING HEATING COMPONENTS.

WBE

OIL

~EFE~

SWING

CHECK

£=.=:=:::l

wee

OIL

8;;;::£D

TO

FIGU~E

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

VN..VE

ATOIIMZING

0

AIR

PURGE

ORIFlCE

NOZZLE

I

AIR

c:::::====l

ou

LOWOIL

TEMPERATURE

SWITCH

D

[3

GENEA-

1·2

HOT WATER

OIL

~FE

OIL

HEATER

(B..ECTRq'

•

THESE

fiFIESSURE

SUPA. Y

CXLHEATER

THe:IMOSTAT

ll"E1o6

OIL

HEA

113=1

THEMOSTAT

(S...ECTRiq

OILHEATCR

.

SH8.J..

(STEAM)

ARE

USED

GENERATOFB

ON

ONLY

OIL

VN..VE

HIGH

REUEF

NOTE: CONCENSA TE FROM STEAM

MUST BE WASTED ANC PIPED

TFIAP TO A

SAFE POINT OF DISCHARGE.

VACUUM

GAUGE

SHUTOFF

VN..VE

CHAPTER 1

[FIGURE

~20

1-12/

SCHEMATIC DIAGRAM FOR

(STEAM-ELECTRIC HEATER))

NO.6

HEAVY OIL FLOW

750-150

CHAPTER!

that

is

provided to supply heated oil on cold starts. The steam heater thermostat controls the operation flow able.

A hot water boiler hot water from the boiler unless other pre-heating

equipment

is

housed separate! y, is sized to provide heated oil on a cold start. The hot water thermostat controls the operation water

able.

The heated oil flows through a fuel oil strainer to prevent any foreign matter from entering the control valves and nozzle.

The fuel oil controller contains in a single unit

the necessary valves, regulators and gauges to

regulate the pressure and flow

The program relay energizes solenoid oil valve to permit the burner. The oil solenoid energized. It cannot the combustion air proving switch, the atomizing air proving switch and the low oil temperature and any pressure switches are closed. These are satisfied, respectively, by sufficient combustion air pressure from the forced draft fan, pressurized air from the air pump and sufficient oil temperature and pressure.

Oil flow to the burner ment valve, demands. The metering valve and the air dam per are controlled simultaneously at all times by the modulating motor to proportion combustion air and fuel for changes

Oil burner shut down. The air purge solenoid valve opens ing air through the oil line. This assures a clean

nozzle and line for the subsequent restart.

of

the steam solenoid valve to permit a

of

steam to the heater when steam

is

equipped to heat the oil with

is

utilized. The electric heater, which

of

to the oil heater when hot water

be

opened (energized) unless

is

of

the metering stem

which

is

purged from the burner gun upon each

as

the fuel valve closes and diverts atomiz-

varies the flow to

in

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

is

avail-

a pump that supplies hot

is

avail-

of

oil to the burner.

or

de-energizes the

or

cut

off

oil fJow to

is

closed when de-

controlled by the move-

of

the oil metering

meet

load demand.

load

P.

GAS

The gas flow system flow

is

indicated by arrows and the pertinent controls are shown. Combustion air travel shown and indicated by a different type

Metered gas from the utility flows through the

pressure regulator at a reduced pressure suitable

to the burner's requirements, through the main

gas

shut-off modulating butterfly gas valve orifice type burner.

The main gas valve

and

is

opened (energized) in proper sequence

the programming relay.

The butterfly gas valve modulates the flow from low through high ofthe

butterfly valve disc modulating cam. The butterfly gas valve, and the air control damper are controlled simultaneously by the modulating inotor to proportion combustion air and fuel for changes

The gas flow rate required for rated burner input depends upon the heating value (BTU/cubic foot)

of

the gas supplied. The gas pressure regulator adjusts the gas pressure (flow rate) the entrance always supplied with the burner, but may provided by others.

The

main (opened) unless the combustion air proving switch combustion air. The low gas pressure and high

gas

pressure switches must

sufficient, but not excessive, gas fuel pressure.

is

closed

of

gas

FUEL

is

cock,

the gas train. The regulator

main

is

of

flre settings. The position

valves

to

indicate a sufficient supply

FLOW

shown in Fig. 1-4. Gas

of

gas

valve(s)

to the non-premix

the normally closed type

is

governed by the gas

to

load demand.

cannot

be

closed

energized

to

is

also

arrow.

and

by

of

gas

to

is

not

be

of

prove

750-150

CHAPTER

1·21

CHAPTERl

Q.

MODULATING

The modulating motor, through a linkage arrangement, controls the air damper and the butterfly

gas

valve or the oil metering valve to maintain a

·constant air-fuel ratio throughout the firing range.

During burner operation, the motor by

a modulating pressure control on a steam boiler, or a hot water boiler. A manually operated tiometer is provided to permit the positioning the motor at a desired burner firing rate. This used primarily for initial and setting

should be with the manual-automatic switch

the "automatic" position and under the control the modulating control.

The modulating motor (commonly called a damper motor) is reversible.

limit switch that restricts shaft rotation to

During nonnal operation the motor will move in either direction

range.

The motor's potentiometer

nected to a modulating control. Changing steam pressure or

water temperature alters the electrical resistance

by

a modulating temperature control on

of

fuel input. Normal operation

or

stop at any position within this

matching

GENERAL DESCRIPTION AND PRINCIPLES OF OPERATION

FIRING

is

controlled

poten-

of

is

or

subsequent checking

in

of

It

has an internal

90".

is

electrically con-

potentiometer

in the

of

the modulating controller's potentiometer. This change balancing relay to start, stop, rotation. Rotation until the resistance ratio tiometers are equal.

When this occurs, the motor stops in a position that allows the proper fuel and combustion air flow

to meet operating demands.

A feature designed into the circuitry modulating motor must

during ignition and remain there until the main

flame to motor. The switch must the damper and fuel metering valves are fire position before the programmer commences into the ignition period. During this time, neither the manual flame control nor the modulating

control have any control over the damper motor,

regardless

·

An optionally equipped boiler has a second in-

tegral switch used to driven the damper pre-purge period. This switch closes, as high fire position circuit in the programmer and allow continuation of

is

the motor, is actuated by the rotation

the programming cycle.

in

resistance compels an integral

or

reverse the motor

in

either direction continues

of

the two poten-

is

be

in the low fire position

established. A low fire switch, integral

be

closed to establish that

of

their setting.

is

approached,

es~blish

to

an open

th~t

.the

pos1t1on

to

complete an internal

dunng

that the

of

the

in

low

mo~or

has

the

CHAPTER 1

~22

750-150

CHAPI'ER2

CHAPTER2

THE

PRESSURE VESSEL

THE

PRESSURE VESSEL

A. General

B.

Construction

C. Water Requirements

1. Hot water boiler

2 Steam boiler D. Water Treatment E. Cleaning F. Boil-out

G.

H.

1.

Washing out

1.

Hot Water Boiler

2 Steam Boiler

Slowdown

1.

Types

I.

Periodic Inspection Preparation for Extended Lay-up

of a New

-Steam

Unit

of

Slowdown

Boiler

A.

GENERAL

This chapter is devoted primarily to the waterside

of

care

The type

provide has an important bearing

of

Although it of

be covered in this manual. For specific tion quirements, contact your Cleaver-Brooks service and parts representative.

750-150

the pressure vessel.

of

service that your boiler is required

in

the amount

waterside care it will

is

of

prime importance, the subject

water supply and treatment cannot adequately

or

assistance with your water treatment re-

requir~

..

informa-

to

Feedwater equipment should ready for use. feed pumps, and receivers are installed in ance with prevailing codes and practices.

Water requirements for both steam and hot water boilers are essential service. Constant attention

dividen~

time, and prevention

in

placing the pressure vessel into initial service

is

vital.

The remodeled steam tain oil, grease of

boiling out the vessel to remove these ac-

cumulations

The operator should be familiar with this chapter before attempting to place the unit into operation.

See

that all valves, piping, boiler

to boiler life and length

in

the form

waterside

or

is

described later in this chapter.

of

costly repairs. Care taken

of

new boilers and new or

or

hot water systems may con-

other foreign matter. A method

be

checked and

accord-

of

to

this area will pay

longer life, less down-

CHAPTER

2-1

CHAPTER2

THE

PRESSURE VESSEL

Boilers,

proper operated shock curring to the pressure vessel.

Those steam boilers designed for water boilers designed for are constructed in accordance with Section Power Boilers,

Those steam boilers designed for operation ceeding with Section Code. Hot water boilers for operation over or 125 psi are likewise built

C.

1.

Air

The hot water outlet includes a dip tube which

extends reduces the possibility trapped at the top the system.

Any oxygen will collect or be trapped at the top

shell.

The air vent tapping

boiler should be piped into the expansion compression tank. Any air that top through this tapping.

as

a part

of

a hot water

circulation

as

intended by its designer

or

severe, possibly damaging, stresses

B.

CONSTRUCTION

and the

zso•p

of

the

ASME

15

psig are constructed in accordance

I,

Power Boilers,

WATER

REQUIREMENTS

syste~

system

15

at 125 psi

Code.

of

to

this Code.

psig and hot

Hot Water Boiler

Removal

2 to 3 inches into the boiler. This dip tube

of

any air which may

of

the shell from entering into

or

air which is released in the boiler

of

on

the top center line

is

trapped at the

of

the boiler will fmd its way out

of

require must be to

avoid

or

the

ASME

zso•p

the boiler

of

the boiler

oc-

less

IV,

ex-

be

the

or

This condensation problem

unit that operates intermittently and that is greatly

oversized for the actual load. This is not a

matter which can be controlled by boiler design,

since

an

efficient boiler extracts all the possible

heat

from the combustion gases. However, this

problem can

water temperatures above

Another reason for maintaining boiler water temperature above

cient temperature "head" when No. 6 fuel oil

to

be heated to the proper atomizing temperature by the boiler water in a safety (The electric preheateron the boiler must provide additional heat ture is not maintained above

be

minimized by maintaining boiler

170°F

to

the oil

is

more severe on a

170•F.

is

to

provide a suffi-

type oil preheater.

if

boiler water tempera-

zoo·F.)

is

CAUTION!

If

the

operating

ture

be

Ing should (200°F oil) used

going

lower

boiler

be a

if

and

mixing

to

than

water

used

avoid

equipment.

Rapid Replacement

system layout and controls should prevent the possibility tities

of

cold water into a hot boiler, thus causing shock number," cannot

cannot be completely replaced with stress. This applies to periods

or

thermal stresses. A formula,

be

in

mind that

in

a few minutes time without causing thermal

tion,"

as

well

200oF

as

during initial stan-up.

water

the

170°F,

tempera-

system

the

operat-

must

temperature

minimum

to

preheat

valves

damage

of

Boiler

of

pumping large quan-

given, but it should be borne

or

240oF

of

170°F

No. 6

should

to

Water-

be

arranged to

or

"magic

water

in

a boiler

so•p

of

"normal opera-

be

the

The

water

Minimum Boiler Water

minimum recommended operating boiler water temperature is lower than are reduced water vapor condenses. The net result corrosion occurs in the boiler and breeching.

CHAPTER 2·2

170°F. When water temperatures

170oF are used, the combustion gases

in

temperature

Temperature-

to

a point where the

is

The

that

75()..150

CHAPTER2

THE

PRESSURE VESSEL

8cH..,

S!a

(BHP)

100 125 150

200

2SO

300

3SO

40)

5CXl

600

700 23.430

800

Boner

Ou•t

{1000)

Btu/Hr

15

20 670

30 4&0

so

60

70

80 2.580

1.005 1,340 1,675

2.010

2.34!

3..150

•.18.5 I

s.02S

6.695

I

a.370 1 1

1o,045 \ 2.o1o 1 ,

11.120 1 2..35o 1

'

I

13,AOO

16.740 1 3.350 1

. 20.080

26.780

10 1

500

100 1 13-4

2001

25a

3351

4021

•1o

5361

I

67o 1

8361

1

1.oos

1.340 .s1s

I 2.680 I 1.340 I

•.020 I 2..01

•.aso

s.3eo

20

50

61

I

100

13-4

I

HS8

201

235j

1

2sa

3351

-'18 1 503

I

67o 1

I

8381

.oos

1.11s

1.67s

I

2..3<45

I 2.680

System

I

1

I

1

1 1.120

o

T..,pe,.ture

30

Muimum =n:uiattnv Rllte - GPM

1,340 ' 1.005

1.565 1 1,785

40 50

I

33

•s

67

89

112 1 134

157 1 179 1

223

2791

335j

4o&7

ssal

67o I

78A 895 610

I

1.

1.340

25

33 50

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101

11e I

134 168

209

251

335

<419 S03 587

838

175

Crap-

10

17

20

27

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33

4&0j

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So4l

I

67

sol

!

I I

I

·I I

I

1.075

67

sol

1a

941

101 1 13-4

168 I 1.-o I 120 I 201 1

268 I 22•

901

,2,

1sa

3351280

402 I

ns

•10

I

392 I 338

535 I

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670 !

ssa

sos

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s.o

1

1a.s

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De9,... F

70

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12

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1

29

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.aj

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sa

sol

57

1

,...,.

I 192 I 168 I

24&0

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383

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s9

nj

stl

961

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1os

1 126

1 210 1 186

251

294 I

33512981258

I

•1e

sa2

sas

1ss

1

sto

10

100

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15

22

30

45 52

1

60

75 1

I

931

112

1 100

1•e

I 134

167

I 223 I

I 312

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201

2:35

251

33.5

4.02

4.&8

.520 1 47o

595

S3S

10 13

20

27

33

40

47

5:4

67

&4

The

circulating

interlocked that unless running

the

burner

the

to

equipment.

When

used, it is

water.

750-150

individual zone circulating

recommended

even

though the heat users

The

relief device

[FIGURE

CAUTION!

pump

with

the

cannot

circulating

avoid

damage

that they

or

by-pass valve thus will

should

burner

be

do

2·1

I CIRCULATION CHART]

be

so

operate

pump

pumps

kept running

not require hot

to

is

the

are

allow continuous circulation through the boiler

of

and will help prevent rapid replacement water

with

"cold"

zone water.

boiler

Continuous Flow Through the Boiler - The

. system

ranged through the boiler The controls

boiler will not through the boiler eliminates the possibility stratification within the unit and results in more even

should

that

operation

should

water temperatures to the system.

be

piped and the controls so ar-

there

will

be

water

under

all operating conditions.

of

three-way valves and system

be

checked

be

by-passed. Constant circulation

to make

sure

CHAPTER

circulation

that the

of

2...3

CHAPTER2

THE

PRESSURE VESSEL

A rule

horsepower can

of

thumb

be

of

used

Vz

to 1 GPM per boiler

to

determine the mini mum continuous flow rate through the boiler under all operating conditions.

The operator should determine that a flow

of

water exists through the boiler before initial

or

firing

Water

refiring after the boiler has been drained.

Circulation

The chart in Fig. 2-1 shows the maximum GPM circulation rate

of

boiler water in relation to full

boiler output and system temperature drop.

Multiple Boiler

boilers must

of

be taken to ensure adequate

flow through the boilers. This can best be complished by use in

the supply line from each boiler.

Installations-

equal

or

When multiple

unequal size are used, care

or

proportional

of

balancing cocks and gauges

If

balancing

ac-

cocks or orifice plates are used, a significant pressure drop (e.g., 3-5 psi) must

be

taken across

the balancing device to accomplish this purpose.

If

care

is

not taken to ensure adequate

or

propor· tiona! flow through the boilers, this can result in wide

variations in firing rates

between

the

boilers.

In

extreme cases, one boiler may be

in

the high

fire position, and the other boiler or boilers may

be at low fire. The net result would

be

that the common header water temperature to the system would not be up

to the desired point. This

important consideration in multiple boiler

is

an

instal-

lations.

Pressure Drop

be a pressure drop

Through

of

Boiler - There will

less than three feet head

(1 psi - 2.31 ft. hd.) through all standard equipped Qeaver-Brooks boilers operating in any system

which has more than a

10°F temperature drop.

It

is

common practice to install a standby system

circulating pump. The main circulating pump

..

usually

is

located adjacent to the boilers

boiler room.

Pump

Operation-

Pumps are n9rmally started and stopped by manual switches. It desirable to interlock the pump with the burner so that the burner cannot operate unless the culating pump

is

running.

Pressure

The design

of

the system and the usage requirements often will dictate the pressure exerted upon the boiler. Some systems are pressurized with air or with an inert gas, such as nitrogen. Caution

be

must relationship within the boiler so that all

exercised to make sure that the proper

of

pressure to temperature· exists

of

the boiler's internal surfaces are fully wetted at all times. reason that the internal boiler pressure,

cated on the water pressure gauge, must be held to

the level shown in Fig. 2-2.

When initially firing a 'newly installed boiler or when .bringing an existing boiler into an ing system, the boiler line

MUST

be

and/or other boilers prior

or

boilers to

pressurized equal

to

opening the header

be

to

valves.

It

is

advisable to have a thermometer installed

the return line to indicate return water tempera-

ture. With this determined and with the supply

water temperature ture

differential

knowledge

to

system known, the tempera-

will

be

established.

of

the pumping rate, the operator easily can detect any excessive load condition and take appropriate corrective action (see Fig. 2-1).

in

the

is

also

cir-

It

is

for this

~

indi-

operatbrought on the system

With

in

Pump

Location - It is recommended that the

system circulating pumps take suction from the outlet connection on the boiler and that they

to

discharge and the expansion tank on the suction side

pump. This location is preferred because

the system load. This puts the boiler

of

the

it

decreases air entry into the system and does not

impose the system head on the boiler.

CHAPTER 2-4

Special any which might a hot boiler particularly

caution must be taken

conditio~

or combination

·lead to the transfer or

hot water

is true in the case

to

guard against

of

conditions,

of

cold water to

to

a cold boiler. This

of

boilers that are

operated for purposes other than supplying hot

750-150

CHAPTERl

,.~--

THE

PRESSURE VESSEL

--

,.

-

"

~-

0

...

..

,.

..

-

!•

..

i.

..

a

•

!

(FIGURE

MINIMUM

!IOIL!l

ll'tt!SSU.E

! I

2·2/

!

!!

PRESSURE-TEMPERATURE CHART FOR HOT WATER BOILERS]

l!COMMENCEJ)

Q~I.AfiNCi

lit

t

..

•

;:;

R

...

lit

...

I

!

•

-

•

-

..

:a

:D

10

0

;

I

water for the normal system load (as an example,

boilers equipped with coils for domestic hot water).

It cannot

in

temperature within the boiler can, and some-

times do, cause damage.

2.

Steam Boiler

Feed

Make certain that all valves in the water feed line are open

to prevent possible damage to the feed pump

mechanism. After opening the valves, momentarily energize the feed pump motor the correct pump rotation. With the correct rota-

750-150

be

over-emphasized that rapid changes

Pump

Operation

BEFORE

turning on the pump motor

to

establish

tion established, close the boiler feed pump

entrance switch. The pump should shut down

when the boiler water level reaches the proper level shown in Fig. 2-3.

Feedwater pumps must have adequate capacity

to maintain the required water level under

operating pumps periodically and maintain prevent unexpected breakdowns.

NOTE:

conditions.

Prior

to

fully check the alignment flexible coupling properly aligned coupling will

last longer and provide

free mechanical operation.

Check

operating the pump, care-

the

as

if

one

is

CHAPTER 2-5

feedwater

necessary to

of

used. A

trouble-

all

the

CHAPTER 2

THE

PRESSURE VESSEL

A

Hgh

level

of

turns off at this point

pressure

height

B.

Pump

reac:tlee

approximately 3/4 inch.

water: Feed

"V88881

tu~

on wnen water level

B.

Dis:tances

pump

Fill

initially to thie

A-8

is

NOTE:

In the event that water column isolation valves are provided installed, it must

be

established

or

that. these valves are not only open but that they are sealed locked in the open position. these valves are installed, it

is

or

If

il-

legal to operate the boiler with

closed

or

unsealed open

valv~.

!WARNING

The water locked during operation. Failure to do so may

tion, catastrophic

personal

Isolation

column

In

the

valves piping

open

and

must

position

result in a low water condi-

failure, serious

D.

WATER

injury

or

death.

TREATMENT

the

be

C.

low

Water

wiH

Jowers

0.

First

Cutoff Point Burner

shut

off

if

water level

to

thMa

point

visi~e

point of gauge glase.

[FIGURE 2·3 I BOILER WATER

LEVEL

Water

This type

boilers operating at necessary to open the water supply line valve and the water feeder discharge valve. The water feeder should close when the water reaches the

proper level

DETAILS (STEAM BOILER)]

Feeder Operation

of

operation

as

shown in Fig. 2-3.

15

is

usually applicable to

psi

steam

or

less.

It

is

only

Maximum effectiveness and long trouble-free life

of

pressure vessels, at the lowest cost consis-

tent with good engineering and operating prac-

of

tice, are functions

properly treated boiler feedwater. Contact your Cleaver-Brooks local representatitive prevent the presence

for information

of

unwanted solids and

on

how to

corrosive gases.

The objectives

(1)

Prevention

water treatment

of

hard scale deposits or

in

general are:

of

soft sludge deposits that impair the rate of

heat transfer and that lead to overheated metal and costly down-time and repairs.

(2) Elimination

of

corrosive gases

in

the

supply or boiler water.

CHAPTER

2..6

750-150

CHAPTER2

THE

PRESSURE VESSEL

(3) Prevention

ing

or

caustic embrittlement

metal.

( 4) Prevention

The accomplishment

ly

requires proper feed water treatment before and

after introduction

selection

upon the water source, teristics, amount

operating practices, etc. These treating methods

include filtering, softening, de-mineralizing, deaerating, and pre-heating. After-treatment volves chemical treatment

Because compound" can be considered a it advisable to experiment with homemade treating methods. Sound recommendations and their employment should be augmented analysis

densate.

The internal vessel should

quency tamination, accumulations

corrosion and/or pitting. detected, contact your Cleaver-Brooks local rep-

resentative for advice on corrective action.

It

is

meter be installed in the raw water make-up line

to accurately determine the amount

admitted the water treatment program proper waterside conditions.

The general feeling exists that a hot water boiler does not require water treatment, but this false generally operate on closed systems and down alert

recommended for water make-up lines.

of

the variables involved, no one "boiler

of

the feed water, boiler water, and con-

or

to

determine the presence

recommended that a properly sized water

to

the boiler (steam

assumption. is

seldom practiced, the need remains to be

to

system water losses and a water meter

of

intercrystalline crack-

of

the boiler

·

of

carryover and foaming.

of

these objectives general-

of

water into the boiler. The

pre-treatment processes depends

its

chemical charac-

of

makeup water needed, plant

in-

of

the boiler water.

"cure-all" nor

by

a periodic

waterside surfaces

be

inspected with sufficient fre-

of

If

Even

though

of

the pressure

of

any con-

foreign matter,

these conditions are

of

raw water

or

hot water)

in

maintaining

these units

of

to

aid

is

blow-

is

a

is

E.

CLEANING

Hot

Water

Steam

boiler may contain oil, grease These impurities must be removed damage to steam system, the condensate should be wasted until

tests show the elimination

impurities. During the period that condensate wasted, attention must be given of

the raw water accumulation does not occur. For more information, contact your local Cleaver-Brooks representative.

On

a hot water system, chemical cleaning

generally necessary.and the entire system should

be

drained after treatment Consult your local Oeaver-Brooks representative for recommendations, cleaning compounds, and application cedures.

and

Steam Piping

and water piping systems connected to the

or

foreign matter.

to

prevent

pressure vessel heating surfaces. On a

of

undesirable

is

to

the treatment

used

as make-up so that an

of

unwanted materials

or

corrosion

is

pro-

Pressure Vessel ·

The waterside

clean from grease, sludge and foreign material.

Such deposits, the life efficient operation and functioning safety devices, but might quite possibly cause unnecessary and expensive re-work, repairs and down-time.

The installation and operating conditions that the

boiler will and cleaning

vessel should be provided during the course

initial start-up.

The pressure vessel and the steam and return

lines

closed system. Although the steam and return

(condensate) lines or the hot water piping

may have

that:

of

or

(1) Cleaning has been inadequate.

of

the pressure vessel must be kept

if

present, will not only shorten

the pressure vessel and interfere with

of

control or

be

subjected

of

the waterside

hot water piping represent, in effect, a

been

previously cleaned,

to

should be considered

of

the pressure

system

it

is

possible

of

750-150

CHAPTER 2·7

CHAPTER2

THE

PRESSURE VESSEL

(2) Partial

Conditions

(3) cleaning

The

pressure vessel

spected

internal conditions and conditions indicated by chemical analysis boiler water. Inspection should be made three

months after initial starting and at regular or of

the internal conditions found.

If

your

recommendations.

Any sludge, mud,

be

down verified and down

periodic draining cated.

Any should be removed promptly by a

an

on

12-month intervals thereafter.

further periodic inspections will depend upon

any unwanted conditions are observed, contact

Cleaver-Brooks

flushed out.

practiced

may have to be revised.

oil

or

alkaline detergent solution.

NOTE:

or

total

old

system is involved.

may

prevent

of

piping.

waterside

a periodic basis. This will reveal true

serve

local representative for

or

sediment

The

effectiveness

on

steam

scheduling

or

grease present

Temperature water for hydrostatic tests, boilout,

or

should be as stated in

Boiler Code.

or

washout

on

of

for

normal

frequency

the heating surfaces

adequate

should

as a

check

The

found will have to

of

boilers

The

will also be indi

boil-out with ·

initial

operation

the

be in-

against

of

6-, 9-,

frequency

the blow

should

of

blow-

need for

fill

of

ASME

the

be

should be ready for

familiar burner operation.

with

fuing.

the

The

procedure

!WARNING

Use

of

a suitable face mask,

gles, rubber gloves, and protec-

tive

recommended when handling mixing caustic chemicals. permit the

centrated

contact Failure

tions

sonal

Your Cleaver-Brooks local representative able to

dure. In the

is

yet unscheduled, the following information

may be

..

There are several chemicals suitable for this

pose.

soda (sodium hydroxide at the rate

~

pounds

with a small

as

a wetting agent is

Generator

Si?P:<IOI.

garments

dry

material

solution

with

to

follow

Is

to

skin

or

these precau-

could result in serious per-

injury

recommend a cleaning

of

assistance.

Soda

ash (sodium carbonate) and caustic

each

100 125 150

or

event

such

per

1,000 pounds

amount

JYatcr-

Normal

I

875 825

995

death.

service is unavailable

of

laundry detergent added

one

combination often used.

O:allccs

F"

"'lOCrec

1032

980

1180

, JYatct-

I

Nnrm~l

operator must

outlined

under

gog-

strongly

Do

not

or

the con-

come

clothing.

wiU

or

boil-out prOce-

of

3 to 5

of

water, along

Wci~bt

I

F1CXXIea

7260

6825

8270

8570 8130

9810

be

or

in

be

or

pur-

F.

BOIL-OUT

The

internal surfaces

may have oil, grease

used

in

manufacturing. removed since they lower the heat transfer rate and could cause over-heating

out

boiling

CHAPTER 2-8

procedures may begin, the burner

OF

A NEW UNIT

of

a newly installed boiler

or

other

protective coatings

Such

coatings must be

of

a tube. Before

200

250

300

350

400

1335 1371 1635 1870 2175 2570

(FIG. 2-4 I WATER

1580 1630 1935 2220

11070 11380 13550 15525 18070

CAPACirf

13100

13510

16050 18420

21350

CHARn

750-150

CHAPTER2

The suggested general procedure for cleaning a boiler is:

(1) Refer to Fig. 2-4 to determine water capacity. material

Have

on

hand to complete the job.

sufficient

cleaning

THE

PRESSURE VESSEL

(7)

The

boiler should then be fired inter· mittently at a low rate sufficient the solution the water for at least five hours. produce

just

at the boiling point. Boil

steam pressure.

to

hold

Do not

(2) When dissolving chemicals, the lowing procedure is suggested. Warm water should be put into a suitable tainer. Slowly introduce the dry chemical into the water stirring

is

chemical the chemical slowly and in small amounts

to

prevent excessive heat and turbulence.

An

(3)

to

one

routed to a safe point

or

relief

used. .

(4) Water relief valves and steam safety valves must be removed before adding the boil-out solution the

grease that taminate these valves. Use care in removing and re-installing valves.

completely dissolved. Add

over-flow pipe should be attached

of

the top boiler openings and

safety valve tapping

it

all times until the

so

that neither it nor

it

may carry

of

discharge. A

fol-

con-

is

usually

~ill

con-

(8) Allow a small amount

to

enter the boiler to create a slight over-

flow that will

(9) Continue to boil and overflow until

the water

(10) Let the boiler cool to 120oF

carry

off

clears. Shut the burner down.

of

fresh water

surface impurities.

or

!WARNING

Be sure a safe scalding sonal

(11) Remove the hand hole plates and

wash the waterside surfaces thoroughly

using a high pressure water stream.

to

drain the

point

or . other

Injury

of

discharge

or

death.

hot

water

to

serious

less.

to

avoid

per-

Min

Refer to Section lation instructions.

(5) All valves in the piping leading from the system must the cleaning solution from getting into the system.

Chapter 7 for valve instal-

be

closed

to

(6) Fill the pressure vessel with clean

water until all tubes are covered. Add the cleaning solution and then fill to the top. The temperature initial fill should be at ambient temperature.

750-150

of

the water used

to

or

prevent

in

this

(12) Inspect the waterside surfaces.

they are not clean, repeat the bailout.

After

(13) reinstalling the safety the boiler and fire until water

at least 180°F to drive

gases that might otherwise corrode the metal.

closing

the

openings

or

relief valves, fill

is

heated

off

any dissolved

CHAPTER 2·9

If

and

to

CHA.PTER2

THE

PRESSURE VESSEL

The above procedure of a unit previously used or known ly

clean. However, consideration must

to the possibility

entering

On wasted until tests show desirable impurities. During

densate

treatment

than corrosion does not occur.

On generally necessary and

be

Brooks local representative for recommendations, cleaning compounds, and application

procedures.

1.

In

theory, been that water treated), and with added, will require ment. may

detected leakage

water make-up or air rosion etc., on the pressure vessel

If

the tem may

If there

watexside

months after initially placing

operation

by

the

boiler from

a steam system, the condensate should be

is

wasted, attention must of

the raw water used

an

accumulation

a hot water

drained after treatment. Consult your Qeaver-

G.

WASHING

Hot Water Boiler

a·

hot water system

initially cleaned, filled with

However, since

allow entrance

and

fonnation

operator

is

tight, then

be

sufficient.

conditions observed during inspections.

is

any

should

and

periodically thereafter

may

be

omitted

of

contaminating materials

the

system.

the

elimination

the

of

unwanted materials or

system.,

chemical cleaning

the

entire system should

in

the

to

be

internal-

be

given

of

period that con-

be

given to the

as

make-up so

OUT

and

boiler that have

raw

water (and

no

make-up water

no

further cleaning or treat-

the

system (new or old)

of

air

and

unnoticed or un-

of

water, introductions

may

lead

to

of

sludge, sediment, scale,

watexside.

absolutely certain that the sysan

annual waterside inspection

doubt, then

be

inspected

the

pressure vessel

no

later than three

the

of

pitting, cor-

boiler into

as

indicated

case

un-

is

raw

2.

Steam Boiler

No

later

than

three months after initially placing

the

boiler into operation and starting service, and

as

thereafter vessel should cooled covers removed, and waterside surfaces spected for corrosion, pitting, or formation of deposits.

Flushing

Upon sel a high pressure hose. removed consultation with your Cleaver-Brooks local resentative sary advice quired.

These inspections will indicate of

treatment,

of fresh water make-up required are

be

pressure vessel washouts. Contact your Cleaver· Brooks local representative for more infonnation.

to

completion

interior should be flushed out

to

is

the

feedwater treatment. The effectiveness

considered

H.

SLOWDOWN

conditions warrant, the pressure

be drained after being properly

near ambient temperature, handhole

of

Pressure Vessel

of

inspection, the pressure ves-

If

by

flushing,

and

resort

recommended if acid cleaning

the

water conditions,

this

in

extreme cases,

to

acid cleaning. Professional

in

esta~lishing

Interior

as

required with

deposits are not fully

may

require immediate

it

may

be

neces-

is

the

effectiveness

and

the

amount

all

factors

the

frequency

STEAM

in-

rep-

re-

of

to

of

BOILER

Boiler water blowdown of

the

concentrated water from

sel

and

its replacement with feedwater lowering boiler water occurs.

Solids are brought though external unwanted substances that contribute deposit formations. However, none of these

in

themselves capable and will

of

the

concentration

this

water

processes that are designed.

regardless

be

present

of

in

is

the

is

the

removal

the

of

in

by

the

feedwater even

treated prior

of

removing

their efficiency, some solids

boiler feedwater.

of

some

pressure ves-

so

that a

solids

to

all

in

use

through

to

remove

to

scale

substances

the

and

are

750-150

CHAPTER2

THE

PRESSURE

VESSEL

Solids become less soluble in the high tempera-

ture

of

the boiler water and tend to accumulate

on

heating surfaces. chemical treatment is, therefore, required to prevent the solids from forming harmful scale and sludge.

Scale has a low heat transfer value and acts as an insulation barrier. which not only results ficiency and consequently higher fuel consumption

but,

more

overheating

tube failures

damage causing boiler down-time and costly

repairs.

Scale is nesium salts, silica and oil. magnesium salts in the boiler water generally are precipitated by the use along with organic materials, to maintain these precipitates

solids such as sodium salts and suspended dirt do

not readily form scale but, as the boiler water

off

boils

water is thicker with the solids.

tion

is priming will occur and the sludge can cause harmful deposits that bring about overheating the metal.

The

lowering

requires the use

1. Types of

There are two principal types

termittent manual blowdown.

of

boiler metal. This can result in

or

ca~

as relatively pure steam, the remaining

permitted to accumulate, foaming and

primarily by calcium and

or

"sludge"

or

of

Blow

Blowdown

This

retards heat transfer,

in

lower operating ef-.

importantly,

other

removal

pressure vessel metal

of

sodium phosphate,

in a fluid form. The

of

boiler water blowdown.

and internal

can

Any

calcium and

If

this concentra-

this concentration

down

of

blowdown: in-

blowdown

and continuous

cause

mag-

of

:Manual Blowdown

Manual operation

not continuous blowdown

or

sludge blowdown is necessary for the

of

the boiler regardless

is

of

whether

employed.

or

the pressure vessel water, it also removes a por-

of

tion part

Equipment generally consists valve and a shut-off valve. These, along with the necessary piping, are with the boiler, but supplied by others. All piping must

be

the sludge which accumulates in the lower

of

the vessel.

of

a quick opening

~ot

normally furnished

be to a safe point

properly supported and free to expand.

of

discharge. Piping must

Continuous Blowdown

Continuous blowdown

with a surface blow-off tapping (furnished on

60" diameter and larger) and

units tinuous removal

The surface blow-off opening,

is

on

the top center line

is

provided with an internal collecting pipe terminating slightly below the working water level for the purpose

or

oil

pressure vessel water.

A controlled orifice valve continual-yet centrated water .

Periodic adjustments are made to the valve setting to increase down

The

provided by others. All piping must

point

other impurities from the surface

in

accordance with water analysis results.

flow control valve and piping are generally

of

discharge.

Frequency

When continuous blowdown

blowdown

suspended

blowdown removes sediment and oil from the

surface

amount

of

or

Manual

is

primarily

solids

the water along with a prescribed

dissolved solids.

is

used in

concentrated water.

of

the pressure vessel and

skimming surface sediment,

is

controlled-flow

decrease the amount

<?Onjunction

is

the con-

when

furnished,

of

used to allow a

of

con-

of

blow-

be

to a safe

Blowdown

is

utilized, manual

or

used

sludge.

to

The

remove

continuous

the

The blowdown tappings are located at the bottom or

lowest part

lowering the concentration

750-150

of

the boiler so that

of

in

addition to

dissolved solids

in

or

When surface

utilized, manual blowdown is used dissolved sludge.

or

continuous blowdown

suspended solids in addition

is

not

to control the

to

the

CHAPTER 2·11

CHAPTER2

THE

PRESSURE VESSEL

In practice, the valve(s) are opened periodically in accordance with an

operating schedule and/or chemical control

From the standpoint

results, frequent short blows are preferred to

infrequent lengthy blows. This true when suspended solids content

is

high. With the use more uniform concentration sel water is maintained.

cases where the feedwater is exceptionally

In

pure, or where there condensate, blowdown may frequently since less sludge accumulates in the

pressure

suspended solids approach

mined limits, manual blowdown

concentrations

Generally it

be

blown down at least once in every eight·hour period, but this may vary depending upon water and amounts and schedule can be recommended by .

your A hot water boiler does not normally include

openings for surface blowdown and bottom

blowdown since blowdowns are seldom ticed. The need remains to

water losses and corresponding amount water make·up. A water meter

for water

vessel.

is

recommended that a steam boiler

operating

Cleaver~Brook:s

make-up lines.

conditions.

of

the bottom blowdown

of

control, economy and

of

frequent short blows a

of

the pressure ves-

is

a high percentage

be

When

required.

local representative.

dissolved

or

exceed predeter-

The

be

is

tests.

is

particularly

of

the water

of

return

employed less

and/or

to

lower these

blowdown

prac-

alert to system

of

raw

recommended

:Manual Blowdown Procedure

Slowdown generation

feedwater input then

minimum dilution concentration feedwater.

Make sure the blowdown piping and the tank, if

used, are in proper operating condition, the dis-

charge vents are clear waste

is

of

piped

most effective at a time when

steam

to

is

at the lowest rate since

is

also low providing a

of

the boiler water with low

of

obstruction, and that the

a point

of

safe discharge.

dem valves may be used. Valves will vary depending upon pressure involved and the make

If

or manufacture. follow the manufacturer's recommendations.

If

a quick opening valve and globe type opening valve are in combination, the former is normally opened first and ing down accomplished with the globe opening valve.

When opening the second crack it slightly

then continue opening slowly.

seatless valves are installed,

or

slow

closed last with blow-

or

slow

or

down stream valve,

to allow the lines to warm up,

CAUTION!

Do

not

pump valve hammer bodies damage

open

is

or

to

occur.

The length

actual

gauge glass approximately

able as a guide

should not be

analysis procedures should prevail. cannot valve, another operator should watch the glass and direct the valve operator.

Close the downstream (slow opening) valve first

as

and

to the boiler. Slightly crack the downstream

valve and then close it tightly. Under no circumstances should a blowdown

valve be left open and the operator should never leave until the blowdown operation and valves

of

each blow should be determined by

water analysis. Lowering the water

to

interpreted

be

viewed by the party operating the

fast as possible. Then close the valve next

closed.

the

and

apt

to

pipe

the

equipment

adequate blow. However, this

lever

closed,

break

the

fittings

1/2"

is

as

a rule since water

action

as

water

valve

could

in

often accept-

If

the glass

is

completed

or

the

Most blowdown lines are provided with two valves, generally a quick opening valve nearest

the boiler and a slow opening globe type valve

downstream. Two slow opening valves or tan-

CHAPTER 2·12

750·150

CHAPTERl

THE

PRESSURE VESSEL

I.

PERIODIC

Insurance regulations or local periodic inspection authorized inspector. Sufficient notice ly

given

service and preparation

to

permit removal

INSPECTION

laws

will require a

of

the

pressure vessel

of

the

for inspection.

by

an

is

general-

boiler from

!WARNING

To avoid

shock, serious personal we recommend the use voltage flashlight

nal

inspection.

spectors should

When

shutting down, gradually that avoids damaging tial that can cause harmful stresses. Vessels

~hou!d

IS relieved

and panded tubes ly present on ever, the

If

request learn conditions prior

side surfaces.

not

temperature differentials that can cause ex-

may

cause

may

boiler.

the

internal inspection

of

from

the

hazard

which

of

could

injury

electrical

cause

or

of

during

an inter-

Preferably,

work

the

load

and

the·

pressure vessel cooled

the

norm~lly

-agatn to

the

heating surfaces. Some heat, how-

be

desirable

an

authorized inspector,

him whether

be

drained until

to

prevent uneven contraction

leak. Draining

baking

to

of

to

he

cleaning or flushing

in pairs.

should be reduced

temperature differen-

all

the

unit too quick-

deposits that

dry out

is desires

the

being made

it

to

observe the

death,

a low

in-

at

a rate

pressure ·

may

interior

at

the

is

well

of

water-

be

of

to

found previously,

Also have available for reference records

tions. of previous inspections.

Be

prepared

the

inspector including a hydrostatic test.

After proper cooling and draining flush out hose. Remove any scale or deposits waterside surfacea temal corrosion

The fireside surface cleaned so that metal surfaces, welds, joints, tube ends, fittings and readily checked.

Be sian tank (hot water), steam valves, feedwater valves, blow-off valves, expansion tank, off prior rear doors, the

Qean out level controls and cross-connecting pipes. Replace water gauge glass and clean out water cocks and and

Check leaks, wear, corrosion, and other damage. Replace or repair

the

waterside with a high pressure water

sure that system valves

to

opening bandholes, manhole, front or

and

pressure vessel prior

the

tri...cock:s.

blowdown valves and piping.

all

water

and

any

repairs or modifica-

to

perform

and

crawlway plug. Adequately vent

low

water cut-off piping,

and

as

any

testing required

of

the

vessel,

from

and

check for internal or ex-

leakage.

also should

any

previous repairs can

and

all

fuel

electrical switches are shut

to

entry.

Also check

steam piping required.

be

thoroughly

valves to expan· valves, valves

the

and

clean drain

and

valves

by

the

be

to

water

for

Be

certain that a supply

gaskets

or items needed

tion after inspection. Have available information on

dimensions, generating capacity, operating

sure or temperature, time

75()..150

is available, along with

to

place

of

manhole

the

unit

and

handhole

any

other gaskets

back

into opera-

the

boiler design,

in

service, defects

pres·

CHAPTER 2·13

CHAPTER2

J.

PREPARATION

FOR

THE

PRESSURE VESSEL

tained, especially with a hot water boiler, to

prevent the flue gases from falling below the dew

point.

EXTENDED

Many boilers or

for periods given nor fireside surfaces are allowed from corrosion.

Too many conditions exist

rules. There are two methods

dry.

can recommend the better method depending upon circumstances

Whichever method is used, common sense dic-

tates a periodic recheck

conditions during lay-up to allow variations from

the above methods for special area

conditions.

Swing open the boiler head at the

unit through the boiler

Although pollution control regulations may

tinue to limit ihe permissible sulphur content fuel oils, care must be taken to avoid corrosion problems that sulphur can cause, especially boiler that is seasonally shutdown.. Dormant periods, and even frequent shutdowns, expose

the fireside surfaces dew point during cooling. This moisture and any sulphur residue certain conditions, and especially in

high humidity, the corrosive effect

will be serious enough damage boiler tubes faces during the time that a boiler is out service.

to these boilers so that neither waterside

Your

to

used

for heating

stand-by

of

non-use. Special attention must be

Cleaver-Brooks local representative

service

in

prevent the flow·

tubes.

to

can

form an acid solution

or

LAY-UP

or

seasonal loads

may

have

extended

to

deteriorate

to

lay

down

of

storage:

the particular installation.

of

fli'eside and waterside

stack

of

warm, moist air

condensation below the

to eat through

other metal heating

definite

or

job-site

end

..

areas

of

the acid

or

severely

wet

or

of

the

con-

of

in

Under

with

sur-

of

At

the

start

of

lay-up, thoroughly clean the

or

fireside by removing any soot of

combustion from the tubes, tube sheets and

fireside surfaces. Brushing will generally

other suffice.

tion.

water. However, all moisture must be eliminated

after flushing and the surface dried by blowing air

practice to protect the cleaned surfaces by

ing

prevent rust.

To control cabinet, keep the control circuit gized. where high humidity temperature removed and stored in a dry atmosphere.

Dry

boiler where freezing temperatures may exist. In this method, the boiler must be thoroughly dried cause any moisture would cause corrosion. Both fireside of taken to eliminate moisture by placing moisture-

absorbing materials such

a

pounds for 3 cubic feet (at

inside the vessel. Fireside surfaces may be coated

with an anti-corrosive material

paint. Refractories should be brushed clean and wash such

tightly. Feed water and steam valves should closed. Damper and vents should be closed to prevent air from reaching fireside surfaces. odic inspection should be made and absorption

materials renewed.

Sweep

The

or

applying

them

prevent condensation from forming in the

For

storage is generally employed when the

will

·and

all scale, deposits, soot, etc. Steps must be

5 pounds for

coaJ,eci.

as

manhole and handholes, should be shut

away

or

vacuum any accumula-

fireside surfaces may be flushed with

some

with

extended lay-up periods, especially

occur,

be

out

waterside surfaces must be cleaned

30cubic

form

an anti-corrosive material to

or

large swings in ambient

the

of

service for some time

of

volume)

feet

All openings to the pressure vessel,

other products

of

heat. It is good

control

as

of

should

quick lime (at 2

or

silica gel

volume)

or

on

grease

coat-

ener-

be-

trays

or

Peri-

be

or

tar

be

This condition does not generally occur during

normal ture However, proper boiler operation must

fli'ing operation since the high tempera-

of

operation vaporizes any condensation.

be main-

Wet storage generally stand-by condition

is not practical.

temperatures must be considered. Care must

again be taken to protect metal surfaces. Vari-

is used for a boiler held in

or

in cases where dry storage

The

possibility

of

freezing

750-150

CHAPTER2

THE

PRESSURE VESSEL

abies preclude definite recommendations. ever, it

is

suggested that the pressure vessel

How·

be

drafoed, thoroughly cleaned internally, and refilled to

overflowing

with treated water.

If

deaerated water is not available, the unit should

be

fired to boil the water for a short period

time. Additional chemicals may

be

suggested by

of

your Cleaver-Brooks local representative

to

min~

imize corrosion. Internal water pressure should

be

maintained at greater than atmospheric pres. sure. Nitrogen often vessel. Fireside surfaces must cleaned

and the refractory

is

used

to

pressurize the

be

thoroughly

should

be

wash

coated.

750-150

CHAPTER 2-15

CHAPTER3

SEQUENCE OF OPERATION

CHAPTER3

SEQUENCE

B.

c.

D.

A.

GENERAL

This chapter outlines the electrical sequencing various controls through the pre-purge, ignition, run, and shutdown cycles

The program relay establishes the sequence operation and directs the controls and components to provide an overall operating sequence.

NOTE: The make

gram relay provided will vary depending upon tions. The following sequence plies regardless model. Please refer to the Wiring Diagram Oeaver-Brooks for your specific installation.

of

the burner.

operat~on

or

model

(WD)

of

job

specifica-

of

the make

prepared

of

all other

the pro-

OF

General A Circuit and Interlock Controls Sequence

Flame

of

ap-

or

by

OPERATION

of

Operation - Oil

Loss

Sequence

components are connected to it through switches or

contacts that permit the component to function

when required.

Abbreviations for the various electrical

ponerits are listed in Figure 3-1. The sequences

outlined in this chapter employ these

tions

to

aid

in

diagram.

For an djaiWlms. reQuest 4095 sentative.

The burner and control system are in a starting condition when the following conditions exist:

explanatocy booklet on schematic wirlnlj

from

your Cleaver-Brooks local

The boiler water is up to the correct level closing the low water cut-off switch.

• The low water

or

Gas

com-

designa-

applying the text to the wiring

Cleaver-Brooks Bulletin C17-

repre-

~ight

(panel)

is

off.

In

the schematic type wiring diagram provided for the boiler, the grounded (common) side power supply right side ponents (coils, solenoids, transformers, lights, etc.) are connected to

supply of

750-150

is

the electrical schematic. All the inductive

is

shown

of

the diagram. All inductive com-

shown

as

a vertical line on the

it. The hot side

a vertical line

of

on

of

the

the power

the left side

• The operating limit pressure control or

(steam boiler) temperature control (hot water boiler) and high limit pressure control are below their cut-off setting.

the operating lim

or

temperature

CHAPTER

it

3-1

CHAPTER3

SEQUENCE OF OPERATION

r-------r-------.:[::....F....:.IG....:.U--R:.::E_:3-....:1.:..:/E=L=E.::.CT.:..:.RICAL

MNEMONIC DESCRIPTION

NOM

ENCLA

TU

MNEMONIC DESCRIPTION

A

AAFL

.AAFR

AAPL AAPS

AAPS--8

.AAPS-C

AASS

AS

ACM ACMCS ACMF ACMS ACMSI AGV

AH

AL.FCO

Al..FR

AlWCO

AM

AMS

AOV

APR

APV

AR

AS

ASBA ASR

ASS

AS>/

AT ATS AWCBOS

Amber

1Cdor

Alcmizing Alcmi.zing Alcmizing Atcmlzing Alcmizing Atcmizing Alcmiz:ing

Alarm

AJr

Compreseor Motor

Air

Compresaor Motor Circuit Breaker

~r

Compresaor Motor Fusee

Air

Compreaaor Motor Starter

~r

Compreeaor Motor Starter lntertoek

A.uxillary

Alarm

Assured

Assured Low Fire Relay

Auxiltary Low Watl!ir Cutoff Ammetl!ir Atcmizing Auxiltary AJr

Purge Relay

Ail Purge v

Alarm

Auxiltary Auxiliary Switch Bypass Relay

Alarm

Alcmiz:ing Steam Annundator Transfcrmer

Alarm

Auxiltary Water Column

of Pilot Ught)

AJr

Failure Light

AJr

Faiklre Relay

AJr

Proven

AJr

Provi~

AJr

Proving

AJr

Proving

AJr

SMctor

BeM

Gu

VaJve

Hom

Low Fire

CUtoff

Media sWitcn

Ctl

v

eJye

&lYe

Relay

Switch (Suffix)

Silencing Relay Silencing Swttch

T

erlt

VaJve

swnc:n

Light

SwitA:I'I

S>Mtd'l S>Mtd1

Switch

Blow

- Burner

- Compreeeor

Down

5\l.titch

BMPS

BMS

eMS~

BMSS

BS

ass

BWPM

FNIT

CAA. CAFR CAP

CAPS

ceca

CCF

CCRS

CCT

CFHL OPL

Cl ClS

COPS

CPOL

CR

csss

C'NPM C'NPMCS CWPMF C'NPMS C'NPMSI C'NPS

cwsv

8lo\wr Manu• Purge Switch

Blower Motor Starter

Slower Motor Starter lnterioc:k

Bc:Nier

- Master

Burner

Switch

Bc:Nier

Selector Switch

eoo.t.

eoo.ter WafM Thennostat

Combustion Combustion

Capacitor

Combustion

Con~

Cln:uit-

Controf

Circuit

Controf

Cln:uit Reset Switcn

Con~

OR::uit

CaU

For Heat Ught

Changeo\W

Canof:»yUght

Canopy Light Switch

Changeover

Control Power on Light Contro4

FleMly

Controf System Selec1or Switch

Crculating Orcula.ting Water Pump Motor OrcuJating Water Pump Motor

OrcuJating Water Pump Motor Starter Crculadng Orculating Water Cooling Water Solenoid

B

8

BC BOCS

BOOS BCRS

BFPL BFPM BFPMF BFPMCS BFPMS BFPS

BHS BIOL

BM

BMCS BMCR BMF BMPR

Slue

(Color of Pilot Light)

Biaa

Con~

Breecning Breecning

Slowdown/Reset Switcn BciJer

Boiler Feed

Boiler Feed Pump Motor Fusee BoiJer Boiler Feed

Boiler

BciJ•-

BciJer

Blower

Blower Motor Circuit Breaker Blower Motor

Blower Blower

Camper Cloeed Swttcn Camper Open Switch

Feed Pump Light

Pump Motor

Feed Pump Motet Circuit Breaker

Pump Motor Starter

Feed Pump Switch

Header

in Operation Light

Motor

Motor Fusee Motor

swnc:n

Contro4

Flower

~y

Reiay

0

OCVM

OG

OOHPV

OHWC

OHWL

OHWR

DISC

r:x.wc

Cll.WL Cll.WA

OM

OMT

ONS

OOCE

DOE

OPS

OS

Denotes Oigestl!ir

CMect

Current

Oratt

Gauge

[)geeter Gas Housing Purge Valve

Oeaerator High Water Control Oeaerator High Water Light Deaetator High Water Relay Dieconnect (Entrance Switcn)

Oeaerator Low WafM Control Deaerator Low Watar Ught Oeaerator Camper Motet Damper Motet Day-Night Switch

Oe4ay

On

o.May

on Energization (1imer)

Damper

s-wnc:n

Door

RE]

B

(Confd)

Seklct.or

WafM Pump Motor

Switch

c

AJr

Failure Ught

AJr

Failure Relay

AJr

Proving Switch

Circuit Breaker

Fuae

Transformer

In

Progreee Ught

Pressure Switch

wat.er

Pump Motor

Clrc:uit

Breaker

Fuaee

Water Pump Motor Starter lntet1ock

Pump Switch

VaJve

0

Gaa

Equipment (Prefix)

VoH

Meter

Low

Water Relay

Transtormer

Oeenergization (1imer)

Flo:sitioning

Switch

CHAPTER 3-2

750·150

CHAPTER3 SEQUENCE OF OPERATION

MNEMONIC

EDS

ESS

ETM

FAOI FADM FAOR FCIPL

FD FDJS

FOPS FFA

FFl

FFR Flame F FGA Flue FMS FOAS

FPM FPMS

FRI

FS FSS FSSM FVEL FVL FVR

F'NC

FWVAS

FWVT

G

GCAS GCS Gaa

GGL

OOL OOR GOS

GPS

GPV

GPW GSSV

GVEL

GVTS

HATC HSWTL HFAV HFGV High Fire Gaa Vahle HFOV HFPS HFS HFS-A HGPL HGPA

Emergency Emergency Stop Switch

8apMd

Frean

Freeh.

Fteeh

Fuel

Flame Detector

Aame Flow Differential Preeaure

Flame

Aame

Firing

Firat

Feed

Feed Pump Firing

Flow Switch

Fua

Aame Fua Fuel Vaive Fua

Feed

Green (Color

Gsa

Gauge

Gaa Operation GaaGaaGaa Presaure Senaor Gsa

Gaa Gaa Gaa Gaa

Hgh Hgh

Hgh

Hgh Hgh

Hgh

DESCRIPTION

Ooof'

Switch

Time Meter

AJr

Damper lnter1odc

Ak

Camper

AJr

Damper

Chengeowr

Oetec::tor

Failure Failure

aiJure

Gas

Mode

Out

Reset Switch

Pump

Rate

Selector Switch

~gnal

V8Ne Energized Ught

Vaive Relay

WatM WatM Wafl!llf V8Ne Transformer

Cock Cock

Glasa

Oil

Pilot p;fot Seneor Solenctd V Valve Energized Valve Test Switch

Ambient Temperature Con1rol

Boiler Fire

Fire 01 Ve.Ne Furnace Preaaure Switch Fire Switch Fire Switch -

Gu Gu

In Prcgreu. Ught

Jundion

AJatm

Ught

R.May

Recirculation

Switch

Mo'&or

Motor

Interlace

Strength

Ught

Conirol V8Ne Auxiliary

of

p;fot Ught)

Auxiliary Switch Switch

Ught

Ae4ay

Switch

vaNe

Vent

Valve

WafM

Temperature

Air

V

e.Ne

Pressure Light Pressure

E

F

Motor

Ae4ay

Starter

Meter

G

aJve

Ught

H

Air

~lay

Box

Switch

Ught

MNEMONIC DESCRIPTION

H (Cont'd)

HGPS

HILWA

H..

H..C

H..FC H..PC

H..TC

HMO

HOPl

HOPA HOPS

HOLC

HOTL

HOTA

HOTS HPCO HSPC

HSPL

HSPA HSTC HSTL

HSTS HWAA HWC HWCO HWL

o.c.)

o.o.)

IL IM

INT

rT

High Gaa Preeeute Switch Hgh

Low

HeaWUght High

1-igtH.ow

High Hgh

Header

High Hgh High Oil Praeaure Switch

Header Operating Umit

Hgh Hgh Hgh High Preeaure Cutoff High Hgh High Steam Preaeure Relay High Stack High High Stack Temperature Switch Hgh Hgh Hgh High WatAr

lnstantaneoua

lnatantaneoua Open

Water Alarm

Umit

Conirol

Fire

Umit

Limit

OW

Oil Preeeure

OW OW

Oil

Conirol Pree.Jre Temperature Control

Modulating Controt

Pree.Jre

Temperawre Temperature Relay Temperature Switch

Control

Ught Ae4ay

Contro4

Ught

Steam Preeaure Control Steam Presaure

Temperature Con1rol

Stack Temperature

WatM

Alarm

WatM

Con1rol

WatAr Cutoff

Ught

Relay

Cloaed

lgrdticn Ught

Ignition Module Interval (Timer) Ignition Transformer

J

..PP Jackahatt Position Potentiometer

L

LAMPS

LASPS

LCR

LDL

LOPS

LOS

LFAV LFGV

LFHTO

L.Ft.

LFOV LFPS LFR LFS LFS-A LFS-F

Low Atomizing Media Pressure Switch Low Atomizing Umit Circuit Relay Load

Demand Light Low Differential Preaeure Switch Low Draft Switch

Low

Fire Low Fire Low Fire Hold Low Fire Ught Low Fire Oil Valve

Low

Fire Low Fire Relay Low Fire Switch Low Fire Switch - Air Low Fire Switch - Fuel

S1eam

Air

Valve

Gu

Ve.ive

1ime

Prei!IISUre

Preaaure Switch

Delay

Switch

750-150

CHAPTER

3...J

CHAPTER3

SEQUENCE OF OPERATION

MNEMONIC

DESCRIPTION

L (Cont'd)

LFS-G LFS-0 LFTC LGPL LGPR LGPS UAPS

LLPC

LLPR Low Urnit Pre8lure Relay U..TC U..TR LOPl LOPR LOPS LOTL LOTR LOTS LPAPS

LPCO

LPS

LSPC LSPL LSPS LTS LWA LWAR LWCO LWFL LWL LWA LWRR

Low

Fire

Switd'l-

Low

Fire Switch - Oil

Low Fire Temperature

Low

Gaa

Low Low Low

Low

Low Umit TemperatUre

Low Low Low Low Low Low Low Low Low

Low Low Low

Lamp Teet

Low Low Low Low

Low Low

Low WatM Reeet

Pre.ure

Gaa

Preeeure Relay

Gaa

Pre.uN

lnlltr'Urn.nt

Umit Prealure Control Umit Temperature

Oil

Preuure

Oil

Pressure Relay

Oil

Preuure

Oil Temperature Light Oil Temperature Relay

Oil

Temperature Switch

Pfant

IW Pressure Switch

Pre881.1At Preaaure

Steam Preeaunt Steam Pressure Light Steam Presaure Switch

WatM Alarm Wafllr Alarm Relay WatM Cutoff Wafllit Flow Light WatM Ught WatM Relay

Cutoff

Switch

Gu

Ught

Switch

AJr

Pr.eure

Light Switd'l ·

ANy

Con~

M

MA

MAS

MAM

MC

MCS

MJM Moclulating

~MAS

MFC

~L

WFW\1

PNJV PNJVAS

MGVEl PNJW ""-.C Moclulatlng

(MC.)M)

~v

~VAS

~VEL

MPC

MPCS

~p

Milll....amp

ManuaJ

- Automatic Switch

Mic:roammeter Moclulatlng Control

Manual Control Switch

Moclulatlng Camper Motor Auxiliary Switch

ManuaJ

Main

Motorized Feed Watl!lr

Main

Main Main

Main

Momentary

Main

Main Moclulating Pressure Control

Main

ManuaJ

Camper Motor

Flame

Con~

Fuel

VaJve

GM

Valve

GM

Valve

GM

Valve Energized Ught

Gaa

Vent Valve

Levet

Oil

Valve

Oil

Valve Auxiliary Switch

Oil-

Valw

Power Circuit Breaker

Positioning Potentiometer

(Potentiometsr)

Ught

Vakve

Au:ldliary

Control

Energized Light

Switch

Con~

ReUay

Switch

MNEMONIC

(M~

MTC

WA

N

(N.C.) (N.C.)

NGHPV

OCA

OOM

COMAS

OOMT

ocs

OH

OHCS

OHF OHR OHS

OHT

OLC

OLPC

OL'S OLTC

<XX..

('.)PM

OPMCB OPMF

('.)PI\.tS OPPM OPR 01 Purge Relay OPRL 01 OPRS OPS OPSPM 01 Pilot Supply

OPV

OFN

OSCN

oss

OT

OTS

CN CNAS

CNEl

Mrlnual Aeelt

Modu&aung

Make-Up Valve Actuator

OenotM Natural

NormaJiy

NomlaBy

Na1Ur'al

Outa.t Outa.t

CutJet

OutJet

011

Drawer Switch

Oil

Heater

Oil

Heater Orcuit Breaker

01 Heatl!lr Fusee Oil

Heater Relay

Oil

Heater Switch

01 Heater Thennoatat

Operating

Operating Umit Preaaure Control

Thermal

Operating Umit Temperature Control

Ol~tionUght

01 Pump 01 Pump Motor 011

Pump Motor

01 Pump Motor Starter 011

Purge Pump

Pump Running Ught 01 Preeaure Sensor 01 Pump Switch

01 Purge

Ql

Aetum Valve 01 Shutoff Valve 01 Selector Switd'l

Outdocr

01 Temperature Sensor OIIVatve 01

V&Ne 01

V&Ne

DESCRIPTION

Temperature~

CSoeed

Opened

Gu

Housing Purge Valve

Camper

Camper Mot« Camper Camper

Limit Control

Overtoade

Motor

VaJve

Thermostat

Auxiliary

Energized Ught

M (Cont'd)

N

Gaa

Equipment (Prefix)

0

Actuator

Motor

Auxiliary Switch

Motor

Transtcnner

CRuit

Breaker

Fuaee

Motor

Pump Motor

Switch

CHAPTER 3-4

750·150

CHAPTER3

MNEMONIC

DESCRIPTION

SEQUENCE OF OPERATION

MNEMONIC DESCRI

Pll

ON

p

PAASV PAPS PC PCL PCR PFCC PFFL PFPS PHGPS

P1Pl

P1S PLC PLGPS

POl

POV

PPL

PPR

PPTO

PR

PRL

PS

PSF

PSS

PSN

PT

FTS

R RAR

AATO

RES

RS

RTO

SBFPL Stand SBFPM SBFPMCB SBFPMF SBFPMS SBOV

SBPS SBR

sc

SCTS

SOL

SHT

SHV

SLCL

SPIR

SPS

Denote. Propene Gas Equipment

Rant

Purge Pump Purge Complete Pump

Power

Pilot Flame Failure Light

Politlw Furnace Preeaure Switch

Pilot High Gas Preeaure Switch Purge Pilot Ignition Programmable Logic Controller Pilot

Power On Ught

Pilot Poet Poet

Post Purge

Program Purge Power Supply

Power

Pump Purge Purgelimer Pump

Red

Remote

Resistor

Range Ae&Jatance

Stand Stand Stand

Stand

Surlace Sootblower Pree8w'e Switch Sootblower Relay Scanner

SupeNieoty

Steam Steam Heater Thennostat Steam Heater Valve Setety Limits Complete Light System Steam Presll.ure Senaor

p

Ak

Atomizing Sdenotd Valve

AJI

Pro~

Con11'01 Contro4

Fec:tor

in

Progreee Ught

low

Gas

Oil

Valw Purge Ught Purge

Relay

Ready Ught Supply

Selector Switch

So4enoid

Transfer Switch

Switch

~t

ReM!y

Correction Capacitor

Switch

PT'eeaure

ReM!y

lime

Delay

Fuse

Valw

R

(Color

of

Pilot Ught)

Alarm

Relay

Alarm

rme

Delay

Switc:n

Temperature

s

BY

Feed

Pump

By

Feed

By

Feed

By

Feed

By

Feed

~ow

Cock

Demand Ught

Pump

Ught

Pump

Motor

Pump

Motor

Pump

Motor Fusee

Pump

Motor Starter

OH

Valve

Test

Swttc:n

lnteriock Relay

Swftcn

Deted:Of

Ciroutt

(Prefile)

Breaker

ss

sse

SSl

SSR

STHWC STHWL STHWR

sn.wc

STl..Wl

STl..WR

(T.C.)

(T.O.)

T8

T/C

TO TOAS

TPL TPM TPMCB TPMF Transfer TPMS

·

TPS

.

lNFO

VM

w

we

WCBDS WFNL WLC

wo

WTS

S.Mtdor Switch

Sequencing Step Controller Safety Shutdown Light Solid

Stat.

Surge Tank High Water C4ntrol Surge Tank High Water Light Surge Tank High Water Relay Surge Tank

Surge Tank Low Water Ught Surge Tank

limed Tmed T enninal 'Thennocouple lime

Delay

Ttme

Delay Auxiliary Switch Transfer Transfer Pump Transfer

Transfer Pump Transfer

Utra-Violet Flame Detector

Volt Meter

White Water Wawr Column Blow

Water Flow Normal Ught

Water

OenotAIS

wau,r Temperature Sensor

S (Cont'd)

Relay

Low

Water

low

Watsr Relay

T

Ooeed

Open

Block

Pump

Light MotOf

Pump

MotOf

Pump

Circuit Breaker

MotOf

Fusee

MotOf

Starter

Switch

u v w

(C41or

of

Pilot

C41umn

level

Waat4 Oil Equipment

Light)

Down

Control

Contro4

Switch

(Prefix)

750

..

150

CHAPTER

3...S

CHAPTERJ

SEQUENCE

OF

OPERATION

• All applicable limits are correct for the burner operation.

• The load demand light glows.

All entrance switches

is

power

present at the line terminals of:

-Blower

-Air provided)

-Oil

~il

motor starter

compressor motor starter (if

heater relay (if provided)

pump motor starter

are closed and the

(if

provided)

The controls used

or

- oil applicable regulatory bodies. Refer to the boiler wiring diagram to determine the actual controls provided. The circuits and controls normally

used

to in the following sequence

gas - and the specific requirement

in these circuits are listed below and referred

vary

depending upon the fuel

of

operation.

of

Limit Circuit:

• Burner switch (BS)

•

Operating limit control

sure

or

temperature

(OLC)-

pres-

• High limit control (HLC) - pressure

or temperature

• Low water cut-off (LWCO)

•

Gas-oil selector switch (GOS) - (Com· bination burner only)

• Oil drawer switch (ODS) - Oil burner

to

These sequences do not attempt

of

action system except for the interlock controls that directly relate Chapters and specific information on setting and adjusting the controls.

INTERLOCK

The burner control circuit designed for 115 volt, single phase, nating current.

The electrical portion

individual circuits with controls that are wired in a manner designed

system. The program relay provides connection

points for the interconnection

circuits.

the fuel supply system

to

the action

4

a_nd

5 contain operating instructions

B.

CIRCUIT

of

CONTROLS

is

of

the boiler is made

to

provide a safe workable

correlate the

or

feedwater

the program relay.

AND

a two-wire system

60Hz,

of

these various

alter-

up

of

• Low oil temperature switch

(No. 5 and 6 oil only)

• Low gas pressure switch (LGPS)

• High gas pressure switch (HGPS)

Fuel Valve Interlock Circuit

•

• Main gas valve auxiliary switch

~GVAS)

Oil valve auxiliary switch (OV AS)

Blower Motor

• Blower motor starter (BMS)

Air compressor motor starter (ACMS)

(if provided)

Air purge valve (APV) (No. only)

Start

Circuit

(LOTS)-

5

or

6 oil

CHAPTER 3-6

750-150

CHAPTER3

SEQUENCE OF OPERATION

Running Interlock Circuit

• Blower motor starter interlock (BMSI)

Combustion air proving switch (CAPS)

•

Atomizing air proving switch (AAPS)

(if

provided)

Low

Fire Proving Circuit

• Low frre switch (LFS)

Pilot Ignition Circuit

Gas pilot valve (GPV)

Ignition transfonner

•

Gas pilot vent valve (GPVV) provided)

(I1)

Flame Detector Circuit

Flame Detector (FD)

(if

• Modulating control (MC)

To

comply with requirements

derwriters such as Factory Mutual (F.M.), Industrial Risk Insurers (I. R.I.)

interlock devices may

mentioned above.

be

used in addition to those

of

insurance un-

or

others, additional

High Fire Proving Circuit

• High fire switch (HFS)

Running Interlock and Limit Circuit

•

Low

oil pressure switch (LOPS)

High oil pressure switch (HOPS)

High oil temperature switch (HOTS)

•

Auxiliary low water

•

C.

SEQUENCE

OPERATION -OIL.

cutoff

OR

(AL WCO)

OF

GAS

Main Fuel Valve Circuit

• Main gas valve (M:GV)

•

Main gas vent valve (M:GVV) provided)

• Oil valve (OV)

Main fuel valve light (FVL)

Firing Rate Circuit

Damper motor transfonner (DMT)

Modulating damper motor

Manual·automatic switch (MAS)

Manual flame control (MFC)

(if

(MOM)

On

a combination fuel unit, the gas/oil switch

be

must

The

present at the program relay (PR) input tenninals and with all other operating conditions satisfied:

set for the proper fuel.

following

sequence

occurs

with

power

Pre-Purge Cycle - When the burner switch

"on,"

(BS) is turned "limit" and "fuel valve interlock" circuits are closed and no flame signal

motor start circuit"

blower motor starter

light (LDL) turns on. When firing oil, the air compressor motor starter (ACMS)

is

also powered. The air purge valve (APV) (No.

and controls wired in the

is

present, the "blower

is

powered energizing the

(BMS). The load demand

(if provided)

5 and 6 oil only) remains de..energized.

At the same time, the program relay signals the

modulating damper motor damper. The damper begins to open and drives

(MOM) to open the air

750-150

CHAPTER 3-7

CHAPTER3

SEQUENCE

OF

OPERATION

to its full open

a flow the ignition cycle.

On certain boilers the circuitry will include a high

fire switch

to prove that the modulating damper motor

(MOM) has driven the damper to the open posi-

tion during the pre-purge cycle. In this instance, the "high fire proving circuit"

The controls wired into the "running. interlock circuit" must be closed within the start sequence. controls are not closed at this time, subsequently open, the program relay will go into a safety shutdown.

At

the program relay signals the modulating damper motor (MDM) fire position.

To assure that the system

prior to ignition, the low fire switch

be

cui t." The sequence will stop and hold until the

modulating damper motor (MDM) has returned

to

low fire switch fire switch continue.

of

the completion

closed to complete the

the low fire position and the contacts

NOTE:

Ignition and gas pilot valve (GPV) are energized from the appropriate pilot ignition

NOTE:

or

high fire position. This allows

purging air through the boiler prior to

(HFS).

is

The

started simulating condition is sensed during the pre-purge period. A safety shutdown will occur

flame

Cycle -

An equipped with an oil pilot rather

than a gas pilot quence

The

purpose

In the event any

ofthe

to

drive the air damper to its low

(LFS) are closed. Once the low

closed, the sequence

ignition

is

The

oil-fired

of

high flre purge period,

if

flame

sensed at this time.

ignition transformer (IT)

terminal.

both is identical.

of

this switch is

is

utilized.

10 seconds after

is

in

low fire position

(LFS) must

"low

fire proving cir

is

trial

cannot

or a flame

burner

..

The ignition

may

of

or

if

of

allowed to

be

if

the

be

se-

these

they

the

The pilot flame must be established and proven

by

the flame detector (FD) within a 10 second

period in order for the ignition cycle to continue.

If

for any reason this does not happen, the system

will shut down and safety lockout will occur.

NOTE:

With a proven pilot, the main fuel valve(s) or MGV) light (FVL) flame the main flame begins. It lasts light oil and natural gas, and 15 seconds for heavy oil. At the end detector still detects main flame, the ignition

..

transformer and pilot valve are de-energized and the pilot flame

NOTE:

Depending ments

surer

the terminal may be used. Both vide the same function but differ

in

proving Refer diagram.

is

ignited and the trial period for proving

If

or close. The safety switch will trip

to lockout the control. Refer to

flame loss sequence section for description

of

or

10

or

the time interval allowed for

energized and the main fuel valve

in the panel

of

the proving period, if the flame

is

extinguished.

the main flame does not light,

stay lit, the fuel valve will

upon

the regulatory body, in-

fuel being burned, either

15 second pilot ignition

main

to

the

of

the

flame

boiler

is

lighted. The main

10 seconds for

action.

!WARNING

The cause any

other should rected before

tart. Failure

In

serious

death.

Run

Cycle-

program relay releases the modulating damper motor (MDM) from trol by either the manual flame control (14FC)

for

loss

unusual

be

Investigated

of

flame

condition

attempting

to

do

so may

personal

With main flame established, the

its low fire position to con-

Injury

require-

pro-

ignition.

wiring

and

cor-

to

res-

result

(OV

or

CHAPTER

3--8

75()..150

CHAPTER3

SEQUENCE

OF

OPERATION

the modulating control (MC) depending upon the position This allows operation above low fire.

With the manual-automatic switch automatic, subsequent modulated firing will at the command which governs the position damper motor fuel valve(s) are actuated by the motor through a linkage and cam assembly to provide modulated

firing rates.

NOTE: Normal operation

of

the manual-automatic switch (MAS).

(MAS) set at

of

the modulating control (MC)

of

the modulating

(MDM). The air damper and the

of

the burner should manual-automatic position and under modulating control. The manual position

justment

entire fll'ing range. When a down occurs while operating the manual position at other than low fll'e, the damper will not a closed position thus allowing more air than desired to flow through the the pressure vessel metal and refractory to undesirable tions. The effectiveness purging burner.

be

with the switch in the

the

direction

is

provided for initial ad-

of

the burner over the

boiler~

is

lost

on a No.6

of

This subjects

of

oil fired

the

shut-

be

condinozzle

be

in in

lights (LDL) and (FVL) are turned off. The blower motor continues to run to force air

through the boiler for the post purge period.

On

a No. 6 oil fired burner, the air purge valve

(APV) is powered from the blower motor start

circuit via the contacts

(APR) to provide an air purge

The damper motor returns to the low fire position

of

the air purge relay

of

the oil nozzle.

if it is not already in that position.

is

The blower motor start circuit the end cycle

The program relay now sequent recycling and, when steam pressure or water temperature drops sufficiently contacts again goes through

ing cycle.

D.

The program relay will recycle automatically each time the operating control closes power failure. shutdown caused by failure to ignite the pilot, or the main flame, also occur dition occurs during the

of

the post purge cycle and the shutdown

is

complete.

is

of

the operating control, the burner

its normal starting and operat·

FLAME

if

LOSS

It

will lockout following a safety

or

by loss

a flame

of

or

a flame simulating con-

pre-pu~ge

de-energized

in readiness for sub-

to close the

SEQUENCE

or

flame. Lockout will

period.

at

after a

This

is

the end

(LDL) and (FVL) lights

Demand firing continues as required by load conditions.

Burner

will fire until steam pressure ture modulated

(MDM) should return

before the operating limit control When the limit control circuit following sequence occurs:

The main fuel valve circuit

ing the main fuel valve (MGV) The flame

750·150

Shut,;.Down Post

in

excess

of

the burner starting cycle. The

on

the panel remain lit.

Purge

of

demand

fll'ing, the modulating damper motor

to

the low fire position

is

extinguished. The control panel

- The burner

or

water tempera-

is

generated. With

(OLC) opens.

is

opened, the

is

de-energized caus-

or

(OV)

to

close.

or

The control will prevent start-up

limit circuit controls are open. The control will lockout upon any abnormal condition affecting air supervisory eontrols wired

or

the fuel valve interlocks

in

the running interlock circuit.

ignition if the

CHAPTER 3·9

CIIAPTER3

SEQUENCE

OF

OPERATION

CAUTION!

The

manually

safety

loss

condition

tlg~ted

tempting

avoid

lockout

shutdown.The

of

flame

and

to

damage

(1)

No pilot flame.

The

pilot flame must be ignited and proven within a 1 0-second period after the ignition cycle begins.

within this period, the main fuel valve circuit will not be powered and the fuel valve(s) will not be energized. tion circuit is inuilediately de--energized and the pilot valve closes.

switch lights and lockout occurs

ately.

The

blower operate. The flame failure light and the alarm bell (optional) are energized

seconds later.

switch

reset

following

or

any

should

corrected

restart

to

the

motor

will

must

cause

unusual

be

lnves-

before

In

order

equipment.

If

not proven

The

immedi·

continue

for

igni •

reset

to

10

be

a

at-

to

guished 10 detecting circuit will respond gize the main fuel valve circuit within 2

to

4 seconds to stop the flow reset switch lights and lockout occurs immediately. tinue to operate.

The flame failure light and alarm bell (optional) are energized 10 seconds later.

The blower motor will The lockout switch must be manually reset before operation can be resumed. (Refer to the previous caution.)

(3)

Loss

If

a flame outage occurs during nonnal operation and/or the flame is no longer sensed by the detector, the will trip within 2 gize the fuel valve circuit and shut fuel flow. The reset switch lights and lockout occurs immediately. The blower motor continues operation. The flame failure light and alarm bell (optional) are energized

or

15 seconds later. The flame

of

The

blower motor will con-

be de-energized.

of

flame.

flame relay

to

4 seconds to de-ener-

10 seconds later.

to

de-ener-

fuel. The

off

the

The blower motor will The lockout switch must be manually reset before operation can be resumed. (Refer

(2)

When the pilot flame fuel valve circuit upon the length period, the pilot flame will be extin-

CHAPTER 3-10

to the previous caution.)

Pilot

but

no

main

is

of

be de--energized.

flame.

is

proven, the main

energized. Depending

the trial-for-ignition

The blower motor will be de-energized. The lockout switch must be manually reset before operation can be resumed. (Refer

If

safety lockout, the trouble shooting tion in the operating manual and the technical bulletin should be referred to for assistance in pinpointing problems that may not

to

the previous caution.)

the burner will not start, or upon a

sec-

be

readily apparent.

750-150

CHAPTER3

SEQUENCE OF OPERATION

Most program relays have

to

self diagnose

and message that indicates tion. Refer to

the

control bulletin for

the

capability

to

display a code or

the

failure condi

specifics and suggested remedies.

the

Familiarity with other controls

tained manual

by

and

Knowledge

will

make

the

event

time

or delays can be prevented

tematic checks

against

the

from

the

stage

normal. Following a routine

in

the system

studying

this

of

bulletin.

the

system

the

troubleshooting

it

is

necessary. Costly

of

the

normal sequence to determine

at

which performance deviates

program relay

can

contents of

and

its

much

actual operation

and

be

ob-

the

controls

easier

in

down

by

sys-

may

possibly eliminate overlooking vious condition, often one that ly

..

simple to correct.

Remember that this for

the most part

it

shuts down or refuses to operate.

attempt to circumvent

is

a safety device

it

is

doing

any

an

ob-

is

relative~

and

its

job when

~

of

the

safety

features.

·

inspection of

all

comJX>nents

followed. Periodic checking of

Preventive maintenance

to see that a safety lockout

under conditions of failure pilot

of

main

flame

is

recommended.

or

and

scheduled

should

will

to ignite either

from

loss

the

of

be

relay

occur flame

750-150

CHAPTER

3-11

CHAPTER4

STARTING AND OPERATlNG

INSTRUCTIONS

CHAPTER

STARTING AND OPERATING

INSTRUCTIONS

A. General Rreparation for Start-up - All Fuels

B.

Control Settings - Steam and Hot Water

C.

Gas Pilot

D.

Atomizing Air

E.

_Firing

F.

Firing Preparations for No. 6 Oil (Series 400-600)

G.

Firing Preparations for Gas (Series 200-400-700) H. Start-up, Operating and Shutdown - All Fuels I.

NOTE:

If

your boiler is equipped with a CB-HA ment control system, refer to CBHA and Servicing Manual No.

133 for

regarding procedures described

in

WKTM

WK

Installation, Operating,

specific

this section.

boiler

manage-

information

A. GENERAL PREPARATION

FOR START-UP -

ALL

Instructions

is

tion

and vent stack connections have been made.

in

this chapter assume that installa-

complete and that all electrical, fuel, water

FUELS

Control Operational Tests and Checks

750-

4

Preparations for

and components mentioned paragraphs, refer

contents

components are given

should

diagram should also have been studied, along

with the sequence

be reviewed prior

!WARNING

It Is

starting through thoroughly attempting to operate the

rather operation as time. Failure

could result in serious personal

injury

No.2

Oil (Series 100-200)

to

call-out photographs and the

of

Chapter

1.

Adjustment

in

Chapter 3.

Chapter 5 and this

to

recommended

Instructions

completely until

understood,

than

or

death.

performing

it

is read for the

to

heed

in

the following

of

the major

frring. The wiring

that

these

be read

they

are

before

boiler,

each

first

this

warning

The operator should be familiar with the burner,

all

boiler, and

quickly locate and identify the various controls

750

..

150

controls and components. To

Verify the supply Check for blown fuses, open circuit breakers, dropped out overloads, etc. Check reset

of

fuel and the proper voltage.

CHAPTER

of

all

4-1

CHAPTER4

STARTING AND OPERATING

INSTRUCfiONS

starters and controls having manual reset fea-

on

tures. Check the lockout switch

if

mer and reset

The

boiler should be filled with water to the proper operating level using water temperature. Make sure that treated feedwater is available and entire system should be filled and vented. Refer

to Chapter 2 for water requirements. On a steam

boiler, open the test valve (Fig. 1-1) to vent air displaced during filling. Leave the test valve open until the escape burner

is

operating.

necessary.

used

..

In heating applications, the

of

steam is noted after the

the program·

of

ambient

CAUTION!

Prior sure from relief piping and SAFE emission

·cannot personal sonnel

to

firing

that

the

the safety

valves, and

from

drain

point

all

valves

of

discharge,

of

hot

possibly

Injury

or

damage

a

boiler,

discharge

valves

the

discharge

the

blowdown

are ·piped

water

or

cause

or

death

to

property.

make

piping

or

the

to

a

so

that

steam

serious

to

per-

For safety's sake, make a final spection, especially checking for any loose

incomplete piping

tions that might present a hazard.

or

wiring

pre~start-up

or

any other situa-

CAUTION!

Note support mounting secured

the

bolts

ment. stalled, and the to allow traction

In

.

sure

damage

that

the

legs

skids

by

pressure

are

tightened

When

prior

bolts

the

securing

skid

for

must

expansion

caused

temperature

vessel

B.

CONTROL

to

and

the

pressure

are

In

bolts

at

vessel.

the

boiler

to

initial

the

be

loosened

by

between

skids

equipment.

SETTINGS -

vessel

welded

front

the

and

rear

These

for

ship·

Is

firing,

rear legs

and

con-

differences

pres-

and

avoid

STEAM AND HOT WATER

in-

or

to

of

in-

to

Check all linkage for full and free movement the damper and metering valves and cams. This

be done by loosening the linkage at the

can damper motor connecting arm and manipulating the linkage by hand.

Check for rotation

closing the motor starter

impeller rotation is counter-clockwise when viewed from the front

is

rotation end.

Before operating the boiler feed pump supply pump, open or properly positioned.

CHAPTER 4-2

clockwise when viewed from its drive

of

all motors by momentarily

or

relay.

of

the boiler. Air pump

be sure all the valves

The

in

the line are

of

blower

or

oil

See

Chapter 5 for adjustment instructions for the

following controls.

Inspect operating limit control for proper setting.

(1)

The

pressure control

should be

desired steam pressure, but at least lower than the setting

(2) The temperature control on a hot water boiler should

the highest desired water temperature but

within the limits

Inspect the high limit control for the proper setting.

set

slightly above the highest

of

a steam boiler

10%

of

the safety valve.

be

set

slightly above

the pressure vessel.

750-150

CHAPTER4

(1)

On

a high pressure steam boiler, control should lbs.

above control setting, between

the

be

set approximately

the

operating limit pressure

if feasible, or midway

operating limit pressure

safety valve setting. The setting on a low

pressure steam boiler

may

be

2 or 3 lbs.

above the operating limit setting, but must

not

exceed

(2)

On

a hot water boiler, temperature control should above

the

safety valve setting.

the

high

be

operating limit temperature

control setting, but within the limits of

design pressure

the

Inspect

This control

modulating control for proper setting.

must

modulating motor returns

before

the

operating limit control opens. further desirable to have somewhat below control so tion

that burner operates

for a brief period

immediately driving

of

the

pressure vessel.

be set

and

adjusted so

to

its

the

cut-in setting of

on

each start rather than

to a high

low fire position

low point setting

in

low

fire

position.

this

10

and

limit

5-10•

the

that

the

fire

posi-

SfARTING

the

It

is

limit

AND OPERATING

the

closing of a valve, pump or opening drained

from of proper functioning not

be

over-emphasized. Make sure that

trol

and

the

piping

of

the

the pressure vessel. The importance

of

are

level.

The settings of controls relating

or

gas,

are covered

In

the

event

the

control devices

in

subsequent sections.

boiler

is

not

listed here,

certain that their settings

information if required, local

representative or contact Cleaver-Brooks.

On

initial start-up or whenever

placed into operation

INSTRUCfiONS

and

the

restarting of

valve when water

low water controls can-

to

fuel,

either

equipped

are

correct. If additional

see

your Cleaver-Brooks

from

with

be

certain

the

boiler

a "cold" start, manual-automatic selector switch should at

"manual"

"close." After

thoroughly warmed,

be

turned

rate

may

in

accordance with

aose

and

the

manual flame control set

the

boiler

to

"automatic,".so that

be

controlled

load

all

power entrance switches (supplied

is

in

operation

the

selector switch should

the

burner firing

by

the

modulating control

demands.

others).

the

is

the

con-

oil

optional

to

as-

is

the

be

set

at

and

by

NOTE: The settings

trols

may

require some readjustment after running

the

for

scale settings

relatively accurate, but principally

are

for

adjustment should

and

agree with

steam pressure gauge or

temperature thermometer.

the

low

Inspect

as

well

as

equipped with no

adjustment pre-set freedom

be

by

of float movement. Float movement can

verified gauge glass when off either

by

water cut-off

the

auxiliary

this

optional device). Normally,

is

required since these controls

the

original manufacturer. Check

by

observing

the

water supply

lhe stopping of

of

all

the

above con-

boiler

is

started

a short period.

on

the controls

use

as

guides. Final

be

based

the

reading of

the

and

pump control

low

water cut-off (if

the

level of water the

feed

water

has

pump

and

The

are

on

the

in

been

or

are

for

the cut

by

C.

GAS

The

gas

pilot should

performance prior

PILOT

be

checked

to initial firing. Follow

for

satisfactory

pilot flame adjustment instructions given

Chapter On

be

line.

serve whether

promptly when lingering flame

valve

5.

initial starting attempts, several efforts might

required

While checking

to

accomplish bleeding

the

pilot adjustment, ob-

the

pilot flame

the

burner switch

is

indicative of a leaking

and

a condition requiring correction before

time

is

extinguished

is

opened. A

of pilot

gas

proceeding.

the

in

pilot

750-150

CHAPTER 4-3

CHAPTER4

D.

ATOMIZING

STARTING AND OPERATING INSTRUCfiONS

AIR

The supply and pressure an

oil fired burner should be checked. Before starting, oil or slightly higher detergent oil and there.

Check the oil level To

switch on the program relay

If

this that the gas/oil selector switch the low

Observe the

(Fig. 4-1). With

be

If

there

inspect the oil pump lube oil level. Add

if

necessary to bring the level to the mid-point

of

a grade mentioned

fill in accordance with the instructions given

verify air flow and pressure, place the run/test

is

a combination fuel burner, make sure

burner switch on. The burner will cycle

fire pre-purge position and stop there.

readmg on the air pressure gauge

no

a minimum

is

of

7

no

pressure, determine the

of

the atomizin'g air on

the sight glass. Use SAE 20

in

Chapter 7

of

the air intake strainer.

to

the test position.

is

set

to

"oil." Tum

to

the

oil flow, the pressure should

psi.

cause

and

correct it before proceeding. Check for obstruc·

tions

in

the air inlet line, incorrect rotation (air

is

pump rotation

or other leaks. without

the

any

discharge line or at

clockwise), or a loose oil nozzle

If

the pressure

oil flow, check for

the

is

much higher

an

obstruction·in

oil nozzle.

FUB.OIL

UNE

0RAweA

IN

FOFIWAFIO

EI.IRNING

POSITION

OIL

FOR

The air pressure will increase when an oil flow exists. At low firing rate, the air pressure may rise

to 12 psi or more.

CAUTION!

The

wear the

to

CHAPTER4-4

air

ceed 30

pressure

air

of

lube

oil

motor,

the

equipment.

pressure

psi

at

the

air

should

high

fire. Greater

causes

pump,

excessive

usage, and can

thus

causing

not

ex-

Increases

overload

damage

OAAWER

IN

REAFIWAAD

EI.IRNING

[FIGURE

4-1 I

POSITIONS

BURNER DRAWER

GAS]

POSITION

GAS

FOR

~

OF

OIL AND

750-150

CHAPTER4

STARTING AND OPERATING

INSTRUCfiONS

NOTE: Abnormally high pressure indi-

cated

on

the nozzle air gauge is an indication that the burner

clogged. nozzle and clean as

After the air flow has been verified, tum the

burner switch

to the run position.

E.

FIRING PREPARATIONS

nozzle

In

this event, check the

off

and return the run/test switch

pr~ure

has

become

n~ary.

FORN0.201L

(SERIES 1 00-200)

Prior to initial firing, oil flow and pressure should

be

established and verified. Atomizing air pressure should also be established Section D. The schematic flow diagram (Fig.

of

1-11) indicates the flow

fuel and atomizing air.

. If the burner is a combination fuel

certain that the main gas shut-off cock and set the gas/oil selector switch to the burner drawer gun . into its most forward

position and latch

Oil

Flow-

oil return lines.

If

the oil supply tank

of

the pump and flow to the pump

it

then

suction line to allow oil to fill the line. This

generally can be accomplished union fitting, or by opening the cap

strainer using care to prevent spillage Tighten fitting

If

pump, it

to the pump must be completely filled with oil

prior to starting the pump of

usually will be necessary

the oil supply tank

is

MANDATORY that the suction line

damage

to

it

in

place (see Fig. 4-1).

Open all valves in the oil suction and

is

located above the level

or

cap as soon as oil flow appears.

is

below the level

to avoid the possibility

the pump gears through operation

as

outlined in

mOdel,

is

closed

"oil." Insert

is

by gravity,

to

vent the

by

cracking a

of

the oil

of

make

oil.

of

oil

without the lubrication afforded Non-lubricating fluids such as kerosene should not

be

used

for priming.

Prior to priming the suction line and the initial

start, check

nections, etc., have been securely tightened prevent leaks.

If

the fuel oil supply originates from a pres-

surized loop, it

loop will would not then have individual pumps furnished as

standard equipment Under these conditions, the relief valve at the terminal block should be adjusted to the point where it becomes tive.

A standard equipped boiler has a selector switch incorporated Momentarily energize the starter proper pump rotation. With the rotation verified,

operate the pump to determine that oil circulation

exists. Observe the oil burner pressure gauge for

·indication that flow shows on this

the oil lower than the pump, it is possible that the initial priming tion

of might be caused line, excessive lift, inadequate priming, suction line leaks, etc. established, avoid prolonged operation pump to minimize risk

parts

of after a second investigation

A vacuum (or a compound pressure-vacuum) gauge should be installed at the suction the pump and its reading observed and recorded

for future guidance. If a vacuum condition exists,

this reading will reveal the tightness tem. It is advisable

ing at less than 10" W.C. A vacuum

this may allow oil to vaporize causing cavitation,

of

loss

to make certain that all plugs, con-

is

assumed that the pressure

be

at a minimum

in

the oil pump motor starter.

is

established. If no pressure

gaug~

pump· and re-prime. If the supply tank

of

the suction line, followed by opera-

the pump, will not eStablish oil flow. This

after a few moments, stop

by

obstruction

If the oil flow is not read

of

the

pump.lftheoil

or

third priming attempt, a full

is

required to determine the cause.

to

prime, and an unstable firing condition.

flow

maintain the vacuum read-

by

the fuel oil.

of

the

of

75 psi. Boilers

inopera-

to check for

in

the suction

i1

of

the

damage to internal

is

not established

port

of

the

sys·

in

excess

to

is

y

of

750-150

CHAPTER

4..S

CHAPTER4

Oil

Pressure-

by

adjusting terminal block (Fig. 1-1). A pressure gauge should relief valve adjusted ing mum

When a multiple boiler installation, the this at point where and

operative, tum

possible. ·

Adjustment on regulating valve directs adjustable spring pressure. Since the atomizing air pump adjustment can adjust the oil

The pressure will

present,

creases. After the burner

air

made Final regulation

be

metering Suggested oil pressures

be

installed

of

75

psi when

rate.

oil

is

loop should

reading.

the terminal block should be adjusted to

openings plugged).

the

fuel

and

is

fuel

burner gauge registers approximately

and

pump

at

the

done later, if necessary,

cam

Oil

supply pressure is regulated

the

pressure relief valve

in

the terminal block

to

obtain a minimum read·

the

burner is flring

supplied

In

it

may

oil

controller (Fig. 1-5). This pressure

adds atomizing air pressure to

not running

oil pressure regulator so

will increase

is

running, final adjustment can be

fuel

screws

from

a pressurized loop to

the

be

properly adjusted to provide

this circumstance,

will

be

inoperative (or removed

To

render the valve in-

the

adjusting screw

also be required

is

equipped with tubing

at

this

time, only tentative

be made. Without this air supply,

be

higher when

as

the

is

firing

oil

controller.

of

the oil

flow

to

by

as

outlined

at

high fire operation:

at

and

at

relief valve

the

relief valve

in

as

to

the regulator

that

35

the

flame

firing rate in-

and

when

the

nozzle can

adjusting

in

Chapter

the

maxi-

the

far

that

the

psi.

the

5.

oil

in

as

is

STARTING AND OPERATING INSTRUCfiONS

Starting - When

and

in

above the

burner

?f

this

mfortnation.

F.

Sections A,

is

ready for firing. Refer to Section H

c~apter

FIRING

all

the

conditions covered

for

funher starting

B, C and

D are assured,

and

PREPARATION

operating

FORNO. SOIL

(SERIES

Prior to initial firing, the oil flow, pressure, temperature should be established The atomizing air pressure should also

lished flow fuel

If

certain that and the position

Oil

oil fuel established. Nonnally, a closed position. However, on cold starts,

be

oil returned flow the

Do not attempt

are

as

outlined

diagram (Fig.1-12) indicates

and

atomizing

the

boiler

set the gas/oil selector switch to "oil." Insert

burnet drawer gun

Flow-

return lines. Open

oil

opened

flow.

is

oil

open.

is

a combination

the

main

and

latch

it

Open

all

controller (Fig.

for

brief periods

The by-pass

to

a closed position

established

supply pressure gauge (Figs. 1-2

to

set pressures while these valves

400-600)

in

Section

air.

gas·

in

place (see

valves

the

1..6)

the

and

as

indicated

and

verified.

be estab-

D.

The schematic

the

fuel

model,

shut-off cock into

its most forward

in

the

by-pass valve on

until

orifice valve

to

aid

orifice valves

as

soon

by

is

Fig.

4-1).

oil suction

the

oil

is

in

establishing

as

proper

a reading

and

flow

make

closed

flow

left

it

may

must

1..S).

and

of

and

the

is

in

be

oil

on

Oil

Supply

Fuel

Oil

Burner

Pressure Guage . . . . .30-45

CHAPTER4-6

at

the

Controller . . .

75

psi

Momentarily energize check for proper pump rotation. With verified, prime the suction line strainer with and

start

the

fuel entrance switch. Observe gauge

If

ments,

in

provide

oil

for

indication

no

pressure shows on gauge after a

stop

the

oil

the

storage tank

oil

viscosity to permit

pump

and

suction

the

oil pump

that

oil

pump

and

must

line.

fuel

oil pump starter

the

by

closing its power

the

oil supply pressure

flow

is established.

re-prime.

be

at

a temperature

flow

If oil

Heavy

through

flow

rotation

few

is

750-150

to

oil

mo-

oil

to

the

not

CHAPTER4

STARTING AND OPERATING INSTRUCfiONS

establis~ed

preventing

rected

mechaniSm.

A vacuum (or gauge should and

its reading observed and recorded for future guidance. This gauge reveals the tightness system.

On

P~re

several valve (Figs. that at maximum firing rate a minimum reading of

75

gauge. The other pressure adjustments are made at the

regulators on the fuel oil controller (Fig. 1-6). Both

s~re

rehef valves are equipped with tubing that

di~ts adjustabl~

not runnmg at ments can be made. Without this air supply adjust burner ly

3S.pst.

that

Its

burner gauge.

After the burner be

made if necessary

The pressure will

present, and will increase as the firing rate increases. The pressure on the controller will, despite this fluctuation should difference

Final regulation done,

screws as outlined

a;fter

several attemps, the conditions

oil flow must be determined and cor-

~

avoid damage

~ompound

be mstalled in the oil suction line

- Oil pressure

points. The first

1-2 and 1-8). This should be set so

psi

is

obtained on the oil supply pressure

th~

pressure

and

spnng

th~

fuel oil pressure regulator so that

~II

p~ure

AdJUSt

gauge reads about 10 psi less than the

be adjusted

of

if

necessary, by adjusting the metering cam

regulat~ng

a~ds

atomizing air pressure

pr~ure.

th1s

the back pressure relief valve so

is

firing, further adjustments can

10 psi.

of

to

the pump's internal

pressure-vacuum)

of

is

regulated at

is

at the oil heater relief

and the back pres·

to

Since the air pump

time, only tentative adjust-

gauge registers approximate-

to

these valves.

be higher when a flame

re~ding

to

retain a nearly constant

oil flow to the nozzle can be

in

Chapter

on the two gauges

S.

the

is

th~

is

Oil supply at the fuel oil controller -

•

75

psi (minimum at maximum firing

rate).

Oil burner pressure gauge -

•

Oil return pressure gauge -

•

than oil supply pressure.

on

Temperature

40-SO

10 psi less

psi

CAUTION!

Before heater the oil order equipment.

After determining that the heater shell and that fuel oil circulation exists, tum the oil heater switch

hea~r

an

od temperature

The electric heater on burners equipped for No. 6 fuel oil. is sized so that it heated for low

fo~.

C?nve~:uence

utllt~tng

provide suffictent heat so that higher rates firing can or hot water thermostat governing the electric heating element governing the admission

circul~tion,

electncally except when steam or hot water available.

turning

switch,

heater

and

thermostat (Figs. 1-2 and 1-8)

ml at a rate no greater than that required

fue. operation and

etther.steam

is

kept at a lower setting than the thermostat

shell

the

to

avoid

to

he:

acco~plished

IS available. In normal operation, the

so that heating

on

the

electric

make

is

flow

Is

"on." Adjust the electric oil

of

approximately 200°F.

on cold starts. Heating coils

or

hot water are supplied

certain

filled

with

established

damage

is

capable

is

primarily supplied

once steam pressure

of

steam or hot water

is

to

is

to

maintain

of

supplying

not performed

that

fuel

the

filled

is

oil

in

to

of

not

Suggested oil pressures at high fire operation:

750-150

Set the steam thermostat (Fig. 1-8)) or the hot water thermostat (Fig.

of

temperature will

be turned

or hot water provides heat.

220·230°F. The electric heater

off

automatically

1-2) to maintain an oil

as

soon

as

steam

CHAPTER 4-7

CHAPTER4

SI' ARTING

AND

OPERATING INSTRUCfiONS

NOTE: The temperatures listed are tenta-

tive. The composition

oil

in

a given grade can vary

of

the

fuel

necessitating a higher or lower

preheating temperature. The cosity should

of

the

oil at the nozzle

be less than 300 SSU

vis

and

..

preferably less than 150 SSU. The

actual

at

the burner should

mined

temperature

by

flame appearance

of

be

the oil

deter-

and good combustion based on a stack analysis.

See Chapter 5 for

additional information.

aose

the

manual by-pass valve after temperature rise on noted. Make certain that hot oil

the

fuel oil controller thermometer is

is

moving through the controller. The orifice gate valve must

~lso

be closed.

the

onfice gate valve unul a nse is noted then

close

it.

Once the correct setting

h~

been

~tablished,

SWitch ly ture.

te~per:tu!e

20

(Ftgs. 1-2 and 1-8) at a point approximate·

30• lower than the normal operating tempera-

H the system

switch, this should be set

-30 higher than normal operating tempera-

If

te~pe~ture

drops, open

· '

of

the

heater thermostats

set

the

low

oil temperature

is

equipped with a high

to

open

oil

at

ture.

Starting - When

above the

?f

and

in

Sections A,

b~mer

thiS

is

ready for firing. Refer to Section H

c~apter

all

the conditions covered

B,

C and D are assured

for further starting

and

operating

mformation.

G.

FIRING

(SERIES

Prior to initial starting, check

to the gas butterfly valve

free

from binding.

PREPARATIONS

FOR

GAS

200-400-700)

the

linkage attached

to

see that movement

is

Verify new should be present when gas first flows system

the

presence

and

availability

installation., representatives

to

supervise purging

of

gas.

On

of

the gas utility

into

the

the new gas line

unless they already have done so. Determine that the pilot

outlin~

in

Section C

Determine that sufficient pressure exists

~tranC:C

tnstalhng a

to

the

gas train. This can be done

te·st

is

operating properly

of

this chapter.

gauge downstream

at

of

as

the

by

the

regulator. The gas pressure regulator must

the

proper pressure level. Since this regulator generally supplied proceed according

by

others, adjustment should

to

instructions supplied

be adjusted to

by

its

manufacturer. It

is

necessary for

~quirem~nts

the

operator

in

gas quantity

to

know

and

pressure. This

the

burner

tnformatton can generally be found on the

by

Dimension Diagram (DO) supplied Brooks information not

a~ver-~rooks

for

the

specific installation. Should this

be

read.ily

available, consult

Service Department, giving

Cleaver-

the

the botler senal number. Chapter 5 contains additional infonnation along with standard gas and

pressure requirements. This section should

be

completely reviewed prior

H the burner

gas/oil switch gun and latch

On

initial start-up,

is

a combination fuel model, set

to

"gas." Withdraw

it

in

its

rearward position.

it

is

to

start·up.

the

recommended that

oil

flow

the

burner

the main gas shut-off cock (Fig. 1-3) remain closed until

the

programmer

purge

lig~tt

action

m~n~

thiS

and

pilot sequences. When the

on the control panel comes on, observe

of

the

motorized

that

it

opens when energized.

IS

confirmed, tum let the.programmer finish its cycle. Check that

the

gas valve

burner "on"

slowly open

and

when

the

main gas cock. The main flame

should ignite unless there

If

the flame

seconds, tum

is

not established within about 5

the

has

cycled through pre-

gas

valve stem

the

burner switch

has

closed. Again tum

the

fuel

is

air present

burner switch

fuel

valve

the

to

deter·

As

soon

as

"off'

and

to

see

the

valve light glows

in

the

line.

"off'

and

allow

a

is

CHAPTER 4-8

750-150

CHAPTER4

the programmer to re-cycle normally for a new lighting trial. Several efforts may be necessary to

"bleed" air from the line.

SfARTING

H.

AND OPERATING INSTRUCfiONS

START-UP,

OPERATING

!WARNING

Do

not

repeat unsuccessful light-

Ing attempts

the burner and

Damage to. the personal result.

NOTE: The burner and control system are

designed

purge" period prior

spark and pilot flame. Do not at

tempt to alter the system any action that might circumvent this feature.

Once main flame extinguished promptly when the burner off. Flame may continue to bum for a second or

two after normal shutdown due to the gas remaining downstream from the fuel valve. continues to blower motor spindown, immediately tum the burner switch

Investigate and correct the cause

leakage before relighting the burner. The main gas valve

prevents tight closure. Foreign material may be present in either new

less adequate care

ing. ,

When the conditions covered above and in Sec-

A, B and C

tions

firing. Refer to Section H

for

further starting and operating information.

bum

is

without

rechecking

pilot adjustments.

boiler

Injury

to

establishing

is

established, observe that it

for a longer period or. during

off

and close the main gas cock.

tight seating provided nothing

or

renovated gas lines un-

is

taken in cleaning and purg·

are

assured, the burner

or

serious

or

death

provide a "pre-

of

fan operation

may

ignition

or

~o

take

is

If

the flame

of

the valve

is

of

this chapter for

..

is

shut

ready

AND

SHUTDOWN

-ALLFUELS

Depending upon the fuel being burned, the applicable previous sections in this chapter should

be reviewed for preliminary instructions.

When firing with oil, make certain that the burner

is

gun place (see Fig. 1-4). When frring with gas, the burner gun should be properly withdrawn and latched in place. The fuel selector switch should

be accordingly set to either "oil" or "gas."

Set the manual-automatic switch (Fig.l-7) "manual" and tum the manual flame control "close."

Tum the burner switch should remain out indicating a safe water level in

the boiler. The programmer will proceed through the normal operating sequence. for sequence details.)

in its most forward position and latched

to "on." The load demand

light should glow, and the low water level light

(See Chapter 3

NOTE: On an initial starting attempt,

be

several efforts might to accomplish lines, main or pilot. does not then occur, do not repeat unsuccessful attempts without rechecking burner and pilot justment.

On ignition failure, the flame failure light will glow and the blower will purge the boiler unburned fuel vapors before stopping. After ig· nition failure, wait a few moments before re-setting the lockout switch.

"bleeding"

required

of

If

ignition

in

to to

fuel

ad-

of

75()...150

CHAPTER 4-9

CHAPTER4

!WARNING

Do

not

re-light the

to

start the main burner, either oil

or

gas, If the

ber Is

hot

and/or If gas combustion gases are present In the furnance

Fallur result In or

to

death.

heed

serious personal Injury

pilot

or

attempt

combustion

or

oil

or

flue passages.

this

warning could

cham-

vapor

STARTING

After the boiler is thoroughly warmed, tum the manual flame control a combustion analysis should be made with struments, and the fuel flow regulated as required. Cbapter ment, manually decrease the firing rate, stopping at each and adjust

To properly perform this testing and adjusting,

is

each rate sufficiently long enough stable condition.

AND

OPERATING INSTRUCfiONS

to high fue. At this point,

Refer

5.

cam

necessary that the burner be allowed to fire at

to

adjustment

After making the high-fire adjust-

screw

as

to

required.

analyze combustion gases

procedures

to

achieve a

in-

in

it

CAUTION!

The are purge" prior spark attempt

take

cumvent ing

After main flame ignition, the burner should be

left on manual control at its low fire setting (that is, boiler is properly warmed. Close the steam header.

In

TEST VALVE when steam begins to appear.

A hot water boiler must have a continuous flow of wann·up period. The entire water content system and boiler must creasing fuel input.

burner

designed

to

and

any

damage

with manual flame control at "close") until the

the case

system water through the vessel during the

and

period

control

to

provide a "pre-

of

fan

operation

establishing

pilot

to

alter

action

this

to

of

a steam boiler, CLOSE

flame. Do

the

system

that

feature

the

·

be warmed prior to

might

thus

equipment.

system

ignition

not

or

cir-

caus-

THE

of

the

in-

Operating - Normal operation

should be with the switch in the automatic tion and under the direction control. The manual position is provided for initial adjustment firing range. When a shutdown operating in the manual position at other than low fire, the damper will not thus allowing through the boiler. The hot flame to cool air cycling subjects the pressure vessel metal and refractory to

With the switch set at

operate on a modulating basis according to the

load de.mand.

The burner will continue to operate with modu-

lated firing until operating limit pressure temperature is reached, unless:

(1) The burner is manually turned "off."

(2) A low water condition the low water level control.

of

the burner over the entire

be in a closed position,

more air . than desired

undesi~ble

conditions.

"auto," the burner will

of

the burner

of

the modulating

occurs while

to

is

detected

posi-

flow

or

by

If

the flame at low fire provides insufficient heat

to reach normal operating pressure or tempera-

ture after 30 minutes, w-adually firing rate one point increments

cam screw.

rate for a period

in

pressure or temperature.

CHAPTER 4-10

by

turning the manual flame control

to

no

higher than the third

Operate at this increased fuel input

of

time until an increase

increa.Se

is

the

noted

in

(3) The current or fuel supply rupted.

(4) Combustion drops below the minimum level.

or

atomizing air pressure

is

inter-

750-150

CHAPTER4

sr

ARTING

AND

OPERATING

INSTRUCfiONS

NOTE:

When the burner

operating

the

switching the burner off, the load

no longer glows.

Shutdown through conditions causing safety interlock controls

failure light (and alarm

load demand light will remain this type investigated, and corrected before operation can

be

resumed. Refer to Chapter 6.

Shutdown.-

setting is reached to open the circuit

burner switch quence occurs.

The fuel valve is extinguished. The timer begins operation as the

blower motor continues running to force air through the furnace in the post-purge period.

At the end

the blower motor

motor The timer has returned to its original starting position and stops. The unit

There can be other reasons for shutdown such as, motor overload, flame outages, tripped cir cuit

breakers, through other interlock devices in the circuitry.

is

shut down normally, by either

limit

to

open will actuate the flame

blown

control

fuses,

or

by manually

demand light

if so equipped) and the

liL

The cause

of

shutdown will have

When the operating limit control

is turned "of:f," the following

de--energized and the flame

of

the programmed post-purge period,

is de--energized. The air pump

of

an oil-fired burner is also de--energized.

to

be located,

or

is

ready to re-start.

or

if

..

or

of

the se-

CAUTION!

It Is

advisable

shut-off

of

precautions

foreign

material In renovated fuel under a valve tight true

closure.

In

new Promptly tions

to

causing

avoid

damage

to

check

for

tight

fuel valves. Despite

and

lines seat

This

strainers,

either

may

new

lodge

preventing

Is

especially

or

Installations.

correct

leakage In

to

any

the

condi-

order

equip-

ment.

I. CONTROL OPERATIONAL

TEST

Proper operation

be

verified and tested when the boiler is initially placed into replaced. Periodic checks should after in accordance with a planned maintenance program.

The operating limit control may

allowing steam pressure increase until the burner shuts down. Depending upon the load, it may increase the firing rate

to

the burner shut the header valve can be closed the pressure increases. Observe the steam gauge

to

check the cutoff pressure as the operating limit control shuts the burner down. header valve to release steam pressure and the cut-in setting as the burner restarts. Check the modulating control for desired operating

sure range. See Chapter 5 for instructions on the

adjustment

service

of

controls.

AND

of

off

CHECKS

the various controls should

or

whenever a control

be

made there-

be

checked

or

water temperature

be

necessary

to

raise the steam pressure

point.

If

to

manually

the load

or

Slowly open the

is

throttled until

is

by

to

heavy,

check

pres-

75Q..150

CHAPTER

4-11

CHAPTER4

SfARTING

AND OPERATING INSTRUCfiONS

Water temperature, on a hot water boiler that may

be

operating at less than full load, may

by

manually increasing the firing rate until the

burner shuts. down through the action

be

raised

of

the

operating limit control. Observe the thermometer

to verify the desired settings at the point

out and again when the burner

restarts. Return

of

cut-

the manual automatic switch to "automatic" and check the modulating control for the desired temperature range. See Chapter on the adjustment

of

the controls.

Check the proper operation and setting water cut-off (and pump operating control,

used).

S for instructions

of

the low

if

Proper operation

be

should

checked at the time

least once a week thereafter. Refer

of

the flame failure device

of

startup and at

to

Chapter 7

for information on flame safety checks. Check

of

the program relay's annunciation failure. Observe the promptness

any system

of

ignition

of

the

pilot flame and the main flame.

Cleek

for tight shut..off

of

all fuel valves. Despite

precautions and strainers, foreign material may lodge under a valve seat preventing tight closure. Promptly correct any conditions causing leakage.

Refer tenance instructions given in Chapters

to the adjustment procedures and main-

S and

7.

CHAPTER 4-12

7S0-150

CHAPTERS

ADJUSTMENT PROCEDURES

CHAPTERS

A General

B.

C.

D. Modulating Motor

E.

F. Modulating G. Operating Limit Pressure Control

H.

I. Modulating Temperature

J.

K.

L.

M.

N. Atomizing

0.

P. Gas Pressure and Flow Information

Q. Gas Fuel Combustion Adjustment

R.

S.

T. Fuel Oil Pressure and Temperature

U.

V. Burner Drawer Adjustments

W. X.

Y.

Z.

AA. Electric Oil Heater Thermostat

BB. CC. Hot Water

DD.

Linkage-Modulating Motor & Air Modulating Motor

Switches

Operating Controls General

Pressure Controls High Limit Pressure Control Operating Limit Temperature Control - (Hot Water)

Hi.gh

Limit Temperature

Low Water Cut-Off Devices

Combustion

Gas Pilot Flame Adjustment

Low Gas Pressure Switch

High

Gas Pressure Switch

Fuel Oil Combustion Adjustment

Oil Drawer Switch Low Oil Temperature Switch

High Oil Temperature Switch

Low Oil Pressure Switch

Steam Oil Heater Thermostat

Steam Heater Pressure Regulator

Air

Proving Switch

Air

Proving Switch

Oil Heater Thermostat

-Low

-(Steam)

Control-

Contt:pl-

ADJUSTMENT

Damper

Fire and High Fire

(Hot Water)

-General

PROCEDURES

NOTE:

75()..150

If. your boiler is equipped with a

CB-HA

ment control system, refer to CBHA and Servicing Manual No. 750-

WKTM

WK.

Installation, Operating

boiler

manage·

133

for

specific

regarding procedures described

in

this section.

information

CHAPTER

5-1

CHAPTERS

A.

GENERAL

ADJUSTMENT

PROCEDURES

A combustion efficiency analysis made during

the

initial start-up

additional adjustments are required

will

help to determine what

in

a par-

ticular installation.

While each boiler is tested for correct operation before shipment from the factory, variable conditions such and

operating load conditions may require fur- ther adjustment after installation mum

operating efficiency

as

burning characteristics

and

economy.

of

the

to

assure maxi-

fuel

GAS

Prior to placing the boiler into service, a complete inspection should be made

of

all controls,

necting piping, wiring, and all fastenings such

nuts, bolts and setscrews to

be

sure that damage or misadjustments occurred during shipment

and

installation.

MODULATING

CAM

·ROTARY

I:WotPER

JACKS

AAM

AIR

HAFT

CAM

ADJUSTING

SCREW

OIL METERING VAL

ROTARY AIR

CAMPER

SHAFT

con~

as

no

OIL MODULATING

~M

FUEL

OIL

CONTROLLER

MODULATING

MOTOR

MODULATING

MOTOR

ARM

SPRINQ LOADED

BUTTERFLY

[FIGURE 5·1/ COMPLETE UNKAGE

CHAPTER 5-2 750-150

BUTTERFLY

GAS

VAL.VE

ROO

.o..--~-..,...;..~-

GAS

VAlVE

AAM

ASSEMBLY-

OVERTRAVEl

UNKAGE

8U1TERFL

GAS

Y

VAlVE

COMBINATION GAS AND OIL]

NOTE:

SETllNGS

INDICATE

SETllNG

IN

LON

OF

UNKAGE.

DIAGRAM

ARE

CHAPTERS

The adjustment procedures in this chapter apply

on

to standard components furnished hot water boilers fired with gas and/or the various

of

grades

oil.

steam

or

ADJUSTMrnNTPROCEDURES

B. UNKAGE-MODULATING IVIOTOR

AND

AIR DAMPER

High Turndown

In order to reduce burner cycling and to improve

operating efficiency, burners have been designed for enhanced fuel turndown capabilities. Turndown Burner

to 800 Hp boilers equipped to fire light oil (Series

00),

or

1

On

inlets, the diffuser, and the air linkage are designed for higher turndown perfor-

mance.

The

from the natural gas housing, which is spudded, and the burner diffuser, which. has a circular pattern

gas, (Series 700),

the High Turndown Burner, air and fuel

High Turndown Burner

of

5/8" holes around the front fmned face.

Burner

(IITB) is installed

or

both (Series 200).

damper

can

be identified

on

A High

250

Hp

control

CAUTION!

Observe linkage

justment

lowed or

SOO)

or

700)

to

the series· data plate head

Contact your local Cleaver-Brooks authorized Representative for recommendations covering

special controls that are not included in this

ter.

that

and

proper

fuel

procedures

for

standard

or

HTB (Series 1 00, 200

burners

equipment.

is

identified

affixed

of

the

boiler.

metering

(Series 400

to

avoid

The

on

to

air

damper

are

damage

burner

the

ad-

fol-

boiler

front

chap-

The

linkage consists rods, and swivel ball joints that transmit motion from the modulating cam(s), to the rotary air damper, and to the gas butterfly valve,

When properly adjusted, a coordinated movement

of

the damper and metering cams within the

limits

of

the modulating motor

to provide proper fu.el-air ratios through the firing

range.

In linkage adjustments, there are several impor-

tant factors that must serve

(a)

The

modulating motor must

complete its

of

if

used.

full

travel range.

various arms, connecting

motor

to the metering

trav~l

is attained

as

guides.

be

able to

CAUTION!

Restriction cause

definite

motor.

b) Initial adjustment should the motor in full closed position, that with the shaft motor in its most counterclockwise position.

(c)

The

closer the connector is to the drive shaft the less the closer the connector is to the driven shaft

the farther that arm will travel.

of

full

travel

damage

be

on

the power end

ann

will travel, while the

will

to

this

made with

is

of

the

750-150

(d)

Over-travel

should not

to fullest stretch.

be

required to extend its spring

linkage, where used,

CHAPTER

S--3

CHAPTERS

FIOTARV

JAC<SHAFT-:r-

ROTARY

AIR

DAMPER

II

OMtF"et

AIR

.AIW

ADJUSTMENT PROCEDURES

The

amount of

rate the ends

jackshaft arm and the air damper arm. When the

air damper shaft arm should the rotary proximately

This is to ensure that the angular movement

the damper starts slowly, increasing in rate as the

fire position

high

Prior

to initially firing a boiler, it

check for damper motor must be allowed to complete its full stroke low

to high fire position.

of

angular movement controlling the

air flow is determined by the location

of

the rotary air damper rod in both the

is

in

the low fire position, the

be

at 45• (47-1/2° for HTB) and

air

damper

6Q•

below horizontal (Figure 5-1).

is

free

movement .of the linkage. The

and

the damper must move freely from

arm should

approached.

is

advisable to

be

jack-

at ap-

of

[FIGURE 5·2/ ROTARY

CAMPER 3/4

With the modulating motor

VIEVV]

in

tion, the arm on its shaft should

45° below the horizontal.

jack shaft should

be

The

parallel to this. Secure both

AIR

the low fire posi-

be

at an angle

of

driven arm on the

arms and fit the connecting linkage rod in place between them. Refer

to

Figure 5-1.

Position the oil and/or gas modulating cams on

the jackshaft so that the cam follower assembly

is

between the first and second cam adjusting screws (under the first adjusting screw for a High Turndown Burner).

is

at low fire rate. Tighten the set screws to secure

the cams

on

the jacks haft.

Refer to Figure 5-2.

In

this position, fuel delivery

The

stop screw in the rotary air damper limits damper travel at both closed (low fire) and fully opened (high fire) positions.

This

screw is provided

even

with

the damper rotor is in fully opened by

rotating the damper open and closed by means

of

the damper arm. Normally, the rate

burner

so

that it is possible to tell,

in place,

whether

or

closed position

of

flow

the

of

air through the damper with the rotor in low fire

is

position

about one-third

standard burner,

or

one~sixth

of

maximum for a

for a HTB.

Adjustment ly

valve

C.

The

modulating motor

90o

has a also provides a plications. someone other than a Cleaver-Brooks Service

of

linkage connected to a gas butterf-

is

described in Section Q

MODULATING

used

of

this chapter.

MOTOR

in this application

shaft rotation.·The motor manufacturer

160° stroke model for other

If

a replacement

is

obtained from

ap·

or

Parts representative, it may have an incorrect

To

stroke.

prevent damage, determine the 90°

stroke prior to installing a replacement.

This may

be

determined by powering the motor and connecting terminals R-B to actually determine the stroke as the motor drives

to

an open

position.

If

adjustment to the stroke

is

required, refer

to

the

manufacturer's Technical Bulletin. The motor

if

may be damaged

it is unable to complete its full

stroke.

CHAPTER 5-4

750-150

CHAPTERS

D.

MODULATING

MOTOR

ADJUSTMENT

Burner controls properly set to match load demands will provide operational advantages and achieve the following desirable objectives:

PROCEDURES

SWITCHES

AND

The modulating motor contains either one

internal switches depending upon application.

These

switches are actuated by adjustable cams tached to the motor shaft.

Factory replacement motors have the cams preset. The low fire start switch red and yellow leads at approximately motor closing. The high tire purge air proving

switch (M954B motor)

blue tracer leads at approximately opening. Normally these settings are left as job

If

low the instructions in the manufacturer's Tech-

nical Manual.

single-pole,

conditions may require readjustment.

the cams require adjustment

-

LOW

HIGH

FIRE

double-throw,

is

set to make red and

FIRE

or

micro-

1s

set to make the

s·

on the

60. on motor

or

resetting, fol-

is

two

at·

but

(a)

The

burner will operate in low fire

position prior

(b)

The

a brief period on each start during normal

operation.

(c) Frequent bumeron-offcycling will be

avoided.

Figure 5

setting

modulating control. drawn to any scale. The burner will be whenever the pressure point B and

ture

points tial

..

3 depicts a typical relationship

of

the operating limit control

is

above point A The distance between

A and B represents the "on-off'' differen-

of

the ·operating limit control.

to shut down.

burner will operate at low fire for

.an~

Please note that

or

"off'

whenever pressure

temperature

thlS

is

or

tempera-

of

the the

IS not

"on"

below

E.

BURNER

OPERATING

CONTROLS -GENERAL

In general, when adjusting controls check

that they are level, especially those containing

mercury switches.

trols, make sure that the bulb

tomed in its well and that connecting tubing not kinked.

Controls are carefully calibrated during their manufacture recalibration. The dial settings generally are quite accurate although it a slight variation between a scale actual pressure gauge and to readjust the control settmg to agree wtth

these readings. This

pressure· gauges and thermometers being accurate.

On temperature sensing con-

is

properly bot-

and

normally

or

is

predicated, however, on

do

not

is

not

unus~al

setting and an

the~ometer

to

see

is

require

to have

readi~g

In normal operation, the burner will shut down

whenever the pressure setting A. The switch in the operating limit

trol will open. As the pressure drops back will restart. The modulating control will ing for the modulating motor to be in position at this point. fire input, the modulating control will respond increase the firing rate proportionately as pres-

sure

or modulating motor will stop at any intermediate point between C and D whenever the fuel input balances the load requirement. quirement changes, the firing rate will change accordingly. This firing.

Point D represents the maximum firing rate burner. In the event pressure drops while the burner input, this generating rate

to B, the switch closes and the burner

temperature falls toward the point D. The

is

indicative that the load exceeds the

of

or

temperature reaches

or

temperature

If

the load exceeds this low

As the load re-

is

referred to as modulated

or

temperature

is

firing at

the boiler.

its

maximum

con-

be

call-

lo~

fire

of

the

to

75()...150

CHAPTER 5-S

CHAPTERS

ADJUSTMENT PROCEDURES

*FIXED

ADJ.

[FIGURE

Although a gap

points may well coincide

conditions. When set

be

in a low fire position upon a restart and will fire at that rate for a short period falling crease in the fuing rate. From this illustration can be seen that this desirable objective will not

be

event, upon a restart, the burner would drive higher firing position immediately after the main flame was proven, and the brief period heat input would not occur. Actual settings will, of which will affect the amount mitted gap,

pressure

attained

course, depend greatly upon load conditions,

to·

if

any, between B and C.

5-3/

OPERATING CONTROL AND MODULATING CONTROL ACTIONS]

is

shown between B and C, these

if

required by load

as shown, the burner will

of

or

temperature requires an in-

if

setting C overlaps point

of

differential per-

the operating limit control and to the

DIFFERENTlAL-STEAM CONTROL

CIFFEREM1AL-HOTWATER CONTROL

time before

it

B.

In that

to a

of

low

CAUTION!

Setting such drives Immediately create sure sure vessel failure.

When fuing a cold boiler, the burner must under manual flame control until normal operat ing pressure

size

of

gradually build up pressure

burner it the program control releases the circuit that holds

is

immediately will move to high fire as soon as

operating

a

way

that

to a higher

upon

cycle

vessel

or

the flame may

not under manual control on a cold start,

stress

and

temperature

be

controls

the

firing

restart

to

eventual

is

manually increased to

or

temperature.

burner

position

can

the

prespres-

be

approached. The

If

in

kept

the

..

CHAPTER 5-6

750-150

CHAPTERS

ADJUSTMENTPR9CEDURES

the burner modulating control will be calling for higher input and the burner will move rapidly travel. This rapid heat input can subject the

sure vessel metal and refractory to undesirable

conditions.

Any control setting must not cause the boiler operate at or

Settings that do not exceed

setting are recommended, with lower settings

greatly desirable if system conditions permit.

Avoid having the operating pressure valve set pressure, because the closer the

ing pressure the possibility leakage, however slight, will cause erosion

necessitate early valve replacement. The control settings on a hot water boiler must

temperature and pressure limits

shown

Ideally,

set under actual load conditions. Often, especial-

ly

on new construction, the boiler

started and set

req~irements.

controls should be reset utilization

To

accomplish this, and assuming that air/fuel

combustion ratios have been set, make

proximate adjustments boiler pressure or temperature

requirements. To properly set the modulating control, carefully

adjust it under load conditions, until the load maintained with the burner

The firing rate or slightly less, depending upon the relationship of the boiler size

When the modulating control

and

if the burner is at full high

setting steam boiler will have a reading that indicates

low point

differential range

tion. The scale setting

in

low fire during ignition. The

to

that position

as

the damper motor can complete its

in

excess

is

to

in

Fig.

2.2

the

burner operating controls should

to operate under less than full load

As

of

the modulating firing system.

at

of

the modulating pressure control

of

the

of

the safety valve setting.

90%

of

too

the valve pressure, the greater

of

valve leakage. Continued

be

within the

of

the boiler

is

soon

as

possible thereafter the

to

provide for maximum

to

the controls

fi.ring

that point may

to

the

load.

is

modulating range. This fixed

is

described later

of

to

meet the load

at a steady rate.

be

full high fire

set

in

this manner

frre,

in

the modulating

as

pres·

to

the valve

near the

operat·

and

as

be

initially

ap-

bring the

is

the scale

on

the

this sec-

a

temperature control on a hot water boiler will have a modulating range. This also

The operating limit control now should be justed and

tions later in this section for the mechanics adjusting. In

a very close control temperature this adjustable differential should set

provide less frequent burner cycling.

The high limit control provides a safety factor shut control should fail control should be sufficiently above

ing limit control The setting, however, must be within the limits of exceed

trol

In the setting

. must

restart. Upon each

of

the

plus approximately 1/2 minute required for damper motor travel from low

allow pressure or temperature desirable limits.

The mechanics

Tum the adjusting screw until the indicator

opposite the low point

range. Modulated firing will range between this

point and a higher point equal

range

trols range

is

reading that indicates the midpoint

is

described later.

its

differential established. See direc-

an

installation that does not require

of

steam pressure or water

as

widely

the

the safety valve settings and preferably not

requires manual resetting after tripping.

be

some length, plus the fixed time required for

proving

F.

MODULATING

of

the

is

12

lbs.

as

conditions permit, since this will

burner off

90 percent

given

in

the event the operating limit

to

do so. The setting

to

avoid nuisance shutdowns.

of

the valve setting. This con-

of

these controls, consideration

to

the time required for a burner

s~rt,

there

of

the pilot

of

setting the controls are:

and

CONTROL

of

the desired modulating

the particular control.

range

is

5 lbs.;

1/2lb.;

in

10-300 psi controls

is

a pre purge period

main flame. This,

to

high fire,

to

PRESSURE

(Steam)

to

the modulating

In

0-15

5·150

psi

of

the

operat-

drop below

psi

controls

the

range

the

ad-

this

may

con-

the

of

be

to

is

750-150

CHAPTER 5-7

CHAPTERS

ADJUSTMENT PROCEDURES

CAUTION!

To

prevent other just

tf:"lan

the

control

BEFORE pressure

burner. Failure tion the

could

equipment.

G.

OPERATING

PRESSURE

burner

low

fire

modulating

to

modulate

the

operating

control

to

result

shutdown

setting,

pressure

to

low

limit

shuts

heed

off

this

cau-

In damage

·

LIMIT

CONTROL

at

adfire the

to

(Steam)

Set "cut-out" (burner-off) pressure scale using the large adjusting screw. Set dif-

on

ferential adjusting desired difference between cut-out and cut-in

pressures. the cut-out pressure cut-out pressure should not exceed safety valve setting.

the short scale turning the small

screw

until the indicator points to the

The

"cut-in" (burner-on) pressure is

MINUS

the differential. The

on

the main

90%

of

the

L

MODULATING

TEMPERATURE

(Hot

Tum

the knob

pointer indicates the desired setpoint tempera-

ture.

This

is the center point

ia.nge. may within which modulation is desired. With the

cover off,

pointer indicates the desired range.

The

control has a 3

be adjusted

tum

Water)

on

front

to

vary the temperature range ·

the adjustment wheel until the

CONTROL

of

the case until the

of

a proportional

..

3o• differential and

CAUTION!

To

prevent

other just ture

than

the

control

fire BEFORE temperature the burner. caution to

the

equipment.

burner

low

fire

modulating

to

modulate

the

operating

control

Failure

could

result

shutdown

setting,

tempera-

to

limit

shuts

to

heed

this

In damage

at

ad-

low

off

H.

HIGH

CONTROL

Set "cut-out" (burner off) pressure

using the adjusting screw. a circuit when pressure reaches this point. setting should

limit pressure control to avoid shutdowns, and

preferably not exceed setting. This control requires manual resetting

after tripping

allow pressure to return

the reset button.

. CHAPTER

LIMIT

PRESSURE

(Steam)

The

control will break

be

sufficiently above the operating

90%

of

the safety valve

on

a pressure increase.

to normal and then press

s..a

on

the scale

To

The

reset,

J.

OPERATING

TEMPERATURE

(Hot

Set the "cut-out" (burner off) temperature on the scale by inserting a screwdriver through the cover opening

ing screw.

The

"cut-in" (burner on) temperature out temperature MINUS the differential. The differential is adjusted from

to

Water)

engage the slotted head adjust-

LIMIT

CONTROL

is

the cut-

So

to 30° F.

750-150

CHAPTERS

ADJUSTMrnNTPROCEDURES

K.

HIGH

TEMPERATURE

(Hot

Set

the

"cut-out" (burner off) temperature on scale using break the circuit

temperature above

be

sufficiently above

ture

to

hot

water boiler,

F.

The control requires manual resetting after

tripping on a temperature increase. allow water temperature out setting less differential, manual reset button.

the

adjusting screw.

and

the

avoid unnecessary shutdowns.

the

setting

LIMIT

CONTROL

Water)

This

control will

lock out on a rise

setting. The setting should

the

operating limit tempera-

is

not

to drop below

and

to

exceed

then

in

On

To

the

press

L. LOWWATERCUTOFF.

DEVICES

(Steam

and Hot

Water)

water

a 30

240°

reset,

the

lb.

cut-

the

The run/test switch on be

set to TEST. Tum

blower will start (provided that all limit circuits

are

completed) through the prepurge portion stopping at

NOTE:

To

have the modulating damper motor drive

high fire (damper open), remove

the

motor

Slowly tum down

it

until programmerwilllockout reset before it can so

breaks the circuit. At this point

to

the

and

the

low fire prepurge position.

On

an

ing air proving switch (AAPS)

must also

On a combination fuel fired burner,

could

the

atomizing air proving switch

from

and

remove

adjusting screw to remake

the

program relay should

the

burner switch on. The

the

programmer will proceed

of

the

oil fired boiler,

be

closed.

the

fuel

be

set

at

"gas" to eliminate

the

circuitry.

the

wire

the

·air

switch adjusting screw

and

be

restarted.

the

selector switch

the

from

it

must

Add

sequence,

atomiz-

to

cover

from

terminal

be

manually

a half tum or

its

circuit.

W.

the

No

adjustment

· preset water level 2-3, inspect these devices immediately and replace

by

as

M.

Air pressure against switch which, when closed, completes a circuit

to prove the presence

the

pressure

mum

value when

switch should

It should

pressure, but

shutdowns.

is

required since these controls

the

original manufacturer. However, if

is

not maintained

required.

COMBUSTION

PROVING

the

of

the

combustion air

the

be

adjusted under

be

set slightly below

not

so

close

as

shown

AIR

SWITCH

diaphragm actuates

combustion

damper

as

to

air.

is

at

is

full

open,

that

condition.

the

minimum

cause nuisance

in

Figure

its

Since

mini-

are

the

Recycle the program relay operation minal switch to the

N.

is

obtained. Replace

Wand

reinstall

RUN

position.

ATOMIZING

to

be

the

cover. Return

AIR

sure that normal the

wire on ter-

the

test

PROVING

SWITCH

Air pressure against switch which, when closed, completes a circuit

to prove the presence

pressure value when there

adjustment

the should sure,

downs.

of

the

of

unit

is

running but not firing. The control

be

set slightly below

but

not

so

the

diaphragm actuates

of

atomizing air. Since

atomizing air

is

no

fuel

the

switch should

close

as

to

the the

is

at

its

minimum

present

cause nuisance shut-

the

minimum

at

the

be

done while

nozzle,

pres~

750--150

CHAPTER

5~9

CHAPTERS

The

control adjustment may be made during the prepurge period programmer during the prepurge period through

of

the use

instruction bulletin for details..

The

ing switch then can be adjusted until it breaks the

circuiL out and it must be manually reset before it can

restarted.

or

so

Since the adjustment made either during the damper closed open position make the adjustment with the relay stopped in the damper open position in a similar manner to the

adjustment

described in the previous section.

After making the adjustment, recycle the control

to be sure that normal operation is obtained.

TEST

the

adjustment screw

At

this point, the programmer will lock-

Tum

to remake the circuiL

switch must be set

0.

GAS

of

operation by stopping the

TEST

of

the combustion air proving switch

switch. Refer to the control

·

of

the atomizing air prov-

the adjusting screw up a half

of

the air switch may be

or

damper

of

prepurge,

PILOT

~t

is also possible to

to

the RUN. position.

FLAME

be

tum

The

ADJUSTMENT

ADJUSTMENT PROCEDURES

The

meter is connected

connecting plug harness (Cleaver-Brooks 884-

72). Connect the plus (red meter lead) to the red tab

of

the harness and the minus (black meter

lead)

to

the black tab before inserting the plug in "

the meter jack.

The

program relay used may

provides message information that includes a constant flame signal

DC

a separate

To

Measure and Adjust Pilot:

(1) When making a pilot adjustment, tum

the

"manual" and the manual flame control

to

"close." Open both the pilot shutoff

cock and the pilot adjusting cock. The

main gas cock should remain closed.

The

provided, reduces the gas pressure to suit the pilot requirement

W.C. flame with the adjusting cock is less sitive with a lower pilot pressure.

voltmeter is not required.

manual-automatic

regulator

The

final adjustment

of

in

to

the

jack

using a meter

be

of

the type that

DC

voltage. In this case

switch

the

pilot

of

between 5-10"

line,

of

the pilot

to

if

sen-

The size

adjusting the gas flow through the pilot gas regulator and the adjusting cock.

be

sufficient to ignite the main flame and to be

seen by the flame detector but an extremely large

flame cause sooting flame can cause ignition problems.

Although it is possible to visibly adjust the size of microamp reading

The relay has a meter jack for this purpose. This reading may be measured with a good quality micro-ammeter 0 to 25 micro-amp

CHAPTER 5-10

of

the gas pilot flame

is not required

of

the pilot flame, it is preferable

amplifier

..

An

overly rich flame can

the flame detector. Too small a

of

the flame signal.

of

the standardly

or

a suitable multi-meter with a

DC

rating.

is

The

used

regulated by

flame must

to

obtain a

program

(2) Connect the micro-ammeter as

lined earlier.

Tum

(3)

burner go through the normal prepurge

cycle. When the ignition trial period is

signaled, set the test switch

position

(4)

within ten seconds, tum

switch. Repeat the lighting attempt.

the burner switch on.

to

stop the sequence.

If

the pilot flame

to

is

not established

off

out-

Let

the

TEST

the burner

750-150

CHAPTERS

ADJUSTMENT PROCEDURES

NOTE:

(5) When the pilot flame and with the pilot adjusting cock wide open, remove the flame detector from the burner plate. The pilot flame then can be observed through this opening.

On

an initial starting attempt, por-

tions

of

the fuel lines may be

empty and require

time. It is better to accomplish this

with repeated short lighting

trial periods purge prolonged fuel introduction. the

several attempts, check all com-

ponents

periods

pilot

of

with

does

the pilot system.

"bleeding"

intervening

than

not

light

is

established,

to

risk

If

after

!WARNING

Wear

suitable glasses and keep eyes sufficiently away from the sight

tube

personal Injury or death. Never remove the

the main burner is firing.

(6) To make the fmal adjustment, slowly close the gas pilot adjusting cock until the flame no longer can be seen through the sight tube. Then slowly open the cock until a flame providing full sight tube coverage

This adjustment must within the time limit or approximately detector down, manually reset it. Replace the detector and repeat from step 5.

a

protective

opening

flame detector while

is

observed.

is

removed.

shield

to

avoid serious

be accomplished

of

the safety switch

30 seconds after the

If

the control shuts

or

(7) When a suitable flame as indicated

number 6 tor. Observe the reading on the microammeter. The reading should be between 2-1/4 and sulfide detector and a standard amplifier. See manufacturer's bulletin for values other combinations.

The flame signal indicated on the annunciator type relay should not 10 volts D.C. and many be or greater.

The reading must be steady. fluctuates, recheck the adjustment. Make sure that the flame detector seated and that the lens

(8) Return the position.

(9)

If been established, proceed accordance with instructions elsewhere in

the manual.

(10) The reading should also be checked. Observe the flame signal for pilot alone, pilot and main burner flame together and the main burner flame at high, low, and intermediate firing rate positions. Readings should

is

obtained, replace the detec-

S microam.ps when using a lead

the

flame

signal

table

be less than

as

high as

If the reading

is

properly

is

clean.

·test switch to the RUN

the main flame previously has not

to

do so

of

the main flame signal

be steady and

in

the range indi-

in

the

of

20

in

750-150

CHAPTER

5-11

CHAPTERS

cated

in

number 7.

tions, refer

to

the trouble shooting section

in the technical bulletin.

P.

GAS

PRESSURE

If

there are any devia-

AND

ADJUSTMENT

PROCEDURES

TABLEt

Minimum Net Regulated Gas Pressure

Rated Boiler

Output

For

FLOW

Because and the supply system, regulate the pressure

of

variables in both the properties

INFORMATJON

of

it

will

be

necessary to

of

the gas to a level that

gas

produces a steady, dependable flame that yields. the highest combustion efficiency at rated

perfor· mance yet prevents overtiring. Once this optimum pressure has been established, recorded and periodic checks made

is

the regulator Occasional modification

holding the pressure at this level.

in

fuel

it

should be

to

verify that

comp(:>sition

or

pressure by the supplier may, at times, require

to

readjustment to return the burner ficiency. Since the gas pressure regulator itself

peak ef-

is usually furnished by others, detailed adjustment instructions and adjusting procedures

recom-

mended by the manufacturer should be followed.

Pressure

The gas supplied must provide not only the quantity

of

gas demanded by the unit, but also must

be

at a pressure high enough to overcome the

pressure-loss due to the frictional resistance

posed

by the burner system and the control val-

ves.

The pressure required at the entrance to the

burner train (Figure 1-3) for rated boiler output is

termed "net regulated pressure." The gas pressure regulator must be adjusted to achieve this pressure to assure full input.

The pressure requirement varies with boiler size,

type

of

altitude, and for

pressure requirements.

gas train. Refer to Table 1

im-

cr

Horse

The BTU/CU.FT. natural gas at elevations up

er

100

125

150

200

250

300

350 30.5"

400 23.5"

pressures

9.0"

lS.O"W.C.

16..5"

21..5"

listed

w.c.

W.C. 22.0"W.C.

w.c. w.c. w.c.

are

26.5"

37.5"

33.5"

based

W.C.

w.c. w.c.

on

1000

to

700 feet above sea level. For installation at higher altitudes, multiply the selected pressure by the proper factor from Table

2.

TABLE%

(Altitude Correction Factor)

Correction

Factor

1.07

1.11

1.16

1.21

1.25

1.30

1.35

1.40

Feet

Altituc.le

Above

Sea

Leve)

1000 1.04 2000 2500 1.09

3000

4000

5000 6000

7000

8)()()

~

Gas Flow

The volume cubic feet and The

gas flow rate required for maximum boiler

output (BTU/CU.FT.) ing utility can provide this information.

of

gas flow

is

determined by a meter reading.

depends

of

is

on

measured

the

in

heating

terms

value

of

the gas supplied. The supply-

CHAPTER 5-12

750-150

CHAPTERS

ADJUS~PROCEDURES

To obtain the required number

hour

of

gas,

divide

the

of

cubic feet per

heating

value (BTU/CU.Ff.) into the required burner input (BT.U/HR. ).

See Tables 3 and 4 for burner gas input requirements at high

Turndown Burners

or

low fire for standard

..

or

High

TABLE3

(Standard

Required

Boiler

Horsepower

100 125 150

200

250

3(X)

350 400 16,737,500

Higb Fire Minimum

Input BTU/Hr Input

4,184,()(X) 5,230,000 6;2.77

8,369,000 10,461,(X)() 12,553,(X)() 14,645,<XX>

Input-

,()(X)

Burner

Btu/H.r)

Low

Fire

BTU!HR

1,046,()(X) 1,308,000 1,S69,()(X)

2,~()(X)

2,615,()(X) 3,138,000 3,661,()(X) 4,184,()(X)

TABLE4

(High

Boiler HighFire Minimum LowFire

Horsepower

250 300 350 400

Turndown

Input-

Input

10,461,000 1,046,100 12,553,000 1,255,300 14,645,000 1,464,500 16,737,500

Burner

BTU/Hr)

BTUIHR

Required

.

Input

BTUIHR

1,673,750

Pressure Correction

The flow rate outlined in the previous section figured on a "base" pressure, which atmospheric

or

14.7 psi.

Meters generally measure gas "line" each cubic foot

or

supply pressure. The pressure at which

is

measured and the correction

factor for this pressure must be known

to convert the quantity indicated by the meter into

the quantity that would

be measured at "base"

is

in

cubic feet at

in

pressure.

is

usually

order

To express the volume obtained from an actual meter reading into cubic feet at base pressure

is

necessary to multiply the meter index reading

by

the proper pressure factor obtained from Table

it

s.

TABLES

Pressure Correction Factors

Regulator

Inlet

Pressure

pstg

1 2psig 3 psig 1.18 4psig 1.25

5 psig 1.32

6psig 1.39 7psig 1.45 8psig

Pressure

Factor Pressure Factor

1.05

1.11

1.53

Conversely;

To determine what the meter index reading

should. be in order to provide the volume required for input, divide the desired flow rate by the

proper

pressure answer indicates the number pressure that must pass through the meter deliver the equivalent number

base pressure.

As

an

example:

Assume that a 150 horsepower boiler at

~000

feet above sea level;

standard gas train; and that

gas

is

available with an incoming gas pressure 3 psig. The pressure and flow requirements can be determined as follows:

Pressure

Correction for the 2,000 feet altitude must made since altitude has a bearing on the net

regulated gas pressure. The standard gas train requires

(Table 1). Table 2 indicates a correction factor

1.13 for 2,000 feet Multiplying these results a calculated net regulated gas requirement approximately 10.

sure to which the regulator should be adjusted.

9.5"

W.C. gas pressure at sea level

7"

Regulatcr

lnJet

~

pstg

10

psig

11

psig 1.72

12

psig

13

psig

14

psig 1.93

15

psig

correction

of

1,000 BTU natural

W.C. This

Pressure

1 •

.:>9

1.66

1.81

1.86

2.00

of

factor. This

cubic feet at line

of

cubic feet at

is

installed

is

equipped with a

is

the initial pres-

gas

to

of

be

of

in

of

750-150

CHAPTER 5-13

CHAPTERS

/

,

v

/

/"'

ADJUSTMENT

12

-"'

1'1

'\

L

-~

v

/

,

L

/

v

/

w

3

u..

;::;

N

0

~

w

0

a:

w

a.

10

9

8

7

6

5

1\

'

\

i\

'

\

1\

'

\

PROCEDURES

I

!...

'"

I

""'

I

I I

I

\:

~

9 8 7 6

-

60 50 40 30 20 10

[FIGURE 5-4/FLUE GAS ANALYSIS CHART FOR NATURAL GAS]

Slight additional adjustment can be made later,

necessary, burner rating.

to

obtain the gas input needed for

PERCENT

02

EXCESS

54

AIR

IN

FLUE

3 2

GAS

if

Flow

Since the gas flow rate

conditions the supply pressure through the meter Determine the flow rate by dividing the BTU content and "correct" this answer by applying the correction factor for 3 psig (Table 4).

BTUIHR Input = CFH (Cubic feet/hour)

BTU/CU.Fr.

of

flow, correction must be made for

of

the gas into the burner input (Table 3)

OR

is

based

on

of

standard

3 psi

g.

0

2 3 4 5 6

PERCENT

CO---

THEN

Q;]JJ_

1.18

This pass through the meter so that the equivalent full

input requirement

sure) will be delivered.

Checking

Your gas supplier generally can furnish a gas meter flow chart from which gas flow can be determined. After a short observation period, this

information aids increase tain the rating.

::

is

the

CFH

Gas

or

decrease the flow

5,319 CFH

(at line pressure) which

of

6,277 CFH (at base pres-

Flow

in

adjusting the regulator

as

required

must

to

ob-

6.277.000 1,000

CHAPTER 5-14

::

6)."n

CFH (A114.7 lb·

atmcspheric "base" pressure)

750

..

150

CHAPTERS

ADJUSTMrnNTPROCEDURES

Final adjustment

of

means ing

cy

analysis. See Section Q for details.

NOTE:

the adjusting screws

cam

while performing a combustion efficien-

The

of

gas fuel is carried out by

in

information given

tion is for all practical purposes

sufficient to set and adjust

trols for gas input.

plier can,

if

necessary, furnish

exact correction factors that take

into consideration

exact

base

pressure,

gravity, ·temperature, etc.,

used.

gas

TOFOUONER

OF

GAS

MOOULA

TING

CAM

OVERRIDE

SPRINGS

the gas modulat-

in

this

sec-

con-

Your

gas

sup·

BTU

content,

specific

of

the

HIGH

ARE

t

!

LON

ARE

Q.

GAS

FUEL

COMBUSTION

ADJUSTMENT

After operating for a sufficient period

assure a warm boiler, adjustments should be

to obtain efficient combustion.

made

The

appearance

an indication

gas

flame will vary from transparent blue

or

color

of

the gas flame

of

its

efficiency since an efficient

translucent yellow.

of

Proper setting

the air/fuel ratios at all firing rates must be established by use gas analyzer. This instrument measures the

tent, by percentage,

(COz),

or

oxygen (Oz), and carbon monoxide

of

either carbon dioxide

(CO) in the flue gas.

Burner efficiency is measured by the amount percentage theoretical maximum gas is approximately 11.7%.

S-4, this

oxygen definite percentage

of

C02

present in the flue gas. The

C02

percentage for natural

As

is

attained when there is no excess

(02)

or

carbon

of

monoxide

excess air (oxygen)

quired by most local authorities and

the burner always should be operated with an air/fuel ratio at which the minimum percentage of

CO is produced.

of

time

of

a combustion

shown

in Fig.

(CO). A

of

course,

is

con-

is

to

not

to

or

re·

HIGH

LON ARE

STOP

SCREW

STOP

ARE

SCREW

[FIGURE 5-5/BUTTERFLY GAS VALVE]

1So..1so

Subject amounts

to local regulations pertaining

of

mended that

excess oxygen, it generally is recom-

C02

readings

of

between 9-1/2 and

to

specific

10% be attained with corresponding Oz readings of

4 to

3%

at high fire.

in

From information

section P

detennine the standard conditions

of

this chapter,

of

gas pressure and flow for the size boiler and the gas train on it. Calculate the actual pressure and flow through

of

the use

correction factors that compensate for

incoming gas pressure and altitude.

CHAPTER 5-15

CHAPTERS

(FIGURE· 5-6 GAS MODULATING CAM]

Basically, gas adjustments are made with a gas pressure regulator (Figure 1-15) that controls the pressure and with the butterfly gas valve (Figure 1-3) that directly controls the rate

In initially

stop

fire

valve

screw

is

closed.

setti~g

the linkage, back

on

the butterfly valve

Then

run the screw

of

flow.

off

so

out

the low that the

to

touch

the arm and give it two complete turns. Adjust

rod

so

the connecting released and

so

the stop screw. Tighten the lock nuts

joints.

See Figure S-5.

that the override tension is

that the arm

now

is

just

on

touching

all ball

This low fire setting should be regarded as tenta-

tive until the proper gas pressure for high fire

is

operation

To

reach the high fire rate,

rontrol switch toward

established.

tum

"OPEN"

the manual flame

in minor increments while monitoring combustion for overly rich

or

lean conditions.

ADJUSTMENT PROCEDURES

At

high fire, the gas butterfly valve should

wide

open

the shaft. that it is

as indicated by the

Set

and lock the high

just

touching the valve arm.

slot

on

fue

stop screw

the end

be

of

so

Determine the actual gas flow from a meter reading.

See section P

terfly

pressure

valve

set

at the calculated

flow rate should

input.

If

corrections are necessary, increase

open

of

this chapter. With the but-

and

with

the regulated gas

pressu~

be

quite close to the required

the actual

or

decrease the gas pressure by adjusting the gas

pressure regulator, following the manufacturer's

directions for regulator adjustment.

is

When proper gas flow gas analysis.

The

C02

9.5-10% with a corresponding

obtained, perform. a flue

value should be between

02

value

of

4-3%

at high fire.

If

the fuel input

values

do

is

correct, but the

C02

and

02

not fall within these ranges, the air

damper travel may need to be adjusted. Adjust-

of

ment

the air

Section B

With the high fire

gas

pressure regulator needs no further adjusting.

After making certain

damper

of

this chapter.

linkage

is

described in ·

air-fuel ratio established, the

·that the air control

damper and its linkage are correctly adjusted to provide the proper amount

of

secondary air and after

adjusting the gas pressure regulator, final adjust-

ment

can

be

made,

if

necessary, to the gas modulating cam to obtain a constant air-fuel ratio throughout the entire firing range.

Since the input ftxed at any

the flue gas reading

of

input

is

gas fuel at that setting. This adjustment

made to the metering

ing screws that are turned

from the hex-socket end) to increase the flow

fue~

and in (clockwise from the hex-socket end)

to decrease it. Flow rate is highest when the cam

follower assembly Figure

S--6.

of

combustion air

is

ordinarily

given poiQt in the modulating cycle,

is

determined by varying the

cam

by means

out

(counterclockwise

of

adjust-

of

is

closest to the jack:shaft. See

CHAPTER 5-16

75().150

CHAPTERS

ADJUSTMENT

PROCEDURES

Through the manual flame control switch, posi-

tion the cam so that the adjusting screw adjacent

to the end

follower. Perform a combustion analysis at this

point. adjustment screw accordingly decrease the fuel flow. Take a combustion read ing to verify the input. Repeat as necessary until

the desired flow stopping at each adjusting fire adjusting screw

or

high fire screw contacts the cam

If

an adjustment

is obtained. Repeat this process,

is

reached.

is

necessary, tum the

to increase

screw,

until the low

or

CAUTION!

Do

not

use

any

lubricant adjusting have a tended torque loosening

setscrews.

nylon

to

provide

and

locking

resistance

could

·equipment.

Standard Burner

Low

Fire Adjustment

With the low fire cam screw, the fuel input should

be

adjusted to approximately fire (Table 3). At low frre the content should be

8.8-9.1% with 4-4.5%

25%

on

the

These

Insert

locking

damage

of

that at high

C02

flue gas

02.

In-

to

High Turndown Burner

Low

Fire Adjustment

With the low fire cam screw, gas flow should be adjusted that at high frre (Table 4). The resulting flue gas

COz

..

responding

It

may

low fire stop screw in order air/fuel ratio at low fire. To ensure that the low

fire position

the same, allow a half tum

overtravel.

H the air damper must be reset

fire air/fuel requirements, combustion at higher firing rates must be rechecked.

The second cam adjusting screw may need

adjusted profile. will deviate from the general overall contour the cam Jace.

to obtain a minimum fuel input 10%

content should be

02

content

be

necessary to readjust the setting

of

the gas butterfly valve

in

order to maintain a smooth cam

If

all screws are properly adjusted, none

R.

LOW GAS

5.8-6.

7% with a cor-

of

11-9.5%.

to obtain the proper

of

the stop screw for

to

PRESSURE

SWITCH

of

the

is

always

meet the low

to

be

of

It

may be necessary to readjust the setting low fire stop screw in order to obtain the proper air/fuel ratio at the low fire rate. To ensure that

of

the low fire position always the same, allow one tum

for overtravel.

If

the air damper needs to be adjusted in order to

provide the correct low fire air/fuel ratio,

bustion must be rechecked at higher firing rates

and adjusted as required.

If

all cam screws are properly adjusted, none will deviate from the general overall contour cam face.

750-150

the gas butterfly valve

of

the stop screw

of

com-

of

the

is

the

Adjust the scale setting to slightly below the normal burning pressure. The control circuit

be

broken when the pressure falls below this point. decrease under some conditions, shutdowns may result ever, regulations be downstream

Manual resetting

drop.

restored. equipped control

Since gas line distribution pressure may

if

the setting

less

than

of

Press the reset lever after the pressure

Make

is

too close to nonnal. How-

reqqire that the setting may not

50%

the regulator.

of

the

rated

is

necessary after a pressure

sure

that a mercury switch

is

level.

CHAPTER 5-17

will

pressure

is

CHAPTERS

ADJUSTMENT PROCEDURES

1:

:za

40

ea

10 100

T!MP!RATUR£.

122.

1110

OEGREES

,.

110

FA.HRENHE.T

:ZOD

:ZO

2110

:ZICI

S.

HIGH

GAS

[FIGURE

PRESSURE

5-7/0IL

SWITCH

Adjust the scale s.etting to slightly above the normal burning pressure. The control circuit will

be

broken when pressure exceeds this point. Un-

necessary shutdowns may result

too close to normal, however, regulations require

that the setting may not

be

the rated pressure.

Manual

resetting

is

necessary after a pressure rise. Press the reset lever after the pressure Make sure that a mercury switch equipped control

is

level.

if

the setting

greater than 50%

fa

is

of

lis.

VISCOSITY CHART]

T.

FUEL

AND

OIL

PRESSURE

TEMPERATURE-

GENERAL

Variations

oil may require adjustments from time to time

assure highest combustion efficiency. The handling and burning characteristics may vary from one delivery

is

recommended that the oil system from time to time viscosity are at the proper operating levels.

in

burning characteristics

of

oil to another. For this reason,

to verify that pressures and

of

be

the fuel

to

it

inspected

CHAPTER 5-18

75()..150

CHAPTERS

ADJUSTMENT

PROCEDURES

Because content, source, blends and viscosity characteristics, the temperatures and pressures listed in Chapter 4 and mentioned

controls in the following paragraphs will vary

and thus may need to tions. Figure 5-7 chart. This may

oil supplier will

ing information based on

Review tions given in Chapter 7 will aid an efficient fuel system.

NOTE:

of

variation in oils including chemical

in

the adjusting

be regarded

be

changed to provide best firing condi •

is

an

be

used

be able to give you more exact-

of

the applicable maintenance instruc-

To prevent oil heater coking, the

fuel oil pump must tion during all times that an oil

heater

time that the oil pump is not

operating, the oil heating system

must manually turning the oil heater switch to the

is

in service. During any

be electrically shut down

as

tentative and may

oil viscosity-temperature

as

a guide, although your

an

"off'

analysis

position.

of

in

maintaining

be

in

opera-

the oil.

of

by

the

Proper setting rates must tion gas analyzer. This instrument measures the flue gas content, dioxide

cases,

Burner efficiency by gas. standpoint oxygen in the flue gas more practical reasonable amount for minor variations or burning properties percent excess air this should result of 6 oil with an

(C02),

smoke.

percentage,

The

12.5-13% for

of

the air/fuel ratios at all firing

be established by the use

by

percentage,

or

oxygen (02), and in some

is

determined by the amount,

of

C02

or

02

ideal

setting

is

reached when the percentage

to set the burner to operate with a

of

in

is

in

No.2

02

value

from an

is

zero.

excess air to compensate

the pressure, temperature,

of

the oil. Fifteen to twenty

considered reasonable and

an

approximate

oil and 13.5-14% for No.

of

3.5-3%.

of

either carbon

present

It

is,

a com bus.

in

efficiency

C02

the flue

of

however,

value

When the boiler

to

gas firing, the pump must operate for a sufficient period Similarly, if

is

heater

of

the heater should

until it has cooled.

U.

removed for servicing, the temperature

FUEL OIL

is

shut down, or switched over

of

time

to

cool the oil heater.

an

electric, steam, or hot water oil

be

reduced by circulating oil

·

COMBUSTION

ADJUSTMENT

After operating for a sufficient period assure a warm boiler, adjustments should be made to obtain efficient combustion.

Efficient combustion cannot solely flame condition or color, although they may used in making approximate settings. This should flame with no visible haze.

be

done so that there

is

of

time

to

be judged

a bright sharp

by

be

OIL

METERING

VALVE

[FIGURE

5-81

OIL MODULATING CAM]

DECREASE

FlOW

750-150

CHAPTER 5-19

CHAPTERS

Final adjustment to fuel input must be made to produce a minimum smoke spot density No. 4 for heavy oil conformance to ASTMD 2156-63T.

Through the use slowly bring the unit to high fire by stages while monitoring combustion for overly rich or lean

At

conditions.

damper should be fully opened and the air and oil pressure readings should given in Chapter 4.

Take a flue gas analysis reading at this point. necessary, make adjustments to the fuel oil troller to increase

should be done before making any effort to adjust

the screws in the metering cam. Ideally, the cam profile spring should casting lower the oil pressure

sary, than to extend adjusting screws to an ex-

treme position

After making certain that the air control damper

and its linkage are operating properly to provide

. the proper amount

oil pressure settings are correct, final adjustment can be made, cam to obtain a constant

entire firing range.

Since the input

fixed at any given point the flue gas reading input

made to the metering cam by means screws, which are turned out (counterclockwise from hex-socket end)

and in (clockwise from hex-socket end) to

decrease follower assembly is closest

Figure 5-8.

If oil pressure, primary air pressure, and linkages

are properly adjusted, the metering cam should

require minimal adjustment.

If

mended procedure.

as

of

fuel at that setting. This adjustment

it.

adjustment

the high fire position, the air

practical and it

in

if

necessary,

of

Flow rate

is

of

smoke. A maximum

of

a No. 2 for light oil, or a

is acceptable, as measured in

of

the manual flame control,

be

on the order

or

decrease oil pressure. This

be

as

close to the cam

is

more desirable

to

reduce flow,

an effort to cut back on flow.

of

secondary air and that fuel

to

the oil modulating

fuel~air

combustion air is ordinarily

in

is determined by varying the

to increase the flow

is

highest when the cam

necessary, follow this recom-

ratio through the

the modulating cycle,

to jackshaft. See

of

if

of

adjusting

those

con~

neces-

of

fuel

If

to

is

ADJUSTMENT PROCEDURES

[FIGURE 5-9/ ELECTRODE

OIL

PILOT]

Through the flame control switch, position the cam so that the adjusting screw adjacent

end or high fire screw contacts the cam follower.

Make a combustion analysis at this point.

If an adjustment screw accordingly to increase or decrease fuel flow. Take a combustion reading Repeat obtained. Continue this process, stopping at each adjusting screw, until the low fire position is reached.

as

is

necessary, turn the adjustment

necessary until the desired flow is

·

SETTING-

to

the

to verify input.

CAUTION!

Do

not

use adjusting· have a

tended torque

loosening damage

Standard Burner

Low

Fuel input at low fire should be approximately being made

screws are properly adjusted, none will deviate from the general contour

Fire Adjustment (Heavy Oil)

of

25%

that at high fire, with final adjustment

any

lubricant

setscrews.

nylon

to

and

the

to optimize combustion. If all cam

locking

provide

resistance

and a

lubricant

equipment.

of

the cam face.

on

the

These

Insert

locking

could

in-

to

CHAPTER 5-20

750-150

CHAPTERS

ADJUSTMENT

GASKET(HTD ONLY)

PROCEDURES

F'FIONT

EDGE

DIFFUSER

,.....---~/

OF

SKJRT

ElJANER

sro

1oo-200HP

src2!5()..4()()HP

HTO~P

OfF

t-----------''A'

DIMENSION

18-3,44'

2\5-!5.8'

22·1.4!'

'A'

-__,.----------1

IGNITlON a.ECn:lOOE

lfl"""-•

DETAIL "A"

GASANOAIR

MIXTURE

TO

PILOT

750-150

3(<4'

(OIL

ONLY)

DETAIL

'8"

·HIGH

TURNDOWN t250-400HP)

DETAIL

"C"

(FIGURE 5-10/BURNER DRAWER WITH GAS PILOT]

CHAPTER

5-21

CHAPTERS

Standard Burner

FLAME

SIGHl

GASPORT$

OIFRJSER

SKIRT

POSITIONED BEHIND

GAS

DETECTOR

:UBE

1/4' HOLES

ADJUSTMENT

PROCEDURES

High Turndown Burner

GAS

SPUDS

DUFF

USER

OIL

NOZZLE

(POSITIONED

OIL

FIRING)

FOR

CHAPTER 5-22

[FIGURE 5-11/BURNER HOUSINGS]

750-150

CHAPTERS

ADJUSTMENT PROCEDURES

High Turndown

Low

Fire Adjustment (Light Oil)

Fuel input at low fire should

125%

should resulting flue gas content

9.3-7.8% 02. The second cam adjusting screw

may

smooth cam profile.

At the

adjusted to obtain

turndown required. The second adjusting screw

may

smooth cam profile.

of

that

at

be

adjusted to obtain this flow rate with

need to

V.

be

low·

frre

be

BURNER

Burner

be

approximately

high fire. The low fire cam screw

of

8.5-9.5%

adjusted

screw,

the

adjusted

in

order to maintain a

the

oil flow should

necessary input for the

in

order to maintain a

ccn

and

be

fuel

DRAWER

ADJUSTMENT

There are relatively few adjustments that can made to the burner. However, a check should made to see that

and

located tightened. Figures S-10 views or portions

The diffuser location on gas fired boilers

important. There should edges (spuds). (See Figure fired burner

should

1-1/8" from the end When

the

setting

should

time

of

It

is

most important that pinge upon the diffuser. The distance that the nozzle and

individual installations may require a slight

deviation. The spacing indicated

Check proper gap gas

pilot electrode

that

of

the diffuser

be

located with

the

proper diffuser location

of

be

checked. This generally

manufacture

is behind

the

setting

and

all

components are properly

all

holding screws

and

S-11

of

the burner.

be

fins

and

the

5-11) The setting

is

less exacting

the

skirt approximately

of

the burner tube.

the nozzle

position. See Figure 5-10 for

the

of

and

in

relation to the diffuser

and

seldom needs altering.

oil

spray does not im-

diffuser

the

ignition electrode(s) for

Figure

are

show various

1/4"

between

gas

outlet tubes

and

the

is

ascertained, is

has

some latitude

is

2".

5-9

for

the

set

be be

properly

is

quite

the

of

an

oil

diffuser

at

the

light oil

pilot. Make sure that

cracked and that

are tight.

The oil

body

place. nozzle tip information.

Cleek to see that

and

respective openings

The integral contacts

proper positioning

in

must drawer

The switch

.

cuit

gas.

X.

nozzle tip

with

the

See

Section G

the gas pilot tube extend through their

W.

OIL

its

forward position. Adjustment

be

such that

is·

not properly positioned

is

when a combination

LOW OIL

electrically removed

the

porcelain insulator

the

ignition cable connections

sho1:1ld

swirler

the

DRAWER

and

be

seated tightly

and

the

seating spring

in

Chapter 7 for additional

flame detector sight tube

in

the

diffuser face. .

SWITCH

of

this

control

latching of

its

contacts open if

fuel

burner

TEMPERATURE

SWITCH

This control prevents stops

its

operation, if

below the normal operating temperature.

To adjust

the

center slot

dial until the fixed (center) pointer

proximately thermostat setting. Tum

screw (located above

indicator

on

the

On

a hot water boiler, switch The switch

approximately ing

temperature

this

control, insert a screwdriver

in

30•F lower than the oil heater

is

approximately

main scale.

is

an

integral part

is

nonadjustable

40•

the

control cover

the

F below

of

the

heater.

burner

temperature of

the

differential adjusting

dial) until

s·

F above

the

low

of

the

electric

and

the

maximum operat-

is

not

in

the

are

closed by

the

oil

drawer

of

the

switch

the

oil

for

oil

firing.

from

the

cir-

is

fired

on

from

starting, or

the

oil

into

and

tum

the

is

ap-

the

movable

the

setting

oil temperature

oil

heater.

is

factory set

in

is

at

750-150

CHAPTER 5·23

CHAPTERS

ADJUSTMENT PROCEDURES

Y.

HIGH

SWITCH

This control prevents stops its operation, exceeds the normal operating temperature.

To

adjust, tum

proximately temperature. These controls generally have a set differential and will close

point..

Z.

SWITCH

This control prevents burner ignition, or stops operation, when the oil pressure _(X)int.. top psi setting indicated on the oil supply pressure gauge. The switch will remain tion setting. The control normally

rese~

Adjust the control

of

the

below

as

when pressure

AA •

OIL

TEMPERATURE

(OPTIONAL)

the

if

the temperature

the

dial until the pointer

25•

F above the normal operating

LOW

OIL

PRESSURE

(OPTIONAL)

by

control case

the

established primary oil pressure

long

as

to

an

the

oil pressure exceeds this

is

restored after a drop.

ELECTRIC

burner from starting, or

of

the oil

is

ap-

s•

F below the set

its

is

below a set

turning the screw on

indicated pressure 10

in

a closed posi-

used

automatically

OIL

HEATER

heater operation when the steam heater functioning. The electric heater vide sufficient heated oil for on cold starts before steam

A

0.005 MFD capacitor

the thermostat lead connections

. tact bounce and arcing. The control differential

is

nonadjustable.

88.

STEAM OIL

is

THERMOSTAT

(400

The maximum temperature setting

is

adjusting knob turned to the "high" end of scale. Lower settings are obtained adjusting knob clockwise

in

The final setting vide oil combustion based on the flue is ture.

A

the

tact bounce

is

and

stamped on the dial. This

the

fuel

at

no

need to heat

0.005 MFD capacitor thermostat lead connections

nonadjustable.

600 Series - Steam)

usi~g

oil controller

of

a sufficient ·temperature for efficient

the

and

arcing. The control differential

as

this

thermostat should pro-

oil in excess

is

sized to pro

low

fire operation

is

available.

wired

in

parallel with

to prevent con-

HEATER

(No.

is

a guide.

gas

wired

6 Oil)

of

attained with

by

the

thermometer

analysis. There of

this

in

parallel with

to

prevent con-

the

turning

tern

is

control

the the the

per a-

..

THERMOSTAT

(400

The maximum temperature setting

is

stamped on adjusting knob turned to scale adjusting knob clockwise, using the thermometer in

the

The final setting

temperature approximately

steam heater thennostat. This prevents electric

CHAPTER 5-24

and

..

Lower settings are obtained

fuel

600 Series

the

dial. This

oil controller

of

this theFlllostat should

the

as

a guide.

is

"high" end

ts• lower

-Steam)

of

the

control

attained with

of

by

turning

be

than

the the the

at

the

a

CC.

HEATER

To

adjust, insert a screwdriver into

in

the control cover and tum pointer control generally close

s•F

(400

is

at

the

below

HOT

WATER

THERMOSTAT

and

600 Series)

desired temperature level. This

has

a set differential

the

set point.

the

OIL

center slot

dial until

and

750-150

the

will

CHAPTERS

The thermostat contacts close to energize the booster water pump, which pumps water from the boiler through the heater. normal practice to manually close the valve pump discharge line until the boiler water temperature exceeds the temperature

oil entering the beater.

On cold starts, it

in

of

the fuel

is

the

ADJUSTMENT

DO.

STEAM

PRESSURE

(400

and

600

PROCEDURES

HEATER

REGULATOR

Series -Steam)

The electric oil heater on a hot water boiler

burning No. 6 oil and equipped with a hot water oil heater has a built-in adjustable thermostat. The maximum temperature setting is stamped

its dial. The desired temperature can be obtained

by turning the adjusting screw. The thermostat should be set at a temperature approximately 15 degrees lower than the hot water heater thermostat. This prevents electric heater operation when

the water heater is functioning. The electric

is

heater

low fire operation on cold starts before hot water

is

available.

sized to provide sufficient heated oil for

on

This regulator is provided on a boiler designed operate at boiler pressures above 15 psi for the

of

purpose level

oil heater. This pressure should be reduced

point that permits sufficient temperature the oil while allowing as continuous a steam flow as

possible. Pressure that is too high will result

in

frequent cycling

It

is best to adjust the regulator under typical flow conditions. To do this, it is suggested that the globe valve that there out the adjusting screw fully to relieve compression on the regulator spring, thus closing the regulator. With steam at normal pressure, open the globe valve and then set the secondary sure until the downstream gauge shows the desired

pressure.

reducing boiler steam pressure to the

necessary for proper operation

of

the steam solenoid valve.

in

the steam supply line be closed so

is

n~

pressure on the regulator. Tum

by

turning the adjusting screw or handle

of

the steam

to

to a

to heat

pres~

750-150

CHAPTER 5-25

Cleaver-Brooks CBW Operation, Service And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual