CleaverBrooks S, CR, HSB Operation And Maintenance Manual
Models S, CR & HSB
Electric Boilers
Steam
Operation and Maintenance Manual
750-137
11/2012
CLEAVER-BROOKS
Models S, CR & HSB
Electric Boilers - Steam
Operation and Maintenance Manual
Cleaver-Brooks 2012
Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative
Manual Part No. 750-137
11/2012
Printed in U.S.A.
!
WARNING
DANGER
DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL
APPLICABLE SECTIONS OF THIS MANUAL.
DO NOT ALLOW OTHERS TO OPERA TE, SER VICE, OR REP AIR THIS EQUIPMENT UNLESS THEY FULL Y
UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.
FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
This instruction and maintenance manual presents information that will help to properly operate and care for
the equipment. Study its contents carefully. The unit will provide good service and continued operation if
proper operating and maintenance instructions are followed.
Cleaver-Brooks boilers are designed and engineered to give long life and excellent service on the job. The
electrical and mechanical devices supplied were chosen because of their known ability to perform, however,
proper operating techniques and maintenance procedures must be followed at all times. Although these
components afford a high degree of protection and safety, operation of the equipment is not to be considered
free from the hazards inherent in handling electricity, pressurized hot water, and steam.
It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instructions can replace intelligent thinking and reasoning and this manual is not intended to relieve the
operating personnel of the responsibility for proper operation or the application of timely preventive maintenance.
It is recommended that a boiler room log or other permanent record be maintained. Recordings of daily,
weekly, monthly, and yearly maintenance activities and recording of may unusual operation will serve as a
valuable guide to any necessary investigation.
It is customary to engage the services of a qualified water treatment company or a water consultant to recommend the proper water treating practices. Contact your local Cleaver-Brooks authorized representative for
details about Cleaver-Brooks water treatment services.
The operation of this equipment must comply with all requirements or regulations of the insurance company
and/or any other authority having jurisdiction. These legal requirements take precedence over anything contained herein.
Model S, CR & HSB Electric Boilers
Table of Contents
CHAPTER 1 General Description 1-1
1.1 — Introduction 1-1
1.1.1 — Safety Precautions 1-1
1.1.2 — Abbreviations 1-2
1.2 — Application 1-2
1.3 — Description 1-2
1.4 — Principles of Operation 1-5
CHAPTER 2 Installation Instructions 2-1
2.1 — Receiving Inspection 2-1
2.2 — Location 2-1
2.3 — Piping 2-1
2.4 — Electrical 2-2
2.4.1 — Electrical Installation Checklist 2-3
2.4.2 — Recommended Torque Settings 2-4
CHAPTER 3 Pre-Start Preparation 3-1
3.1 — Inspection 3-1
3.2 — Boiler and System Cleaning 3-2
3.3 — Boiler Water Treatment 3-3
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CHAPTER 4 Operating Instructions 4-1
4.1 — Initial Startup 4-1
4.2 — Control Adjustment 4-2
4.2.1 — Pressure Control Setup 4-2
4.3 — Blowdown 4-3
4.3.1 — Vessel Blowdown 4-3
4.3.2 — Gauge Glass Blowdown 4-3
4.3.3 — Water Level Control Blowdown 4-4
4.4 — Maintenance 4-4
4.4.1 — Quarterly Procedure 4-4
4.4.2 — Annual Procedure 4-5
4.5 — Element Replacement Procedure 4-5
4.5.1 — Replacement of Individual Elements 4-6
CHAPTER 5 Troubleshooting 5-1
5.1 — Problems, Causes, and Actions 5-1
CHAPTER 6 Parts 6-1
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750-137 (revised 2012)
Model S, CR & HSB Electric Boiler Manual
CHAPTER 1 General Description
1.1 — Introduction
1.1.1 — Safety Precautions
A complete understanding of this manual is required before attempting to operate or maintain the equipment.
It is essential to read and understand all safety precautions before attempting to operate the equipment.
Failure to follow these precautions may result in damage to equipment, serious personal injury, or death.
The equipment should be operated and maintained only by personnel who have read this manual and who have
a working knowledge and understanding of the equipment.
Warning
!
Warning indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death.
Caution
!
Caution indicates a potentially hazardous situation which, if not avoided, could result in damage to the equipment.
NOTE: ”NOTE:” indicates information that is vital to the operation of the equipment.
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1.1.2 — Abbreviations
Following is an explanation of the abbreviations, acronyms, and symbols used in this manual.
Abbreviation Explanation Abbreviation Explanation
ASME American Society of Mechani-
cal Engineers
AR Automatic Reset MR Manual Reset
BHP Boiler Horsepower pH Measure of the degree of acid
BTU British Thermal Unit P/N Part Number
C Degree Celsius PPB Parts Per Billion
F Degree Fahrenheit PPM Parts Per Million
GPM Gallons Per Minute PSI Pounds Per Square Inch
Ht Height T Temperature
Hz Hertz TC Temperature Control
KW Kilowatt TI Temperature Gauge
Lb Pound wsi Watts Per Square Inch
LWCO Low Water Cut Off
or base of a solution
General Description
1.2 — Application
The Cleaver-Brooks models S, CR & HSB are Immersion Element Steam Boilers designed for the heavy duty, continuous demand of commercial and industrial applications. They can be used as a primary, supplementary, or
auxiliary source of stem for space and process heating. The model HSB comes equipped with a 75 wsi Incoloy
element. The models S and CR come equipped with a 67 wsi Incoloy element. Some 600v models are equipped
with a 78 wsi Incoloy element.
1.3 — Description
Typical Cleaver-Brooks Models S, CR & HSB Steam Boilers are shown in Figures 1-1, 1-2, and 1-3. Illustrated
are packaged steam boilers with either horizontal or vertical insulated vessels. The boilers include control cabinets mounted on a common base and operating controls, elements, fuses, contactors, safety valve, and instrumentation. All boilers are wired, piped, tested, and ready for installation.
The vessel construction complies with ASME Boiler & Pressure Vessel Code: either Section I, “Power Boilers,” or
Section IV, “Low Pressure Heating Boilers.” Section I vessels are either “M” stamped for 100 psi design and up
to 90 psi operating pressure (models S & CR-120 through 162) or “S” stamped for operation and design pressures of 125 psi or more. Section IV vessels have the “H” stamp for 15 psi design for 13 psi maximum operating
pressure. All boilers are National Board inspected and registered, and are UL listed.
Refer to the Dimension Diagram (DD) and Wiring Diagram (WD) prepared by Cleaver-Brooks for your specific
installation.
1-2
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1.3 — Description
The following items are standard on all Cleaver-Brooks Electric Steam Boilers.
Component Description
1. Main Lugs for Supply Circuit Standard boilers are supplied with solderless wire connectors suitable for
copper supply wires. The main lugs are mounted on distribution busses
that provide individual connections for each heating element circuit. Standard boilers are designed for top connection to main power supply.
2. Supplemental Internal Protection
Fuses
3. Built-In Magnetic Contactors All boilers use definite purpose magnetic contactors designed for use with
4. Heating Elements Standard heating elements are Incoloy sheathed and rated at 75 watts
5. 120 Volt Control Circuit All boilers have 120 volt control circuits. Control circuit transformers with
6. Customer Control Interlock Con-
nection
7. High Pressure Cutoff All standard boilers with more than 2 control steps are supplied with one
8. Water Level Controller/Low Water
Cutoff
Boilers are provided with supplemental internal protection fuses rated at
approximately 125% of the element circuit load. These current-limiting
cartridge fuses have a minimum 200,000 ampere interrupting capacity to
provide protection for the element circuit wiring.
resistance heating loads. Contactors are rated for at least 50 amps resistive load and a minimum of 500,000 duty cycles.
per square inch (model HSB), or 67 or 78 wsi (models S and CR). These
elements are individually replaceable.
primary fusing and grounded secondary are provided on all models,
except when the customer specifies a 208/120 volt, 3-phase, 4-wire configuration. All boilers have 120 volt control circuits and are available for
either 50 or 60 Hz.
A terminal slip is provided on all boilers for connection of the customer’s
control devices and interlocks.
automatic-resetting and one manual-resetting high pressure cutoff. These
normally are set at 10% and 5% below the safety valve set pressure
respectively, unless otherwise specified. On smaller boilers, one autoresetting high pressure cutoff is standard as a backup to the limit duty
rated pressure control.
An automatic resetting, float type, combination low water cutoff and
water level controller is installed on each Cleaver-Brooks electric steam
boiler. If the vessel water level drops, the controller closes a switch, which
may be used to operate either a feed-pump relay or feedwater solenoid
valve. If the water level drops below the cutoff level, the heating elements
are de-energized by the controller until the water level returns to operating
level.
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General Description
Component Description
9. Pressure Control System Boilers with 1 and 2 stages of control are standardly provided with on-off
pressure controls. Larger boilers are provided with a solid state, proportional, modulating step-type pressure control system. As the system
steam pressure varies, the pressure control system proportions the input
power to the boiler demand, by increasing (or decreasing) the number of
heating element groups (steps) in use.
Both control systems (on-off and proportional) have adjustable pressure
ranges. The on-off controls have fixed differentials. The proportioning controls have adjustable proportioning ranges.
This proportional solid state electronic sequencers also have an adjustable
time delay between steps varying from 5 seconds up to 10 minutes.
These adjustable controls enable the boiler to be tuned to the system it
regulates in order to optimize boiler responsiveness and system operation.
The controller features rapid recycling after power interruption. When
power is restored, the boiler starts with all elements off. To prevent current surges, the step control ensures that the element groups are switched
on, one at a time.
10. Pilot Switch and Pilot Lights Pilot lights are standardly provided to indicate “power on,” “high pressure,” and “low water.”
11. Safety Valve The safety valve is properly sized according to the boiler’s electrical rating
and per ASME and National Board.
12. Built-In Condensate/make-Up
Tank and Feedpump (model CR boilers only)
This includes a condensate return tank and feedwater pump, completely
wired and piped. The condensate return tank is provided with a float-type
make-up valve, drain valve, and the necessary condensate return, vent,
and overflow connections.
The following optional equipment can be furnished by Cleaver-Brooks. The Dimension Drawings (DD) and Wiring
Diagrams (WD) shows the optional boiler equipment:
1. Manual reset low water cutoff
2. Auxiliary low water cutoff (manual or auto-reset)
3. Low pressure alarm
4. Pilot lights for individual steps
5. Toggle switches to enable/disable individual steps
6. Solid state progressive sequencing step control
7. Preheat switch
8. Demand limiting controls or interface
9. Control cabinet door interlock
10. Boiler disconnect switch or circuit breaker (with or without shunt trip, shipped loose for field mounting)
11. Ground fault detection
12. Metering ammeter, voltmeter or KWH meter
13. Alarm circuit (with or without horn/silence push button)
14. Automatic surface blowdown system
15. Local/remote modulation switch
16. SCR controller
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1.4 — Principles of Operation
17. Feedwater valve
18. Other miscellaneous options
1.4 — Principles of Operation
Immersion element steam boilers consist of a number of resistance-type heating elements assembled within a
pressure vessel. Electrical power applied to these elements is converted into heat and conducted into the surrounding water. Steam bubbles form at the element surface and then rise to the steam place at the top of the
vessel.
Controls are provided in order to match the input of electricity with the load requirements of the system. Heating
elements are switched on and off by magnetic contactors in response to the pressure control system. The simplest pressure control consists of a single pressure activated switch that energizes all heating elements simultaneously. This on-off control is suitable for small steam boilers (single stage). For 2-stage boilers, two pressure
controls are used to provide on-off switching of selected element groups at different settings.
The close control of boiler output demanded by large, complex, or critical steam systems requires the use of fully
modulating step controls. To proportion input power to steam demand, these modulating step controls select the
number of heating element groups, or steps, in sequence, in order to maintain the desired steam pressure.
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