CleaverBrooks Model 4 User Manual

Model 4

FEATURES PRODUCT OFFERING

Standard Optional

Insurance/Codes DIMENSIONS PERFORMANCE

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emissions ENGINEERING

Feedwater

Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boiler Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas SPECIFICATIONS

AND

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7

Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-20

1,500 – 6,000 MBTU

MODEL 4 BOILER

1,500 - 6,000 MBTU &

Watertube Boiler

CONTENTS

BENEFITS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7

AND

RATINGS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-8

DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16

DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-27

B2

-15

B2

-17

B2

-17

B2

-20

Section B2-1

Rev . 03-08

Model 4

Figure Figure Figure Figure

Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table

This pressure

B2-1. B2-2. B2-3. Boiler B2-4.

B2-1. B2-2. B2-3. B2-4.

Model 4 Dimension Model 4 Standard

room

Typical gas header

Model

4 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5

Model 4 Dimensions Model 4 Steam Ratings Recommended Steam Nozzle Size

B2-5. Min. req. B2-6. Min. req. B2-7. Min. req. B2-8. Min. req. B2-9. B2-10. B2-11. B2-12. B2-13. B2-14. B2-15. B2-16. B2-17. B2-18. B2-19. B2-20.

Safety valve

Predicted efficiency, Model 4 emission Model 4 emission Feedwater makeup Water Model Gas

line

Gas

line

Gas

line

Gas

line

Gas

line

section contains

steam

applications. Siz es range where high outputs are 6000,

representing

MBtu/hr input (1,500,000 to

1,500 – 6,000 MBTU

ILLUSTRATIONS

Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-9

Pilot and Main

air

supply - “Engineered

Gas

Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-2

Design” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-19

piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-26

TABLES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-11

(to maintain 4000 to 5000 fpm NATURAL GAS pressure STANDARD NATURAL GAS pressure OVERSIZED PROPANE GAS pressure STANDARD PROPANE GAS pressure OVERSIZED

outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15

10 psig

operating (includes radiation

data - Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16

data - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16

rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17

quality parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17

4 fuel,

combustion capacity - Schedule capacity - Schedule capacity - Schedule capacity - Schedule capacity - Schedule

air, and flue

40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-22

40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-23

40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-24

40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-25

information on the Model 4

gas

flow rates . . . . . . . . . . . . . . . . . . . . . . . B2-19

Commercial Watertube

from 1.5 to 6 MMBtu/hr. The Model 4 Boiler is an

needed

but

space

limitations exist. The model number

6,000,000

UL, FM, &

UL, FM, & UL, FM, & UL, FM, &

Btu/hr).

nozzle

XL GAP gas

XL GAP gas XL GAP gas XL GAP gas

and

convection

velocity) . . . B2-11

trains . . . . . . . B2-13

trains . . . . . . . B2-14

losses) . . . B2-15

Boiler product line for low and high

excellent

designation

is 1500 through

choice

Fuel series designation

• Series

100: No. 2 oil firing. 700: Natural 200: No. 2 oil/natural

is as fol lows:

Design pressure designation 700-2500-150ST boiler

gas

firing.

gas

firing.

is stated as 15 psig, 150 psig, and 250 psig for steam. For

designates a gas-fired,

2,500,000

Section B2-2

Btu/hr, 150 psig,

steam

boiler.

example,

an M4P-

Rev . 03-08

Model 4

FEATURES AND BENEFITS

The

33" Cased Width:

Direct Driven, Vibration-Free Centrifugal Impeller:

Minimum Refractory:

Membrane Waterwalls:

Small Boiler Footprint:

Weighs up to 40% less than Comparable Boilers:

Standard Built-in Soot Washers:

Packaged Forced Draft Burner:

Burner/Windbox Davit:

Steam Design Pressures to 500 psig (optional):

following

•

Boiler fits

• Reduced

• Quiet

• Sound levels

•

Ideal for

features

and

through

most

installation costs.

operation.

below 79 dBA.

noise

critical

benefits

standard

areas such

• Membrane waterwalls reduce

• Reduced maintenance costs

• Enhanced

•

Full water wall

• Savings

• Lower freight

• Reduced structural

•

Boiler

• Maintains peak

•

High

•

Optimum fuel and air mixing.

heat

transfer area

furnace improves

of up to 50% in floor space.

and

rigging

requirements.

fireside cleaning

boiler performance.

pressure

drop design.

• Improved combustion

• Easy access

to

furnace

• Reduced maintenance

•

High

• Proven vessel design

performance

in a

for high

and

costs.

without shutdown.

efficiency.

with

swing-open

costs.

compact

apply to the

doorways.

as

hospitals, churches,

the

need

for

refractory repair

in

compact

heat

design.

design pressure

design.

transfer

windbox.

1,500 – 6,000 MBTU

Model

refractory

4 Boiler product line.

by

95%.

requirements.

for high efficiency .

applications.

etc.

Section B2-3

Rev . 03-08

Model 4

PRODUCT OFFERING

Standard

Equipment

1500 - 6000 MBTU/hr

The

Model 4 (M4) Boiler is a Heat transfer design is surfaces. The pressure vessel Section pressure)

IV for low

or

Section

pressure steam

I for

The vessel (boiler) consists of two rows on each side of the vessel, of formed seamless tubes

with

extended drum and lower drum. To reduce standby losses, the fiberglass blanket

and

removable steel

Complete with an integral burner for either No.2 fuel oil or Natural Gas, the complete burner/boiler package

The standard boiler/burner package devices noted following

may be added to meet project

this

standards list.

1. Boiler A. Designed, constructed, and hydrostatically tested in accordance with the

A.S.M.E. Boiler and structural steel

Pressure Vessel

frame.

B. Steam d rum includes a hand hole in the rear head for drum water side inspection.

• Feedwater Makeup

• Surface

• Steam

• Safety Relief

C.

Lower

blowoff tapping is

Connections are included

Blowoff.

Supply.

Valve.

Drum

includes

provided

centerline.

compact carbon

configured

in a "3-pass" gas travel across the watertube

is

constructed

@ 15

MAWP greater

fin

surfaces

is UL

Approved,

is

Code. The

for the following:

w/internal

hand

dispersion

holes

at

at the front, bottom

steel,

to

conform

extended

to the

fin,

watertube

A.S.M.E. Code,

PSIG MAWP (maximum allowable

than 15 PSIG.

and

downcomers connected

vessel

is insulated with a

jacket.

listed, and labeled.

described

requirements.

each

below.

complete vessel

tube.

end for

waterside

Optional controls, Some of those options are

is mounted on a

inspection. A drain/

boiler.

either

working

to the steam

trim, and

D. Soot washer lances are provided on each side of the rows of the boiler, with

tubes

for

fireside

connections

cleaning.

to drain

Soot washer drains are l ocated

located

on

each

side of the lower drum at the

vessel

between the two

at the bottom of

rear. E.

Refractory

High

temperature

is limited to the furnace floor, lower drum, and burner throat

insulation is installed on the front water wall and

furnace access

tile.

door. F. Two lifting

eyes

are

provided

on the top

centerline

of the upper drum for

ease

of

installation.

Furnace inspection/access door

G. H. The

thermometer

exhaust gas

is shipped

vent is

loose

located

is

provided

at the top rear

in the

furnace

centerline

front

wall.

of the boiler. A stack

for field installation by the installing

contractor

into

the stack. I. The

sectional steel

complete vessel

jacket.

Section B2-4

is fully

insulated

(2"

fiberglass

blanket) under a preformed,

Rev . 03-08

Model 4

MODEL

NO.

Table

INPUT

MBH

B2-1.

Model

HEAT

OUTPUT

MBH

4

Boiler Sizes

EQUIV

HP

STEAM

OUTPUT

LB

/

HR

SHIPPING

WEIGHT

LBS

1500 - 6000 MBTU/hr

1500 1500 1200 2000 2000 1600 2500 2500 2000 3000 3000 2400 3500 3500 2800 4000 4000 3200 4500 4500 3600 107 3711 4700 5000 5000 4000 119 4124 4700 6000 6000 4800 143 4949 5400

NOTE: Steam output from and at 212 °F.

J.

Factory

painted

using hard-finish

35

1237 3100

47

1649 3100

59

2062 3700

71

2474 3700

83

2887 4100

95

3299 4100

enamel.

2.

Forced

A. The and a fuel oil.

Consisting

B. damper factory mounted

Draft Burner

burner

is a high radiant multi-port type

pressure atomizing

of the fan which is direct

that is

linkage connected

and tested.

type

approved

to a

damper

approved

for

operation

connected

drive motor , the

for

operation

with

commercial grade

on natural gas

No.

2

to the fan motor, wind box, air

complete assembly

is

C. To ensure proper air for pre purge and combustion is provided by the fan, a combustion

D. The drum. This permits

E.

Responding

air

proving

switch is provided.

complete burner/wind

fireside inspection

to

steam demand

box

swings open

of the

from the drum

via a davit arm

furnace

and

burner

mounted pressure

attached

to the upper

internals.

control, the burner operates in the low-high-low-off firing mode. Ultra-violet (UV) flame scanner is provided

F. An Ignition G. Ignition is direct

combination gas/oil H. Oil Train

for flame

presence during

transformer

spark

is provided. on straight oil fired

burners.

consists

•

4

Solenoid Shutoff Valves providing

to high and high fire.

•

An oil pump is

the fuel

•

Oil

Pressure

• Suction

of the following:

mounted

oil.

Gauge.

and return tubing

firing.

(belt

driven

connected

burners,

low fire,

from the fan motor) for

to an oil

and

gas

intermediate transitional

connection

pilot on

pressure atomization

block.

straight gas

firing from low

or

of

Section B2-5

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Gas

Train

consists

• Primary gas shutoff valve

•

A

manual shutoff valve located ahead

•

A

plugged leakage

checking

• Separate Gas Pressure Regulators

•

Low

•

A

• The

Gas Pressure

second motorized gas valve

6000

pilot

3. Boiler Trim and A. 15 psig or 150 psig set B.

Steam pressure gauge Primary Water Column complete

C. D. Low Water cutoff switch and pump control switch, integrally mounted in the

primary water column.

Auxiliary

E.

Steam Pressure

F.

• Operating

• Excess Steam Pressure

• Burner

4.

Burner Control Panel

Low

A. The control panel is the

burner

wind

B. Mounted within or on the control panel box are the following controls. Panel wiring is

5. An electric

external

factory

• Combustion Flame Safeguard Control, Model purge,

• Fan

• Indicating Lights

• Burner On/Off

• Damper Positioning

• Fuel Selector Switch

• Control

• Terminals

•

Motor

control.

Oil, heat, and

the wiring diagram.

Electric Service

service

wiring boiler. Wiring to this panel burner

wind

of the following:

with

test

connection

of the

primary shutoff

and High

un

its.

gas

train

includes a manual shutoff valve

Controls

A.S.M.E. safety

with

inspectors

Water Cutoff,

manual

Controls:

Limit.

(High Limit),

firing rate, low high low .

and

Controls

enclosed

box

at

approximately eye level

tested.

trial for ignition, main

Starter

Circuit

for

wired into the non

for low water, flame failure, load

Switch.

for

combination

Step-down Transfor mer

interface

moisture resistant

wiring

Panel

panel

(entrance

connections

to remote control

eliminates

box

is

opened

for

burner

integral proof

and a

valve.

for the pilot train and main

Gas Pressure Switches

is

provided

test

with

gauge glass

reset

manual

of

closure

of the primary

second manual shutoff valve

in addition to the primar y

relief

valves.

cock

and connection.

type.

reset.

within a NEMA 1A

height.

CB120 that

flame/burner operation,

recycling

fuel fired burners.

with primary

connection

wire used.

box) is

provided

circuit of the flame safeguard

of controls.

Each

devices

the

need

to

disconnect

or boiler servicing.

switch.

gas

valve.

for tightness

gas

train.

for units at 3000 and greater.

valve

on size

and

solenoid shutoff

valve.

and column drain valve.

Rated enclosure, mounted

provides

and

safety

demand,

fuse

protection.

wire is

number coded relative

pre

shutdown.

and fuel

purge,

valve

on

post

on.

to

on the side of the boiler for all

and the main power for the

wiring when the front

Section B2-6

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Optional Equipment For more detailed information on optional equipment, contact your local Cleaver-

Brooks authorized representative.

In

summary, options

include the following:

1. Boiler

• Larger pressure g auges

•

Bottom Drain

•

Bottom Blowoff

• Surface

• Feedwater Stop

• Steam Stop

• ASME Hydro Test

• Design pressures above

2.

Burner/Control Options

•

Full

Modulation Firing

• Lead/Lag Control.

• Day-Night

•

Low

• Elapsed

•

Alarm with

• Additional Indicator

•

Main

• Remote

• Optional NEMA

• Special Fan

3.

Fuel Options

• Automatic Fuel Changeover (combination

• Propane Fuel

• Special Gas Pressure

• Special

•

Dual Pilots

• Gas

Fire

Power

strainer.

Valves

Blowoff

Time Meter .

Oil Pump.

Valve and

Valve.

Controls.

Hold Control.

silence

Disconnect.

Enclosures.

Motor

Firing.

fuel

shut-off

(gas

and oil).

or

specific manufacturer

for low

Check

of

Valves

pressure

for high

with internal

Valves.

and

150 PS

on Gas.

switch.

Lights.

requirements

Regulators.

valves.

applications.

pressure

collector

Valve

Piping.

IG.

(TEFC).

type.

applications.

pipe.

burner).

Insurance/Codes The boiler package can be equipped to meet various insurance or code

requirements.

• Factory

• XL GAP (Formerly GE

• A.S.M.E. CSD-1.

A.

Factory

pertain

to hr input on oil. Boilers that are labeled and tested in accordance with an independent from

these

The Model 4 boiler is UL listed and labeled. In addition to the standard UL requirements

•

Alarm Bell with

•

Low Oil

B. XL GAP

GAP

pertain to

Some

of

these insurance/code requirements

Mutual (FM)

GAP/IRI).

Mutual (FM

boilers rated

Global) - Recommended

at

greater

testing lab such as UL or

recommendations.

the

following are needed

silence

Pressure Switch

(Formerly

boilers

switch for low water and

if the oil pump is not direct

GE GAP/IRI)

rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. For

are:

guidelines as described by FM

than 2.5 MMBtu/hr input on

CSA

and are below

to

comply

with FM when required.

safety

these

shutdowns.

driven

from the fan motor .

Recommended guidelines

gas

and 2.8 MMBtu/

inputs are exempt

as

described

by XL

Section B2-7

Rev . 03-08

Model 4

these

boilers, the

Above

12.0 MMBtu/hr input, the

single burner

C.

A.S.M.E. CSD-1 - Recommended guidelines as described

boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. Above MMBtu/hr input, the boilers. For the to the

standard

•

Low Oil

• ¾"

•

If

the main and pilot

• Lever Handled shutoff cock

• Non-fused disconnect

DIMENSIONS AND RATINGS

requirements

boilers.

requirements defer

sizes

UL package:

Pressure Switch

Pressure Control

gas supply

is > 5

are the

this

Code covers,

for oil firing

Piping

psig, a relief valve

gas

trains.

for the pilot

to

remove

same

as for

requirements defer

to the

NFPA

the

requirements

is

required after

gas

train.

boiler from all

sources

1500 - 6000 MBTU/hr

A.S.M.E CSD-1

to the

NFPA

by this

85

standards

are as follows, in addition

the

gas pressure regulator

of power .

requir

85

standards

Code pertain

for

single

emen

12.0

burner

in

ts.

for

to

For layout purposes, the nominal dimensions and Standard Package Boiler are shown

size are noted

boiler figures, tables,

Table

B2-4:

lower and Figure Table

B2-5: Natural

Table

B2-6: Natural

Ta

ble

B2-7:

Table

B2-8:

Table

B2-9:

Recommended steam nozzle sizes

higher

B2-2:

Standard gas

Propane Gas Pressure Requirements, standard gas Propane Gas Pressure Requirements, oversized gas Safety Valve Outlet

in

Table

B2-3.

and illustrations.

pressures.

train Gas Pressure Requirements, standard gas Gas Pressure Requirements, oversized gas

in

Figure

B2-1 and

Additional information

for high

dimensions

and

components.

Sizes.

connections

Table

is

for the Model 4

B2-2.

shown

Ratings in the following

pressure boilers operating

train size.

train

.

train size.

train.

of each

at

Section B2-8

Rev . 03-08

2

-

l

4

Model 4

Figure

1500 - 6000 MBTU/hr

B

1.

Mode

DimensionDrawing

Section B2-9

Rev . 03-08

Model 4

Note

1

A

Overall

B

Pressure Vessel

C

Base Fram e

C

1

C

2

CC

Rear Casing to Stac k Connec

D

Burner/W indbox

DD

Front Casing to Steam

HH

E F

Center to Water

G

Center to Opt. Aux.

H

Center to Outside

I

Ba se Fram e

J

Ba se Fram e

K

Soot Washers, Center to

L

Bo iler Cente rline to Soot

M

Boiler Ce nterline to Base Cen terli ne

N

Boiler Centerline to Soot

OO

O

Base to Steam Nozzle

O

Base to Steam Nozzle

O

1

O

2

P

Base to Surfa ce

Q

Ba se to Feedwater

R

Base to Soot Washer

S

Height of

OS

Base to Oil Supply

OR

Base to Oil Return

BB.

T

Bottom Drum Blow Down, 15#

T

1

U

Steam Nozzle,

V

Steam Nozzle,

W

Soot Washer

X

Sur face Blow off

Y

Feedwater Inlet

Z

Soot Washer

GG

Oil Supply and

JJ

EE

FF

Tube removal eac h

RF

RD

NOTES: 1.

Base to Burn er/W Base Fram e Anchor

Steam Nozzle to Safety Valve Steam Nozzle to Safety Valve

Overall

Overall [Base to Stack

Base to Stack Base to T op of Control

Base

Connections

OD Stac k - Sleeve C

Bottom Drum Blow Down, 150#

Relief Va lve, Relief Va lve,

Clearances

Burner/W indbox

Allowance for and 30" Rear Aisle

Allowance for Tube Removal Side and

Burner/Windbox Swing.

The above dimension s,

prints.

2. Allow

3.

For access Control Panel

4. A.

Connection Connection

B.

Lengths

w/casing

indbox

Holes

Ex tension

Nozzle

Widths

Column

W

ater C olu m

Casing Inside Outside 28 28 28 28 28 28 28

Heights

Connection] 150# 15#

Box.

Panel

Blowoff

Inlet

Lance

Connection

C onnection

onnection

15# 150#

D

rains

[Two]

[One]

[Two]

Return 15# 150#

Sw ing

s ide

Burner/Windbox Swing

Space.

For

200

sufficient space

to the

is a

Table

B2-2.

1500 2000 2500 3000 3500 4000 4500 5000 6000

tion

15# 150#

84.25 84.25 100.25 100.25 117.375 117.375 136.75 61 61 77 77 92.375 92.375 109 54 54 69 .625 69.625 85.25 85.25 101

9.625 9.625 9.625 9.625 9.625 9.625 10

51.5 51.5 67.125 67.125 82.75 82.75 98.375 98.375 114

25.8 25.8 26.25 26.25 26.25 26.25 30.375 30.375 30.375

20.1 20.1 20.1 20.1 21.9 21.9 24.6 24.6 24.6

17.25 17.25 25.25 25.25 30.75 30.75 37.375 37.375 45.25

8 8 12 12 11.5 11.5 13 8 8 12 12 17 17 17

53.25 53.25 53.25 53.25 53.25 53.25 53.25

32.4 32.4 32.4 32.4 32.4 32.4 32.4 32.4 32.4

n

26.6 26.6 26.5 26.6 26.6 26.6 26.6 26.6 26.6

16.375 16.375 17 .375 16.375 16.375 16.375 16.375 16.375 16.375 20 20 20 20 20 20 20

Model 4 Dimensions

BoilerSize

All D imensions are in

inches

Center

Washer

Drain

[one] 1.25 1.25 1.25 1.25 1.5 1.5 1.5

Each

PSIG design pressure

furnace,

may be

Female Pipe

150#

21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4

10.7 10.7 10.7 10.7 10.7 10.7 10.7 10.7 10.7 12 12 12 12 12 12 12

5.25 5.25 5.25 5.25 5.25 5.25 5.25 5.25 5.25

78.75 78.75 78.75 78.75 78.75 78.75 78.75

74.75 75.75 74.75 74.75 74.75 74.75 78 75 75 75 75 78.25 78.25 78.25 78.25 78.25

77.8 77.8 77.8 77.8 77.8 77.8 77.8 77.8 77.8

83.25 83.25 83.25 83.25 83.25 83.25 83.25 83.25 83.25

59.25 59.25 59.25 59.25 59.25 59.25 59.25 59.25 59.25

57.25 57.25 57.25 57.25 57.25 57.25 57.25 57.25 57.25

55.5 55.5 55.5 55.5 55.5 55.5 55.5 55.5 55.5 4 4 4 4 4 4 4

27.75 27.75 27.75 27.75 27.75 27.75 27.75 27.75 27.75

25.75 25.75 25.75 25.75 25.75 25.75 25.75 25.75 25.75

12

16

[one] 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25

at

larger

A

4

2.5 2 2 2 2 2 2 2

0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 1 1 1 1 1 1 1

0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25

0.5 0.5 0.5 0.5 0.5 0.5 0.5 2 2 2 2 2 2.5 2.5 1 1.25 1.25 1.25 1.5 1.5 1.5

A

4

A

2.5

A

4

A

3

A

4

A

3

B

6 3

6

A

3

6

B

4

while

rear

a 13" x 21"

Flange,

33 30 30 30 30 30 30 30

124 124 140 140 155 155 172

93 93 93 93 93 93 93

sufficiently accurate

of boiler for

(up to 4" in

Thread.

Flat Face.

33

and

greater, contact Milwaukee Sales

removal

access door

height)

33

for layout

of

is

if

certain control options are

33

purposes,

soot washer

provided behind

33

must be

lance.

the front door .

33

confirmed

for

certified

provided.

33

for

construction

prints.

1500 - 6000 MBTU/hr

136.75

152.375 109 124.625 101 116.5

10

13

4

B

6

B

4

2

1

via certified

17 17

53.25

20 28

12

78.75 78

4

16

1.5

6 4

2

1

0.5 3 2

33 30

187

93

B B

17

53.25

20 28

12

78.75 78

16

1.5

0.5

2.5

1.5

33 30

172

93

Section B2-10

Rev . 03-08

Model 4

Table

Boiler

SIZE

Ratings [Note

Rated from & at 212o F.) Rated Steam

100 C Output Btu/hr [1,000 Output K cal/Hr [1,000 Output

Appr oxim ate F uel C onsumption At Rated C apacity [ Input - N ote

Natural Gas [ft3/hr] - 15# Natural Gas [ft3/hr] - 150# Natural Gas [m3/hr] - 15# Natural Gas [m3/hr] - 150# Propane Gas [ft3/hr] - 15# Propane Gas [ft3/hr] - 150# Propane Gas [m3/hr ] - 15 # Propane Gas [m3/hr ] - 15 0# No.2 Oil Fuel - 15# Steam, No.2 Oil Fuel - 150# Steam, No.2 Oil Fuel - 15# Steam, No.2 Oil Fuel - 150# Steam,

Pow

Blower Motor HP - Gas Blower Motor HP - Oil or Oil Pump for Oil or C

Minimum

Blower Motor - Gas Firing Only, Blower Motor - Gas Firing Only, Blower Motor - Oil or Combination, Blower Motor - Oil or Combination, Control C

Weights

Operating W eight, Operating W eight, k Water C ontent Normal, Water C ontent Normal, l Water C ontent Flooded, Water C ontent Flooded, Shipping Weight, approxim ate Shipping Weight, approxim ate

Notes:

Table

B2-4.

A]

Capaci

ty - Steam

(lbs

. s

team/hr

Capaci

ty [kg/hr from and at

Btu/h]

Kcal/h]

Steam

gph

liters/hour

Firing

Combinati on

ombination

230V 460V

]

KW

er Re quiremen ts - 3 Phase 60 Hz Standar d [Not e

Ampacity

irc ui t

lbs .

g

gallons

iters

gallons liters

lbs. kg

A. Ratings shown for elevation to 1000 Feet. For ratings above 1000 Feet, B. Input calculated w ith N at. Gas @ 1000 Btu/ft

C

. For altitudes above 1000 Feet, contact your

Recommended Steam Nozzle Size (to maintain

1500 2000 2500 3000 35 00 4000 4500 5000 6000

1,237 1,649 2,062 2,474 2,887 3,299 3,711

461.7

1,200 1,600 2,000 2,400 2,800 3,200 3,600 4,000 4,800

302 403 504 605 706 806 907 1,007 1,210 348 464 580 696 812 928 1,044 1,160 1,392

1,511 1,538 2,500 3,038 3,487 4,025 4,494 5,050 6,052 1,572 2,133 2,597 3,117 3,590 4,155 4,657 5,194 6,233

42.8 43.5 70.8 86 98.7 114.0 127.0 143.0 171.4

44.5 60.4 73.5 88.3 101.6 117.6 131.8 147.0 176.5 604 615 1,000 1,215 1,395 1,610 1,798 2,020 2,421 629 853 1,039 1,247 1,436 1,662 1,863 2,078 2,493

17 17.4 28.3 34.4 39.5 45.6 51

17.8 24.1 29.4 35.3 40.7 47 52.7 58.8 70.6

10 14 17 21 24 28 31 11 15 18 22 25 28.9 32 38 53 64 79 91 106 117 41 56 68 82 95 109 121

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

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

1.53 3.3 4.7 6 6 9 9

0.77 1.7 2.4 3 3 4.5 4.5

4.7 4.7 6 6 9 15 9

2.4 2.4 3 3 4.5 7.5 4.5

1.7 1.7 1.7 1.9 1.9 1.9 2.4

3,758 3,758 4,566 4,566 5,175 5,175 5,991 5,991 6,900 1,399 1,399 1,704 1,704 1,932 1,932 2,236 2,236 2,575

79 79 104 104 130 130 156 299 299 394 394 492 492 591 109 109 145 145 177 177 213 413 413 549 549 670 670 806

3,100 3,100 3,700 3,700 4,100 4,100 4,700 4,700 5,400 1,157 1,157 1,381 1,381 1,530 1,530 1,754 1,754 2,015

Operating Pressure

(PSIG)

95 -

250 -

1500 - 6000 MBTU/hr

B2-3.

3,

loc

15 4 4 6 6 6 6 8 20 3 4 4 6 6 6 8 30 3 4 4 4 4 6 6 40 2-1/2 3 3 4 4 4 6 50 2-1/2 3 3 4 4 4 4 65 2-1/2 2-1/2 3 3 3 4 4 75 2-1/2 2-1/2 3 3 3 4 4

125

150 1-1/2 2 2 2-1/2 2-1/2 2-1/2 3 200 1-1/ 2 1-1/2 1-1/2 2 2 2-1/2 2-1/2 2-1/2

400 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2

Model 4 Steam Ratings

C]

Propane @ 2500

al C leaver-Brooks authorized representative for

A

A.

615.5

B]

1500 2000 2500 3000 3500 4000 4500 5000 6000

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

Standard nozzle size for 150 PSIG MAWP Boiler Example 1: Size 3500, 150# boiler to operate @ 30 PSIG requires 4" steam nozzle in lieu

standard 3" Example 2: Size 3500, 150# boiler to operate @ 200 PSIG requires 2" steam nozzle in lieu standard 3"

Section B2-11

769.6

923.4

Belt Driven from the Blower

c

ontact your local Cleaver-Brooks

3,

Btu/f

t

nozzle.

and Oil @

140,000Btu/gal.

1,077.5 1,231.3 1,385.0

Motor

Representative.

verifi

catio n of capacity

4000 to 5000

BO ILER

SIZE

Design

fpm nozzle

4,124

1,539.2

57.2 68.5

35 36

132

136

3 3

9

4.5 9

4.5

2.4

156 591 213 806

rating.

4,949

1,847.2

42

43 159 163

5 5

15

7.5 15

7.5

2.4

181 685 245 927

velocity)

8 8 6 6 4 4 4 4 3

2

2-1/2

8 8 6 6 6 4 4 4 3 3

of

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Figure

Pilot

Main

2

5

3

5

6

5

6

B2-2.

7

8

Model 4 Standard Pilot and Main Gas Tr

ITEM PART DESCRIPTION

1 2 3 4 5 6 7

1 2 3 4 5 6 7 8 9

10

8

4

7 9

7

1

7

8 9

5

9

5

10

Sizes 1500 TO 2500 Butterfly Valve 1-1/2 Pilot Shutoff Cock Pilot Gas Regulator Pilot Solenoid V alve Manual Shutoff Valve 1-1/2 Main Gas Regulator 1-1/2 Motorized V alve with P.O.C. 1-1/2

Butterfly Valve 1-1/2 Pilot Shutoff Cock Pilot Gas Regulator Pilot Solenoid V alve Manual Shutoff Valve 1-1/2 Main Gas Regulator 1-1/2 Low Gas Pressure Switch Motorized V alve with P.O.C. 1-1/2 High Gas Pressure Switch

Sizes 3500 to 5000 Butterfly Valve Pilot Shutoff Cock Pilot Gas Regulator Pilot Solenoid V alve Manual Shutoff Valve Main Gas Regulator Low Gas Pressure Switch Motorized V alve with P.O.C. High Gas Pressure Switch

Butterfly Valve Pilot Shutoff Cock Pilot Gas Regulator Pilot Solenoid V alve Manual Shutoff Valve Main Gas Regulator 2-1/2 Low Gas Pressure Switch Motorized Valve (std) Motorized V alve with P.O.C. High Gas Pressure Switch

ains

Size

3000

6000

SIZES

INCHES

1/2 1/2 1/2

1/4

2 1/2 1/2 1/2

2

2 1/4

2 1/2 1/2 1/2

2

1/4

2

2 1/4

Section B2-12

Rev . 03-08

Model 4

Table

B2-5.

B2-6.

Minimum required NATURAL GAS pressure

trains (upstream

BOILER

SIZE 1500

2000 2500 3000 3500

4000 4500 5000

6000

N ote: For altitude above 1000 feet, contact your local Cleaver-Brook s representative. N atural Gas @ 1000 B tu/c u-ft, specific gravity @ 0.65

INL ET PI PE

SIZE

(inches)

1.5 1.5 4.4 28.0

1.5 1.5 8.4 28.0

1.5 1.5 12.9 28.0 2500

1.5 1.5 17.1 28.0

2.0 2.0 11.3 28.0

2.0 2.0 13.6 28.0

2.0 2.0 12.2 28.0 4500

2.0 2.0 16.8 28.0

2.0 2.0 21.5 28.0

HONEYWELL

VALVE SIZE

(inches)

of

Minimum required NATURAL GAS pressure

trains (upstream

INLET

BOILER

SIZE

1500 2000

2500

3000

3500

4000

4500

5000

6000

N

ote: For altitude above 1000 feet, contact your local Cl eav er-Broo k s representati

N

atural Gas @ 1000 Btu/c u-ft, specific gravity @

PIPE

SIZE

(inches)

2.0

2.5

2.0

2.5

3.0

2.5

3.0

2.5

3.0

2.5

3.0

2.5

3.0

4.0

2.5

3.0

4.0

HONEYW

VALVE

(inches)

of

ELL

SIZE

2.0 2.3 28.0

2.0 4.8 28.0 2000

2.0 6.5

2.5 5.7

2.0 9.0

2.5 6.8

3.0 6.0

2.5 9.7

3.0 7.1

2.5 11.8

3.0 8.5

2.5 9.8

3.0 5.6

2.5 12.9

3.0 7.1

4.0 5.6

2.5 17.5

3.0 10.0

4.0 7.9

0.65

at

entrance

gas pressure

PRESSUR E REQ UIRED

MIN ("W .C.) MAX ("W.C.)

at

entrance

gas pressure

PRESSUR E REQ

MIN

("W.C.)

MAX

to

regulator)

to

regulator)

UIRED

("W .C.)

28.0

STANDARD

REQ UIRED FUEL

OVERSIZED

REQ UIRED

FLOW

ve.

1500 - 6000 MBTU/hr

UL, FM, &

FLOW (SC FH)

1500 2000

3000 3500

4000

5000 6000

UL, FM, &

FUEL

(SC FH)

1500

XL GAP gas

2500

3000

3500

4000

4500

5000

6000

Section B2-13

Rev . 03-08

(

)

(

)

Model 4

Table

B2-7.

B2-8.

Minimum required PROPANE GAS pr essure

trains (upstream

INLET

BOILER

SIZE 1500

2000 2500 3000 3500 4000 4500 5000

6000 N Propane @ 2500 Btu/cu-ft, specific gravity @

ote: For altitude above 1000 feet, contact your local Cl eav er-Broo k s representati

SIZE

inches

1.5

2.0

PIPE

HONEYW

VALVE

inches

of

ELL

SIZE

1.5 6.7 28.0

1.5 10.5 28.0 800

1.5 13.3 28.0

1.5 17.0 28.0

2.0 14.3 28.0

2.0 16.5 28.0 1600

2.0 14.8 28.0

2.0 16.4 28.0

2.0 19.6 28.0 2400

1.6

Minimum required PROPANE GAS pressure

trains (upstream

BOILER

SIZE

1500 2000

2500

3000

3500

4000

4500

5000

6000

N

ote: For altitude above 1000 feet, contact your local Cl eav er-Brook s representati

Propane @ 2500 Btu/cu-ft, specific gravity @

INLET

PIPE

SIZE

(inches)

2.0

2.5

2.0

2.5

3.0

2.5

3.0

2.5

3.0

2.5

3.0

2.5

3.0

4.0

2.5

3.0

4.0

HONEYW

VALVE

(inches)

of

ELL

SIZE

2.0 5.9 28.0

2.0 9.0 28.0

2.0 10.8

2.5 10.5

2.0 13.8

2.5 12.9

3.0 12.6

2.5 13.6

3.0 12.6

2.5 15.8

3.0 14.5

2.5 13.8

3.0 12.1

2.5 14.8

3.0 12.5

4.0 12.0

2.5 18.0

3.0 15.0

4.0 14.1

1.6

at

entrance

gas pressure regula

PRESSUR E REQ

MIN

("W.C.)

at

entrance

UIRED

MAX

gas pressure regula

PRESSUR E REQ

MIN

("W.C.)

MAX

1500 - 6000 MBTU/hr

to

STANDARD

tor)

("W .C.)

UL, FM, &

REQ UIRED

FLOW

(SC FH)

600

FUEL

1000 1200 1400

1800 2000

ve.

to OVERSIZED UL, FM, &

tor)

UIRED

("W .C.)

28.0

ve.

REQ UIRED

FLOW

(SC FH)

600 800

1000

1200

1400

1600

1800

2000

2400

FUEL

XL GAP gas

Section B2-14

Rev . 03-08

Model 4

Boiler

1500 2000

2500 3000

3500 4000

4500 5000 6000

VALVES

Size

REQ'D

1 1

1 1 1

** Fem ale Pipe T hread Connection

PERFORMANCE DATA

Efficiency

Table

B2-10.

Efficiency

For high representative

Predicted efficiency,

Boiler Size

1500 2000

2500 3000 3500

4000 4500 5000

6000

15 PS I G

OUTLET

(IN.)**

'D

G

150 P S I G

OU

TLET

based

O

Firing R at

.)**

(IN

on low

il Fuel

Table

B2-9.

STEAM

SIZE

2

3161

2

3161

2

3161

2

3161

2

3161

2-1/2

4676

2-1/2

4676

2-1/2

4676

3

6942

data

provided

pressure

for

10

Gas Fuel

Firing Rate

Low Fire

81.6 81.9 84.1 84.4

81.1 80.0 83.6 82.5

81.6 81.5 84.1 84.0

81.3 80.3 83.8 82.8

81.6 81.5 84.1 84.0

81.3 80.7 83.8 83.0

81.1 80.9 83.6 83.4

81.3 80.0 83.8 82.5

81.6 79.8 84.1 82.4

Safety valve outlet size

SAFE TY VALVE SETTI N

VALVE

C APACITY

lbs/hr 1 1 lbs/hr 1 1-1/4

lbs/hr 1 1-1/4 lbs/hr 1 1-1/4

lbs/hr 1 1-1/2 lbs/hr 1 1-1/2

lbs/hr 1 1-1/2 lbs/hr 1 1-1/2 lbs/hr 1 2

[FPT]

in

Table

VALVES

REQ

B2-10 is

steam operation contact your local

expected efficiency

data.

psig operating (includes radiation and convection lo

High Fire

Low Fire H

1500 - 6000 MBTU/hr

STEAM

SIZE

e

VALVE

CAPACITY 1651

lbs/hr

2585

lbs/hr

2585

lbs/hr

2585

lbs/hr

4240

lbs/hr

4240

lbs/hr

4240

lbs/hr

4240

lbs/hr

6596

lbs/hr

pressure steam

Cleaver-Brooks

igh Fire

operation.

authorized

sses)

Section B2-15

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Emissions The following tables give typical emission levels for Nature Gas and No. 2 Oil.

Please guarantee

contact your local

is required.

Cleaver-Brooks authorized representative

if an emission

Table

B2-11.

CO

NOx

SOx

HC/

VOCs PM

data - Natural Gas

POLLUTANT UNCONTROLLED

ppm lb/MMBtu ppm lb/MMBtu ppm lb/MMBtu ppm lb/MMBtu ppm lb/MMBtu

Model 4 emission

xx200

0.15 100

0.12

1

0.001 40

0.016

–

0.01

HC/ VOCs

PM

NOTES: Based on fuel oil constituent levels: Fuel bound nitro gen = 0.05% (max) by weight . Sulfur = 0.5% (max) by weight. Ash = 0.01% (max) by weight.

B2-12.

POLLUTANT UNCONTROLLED

ppm lb/MMBtu ppm lb/MMBtu ppm lb/MMBtu ppm lb/MMBtu ppm lb/MMBtu

CO

NOx

SOx

Model 4 emission

data

- No. 2 Oil

90

0.07 187

0.248 270

0.515

50

0.025

–

0.025

ENGINEERING DATA

Feedwater

The following Additional information may be representative.

Steam boilers require make-up combination of 100% raw make-up. Proper treatment of make-up water and boiler water is essential of make-up required and Table B2-14 shows the guidelines.

As a minimum, raw feed tank, which also can be the container that returns. up line

feeding

engineering

condensate

to the

longevity

make-up

Chemical feed

the boiler.

information is provided for the Model 4 steam boiler.

obtained

water for

return and raw make-up, 100%

and

performance

should be piped into a water

is

recommended

from your local

steam production.

of the boiler .

Cleaver-Brooks

This

Table

B2-13

recommended

softener

receives

the system

make-up

condensate

shows

water quality

and then to a

authorized

can be a

return or

the rate

condensate

to be fed via a quill into the water make-

Section B2-16

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Table

B2-13.

Feedwater makeup

rates

Table

B2-14.

Water quality

parameters

Boiler

Size 1500 2000 2500 3000 3500 4000 4500 5000 6000

Gallons/Minute

2.5

3.3

4.1 5

5.8

6.6

7.5

8.3

9.9

Parameter

Ox ygen

Specific

Suspended

Total

pH

Iron

Conductivity

Solids

Hardness

Boiler W ater

8.3 -

10.5

0.1

ppm

0.1

mg/liter

2000 µ

mho/cm

300

ppm

0 ppm as

CaC O

Limit

3

Blowdown As steam is produced, unwanted solids are left behind in the boiler water and

Boiler Stacks

become concentrated to the heat transfer Their removal requires proper blowdown that will include bottom and possibly surface blowoff. For proper device is recommended. Local codes will dictate the manner of treating the blowdown affluent.

General

- The Model 4 boiler temperature that is pressure

Proper design

design.

and installation of the flue operation of the burner. The vent should be clearances vent

The design

from

passes through

of the stack connection. it is

necessary Consideration unusually design

of the

w.c. (+62

to

of the draft must be given where lengthy runs of breeching or

high

stacks

stack

Pa)

for not pertain to the boiler room; that is, the boiler room must be neutral or slightly positive, never negative

When two or more Model 4 boilers are one should

evaluate sequencing while boilers are firing. It may be determined that some type of mechanical draft system be employed to ensure proper draft at each boiler is maintained.

Combustion Air - The burner

of

uncontaminated shall be free of chlorides, halogens, fluorocarbons, construction dust or other contaminants

Combustion

that

air can be supplied by means of

combustion air drawn from the area immediately

within the vessel. If

surfaces,

non-condensing.

combustible

they will impede the flow of

TDS

control, surface blowoff with a TDS monitoring

operates

with a

Therefore, the stack must be a positive

materials. Use insulated vent pipe

walls and roofs.

stack

and

breeching

must

Although constant pressure

size

the

breeching

are employed.

and

breeching

proper

the

light

when

affects

offs

using

for

air to support

are detrimental

and stack to limit flue

Please

is

negative

and

combustion.

air from the boiler

of

pressure variations

each boiler

proper combustion

to the

burner

these constituents

positive

gas venting

vent

is critical to efficient and safe

designed

provide

the

required

at the flue

note: the

allowable pressure range

0.25" w.c. (-62

NOTE:

room

connected

to a common

that may occur during boiler

must be

supplied

and

or boiler

heating

conventional

surrounding

are

allowed

energy

pressure

to adhere

into the water.

and a vent gas

with proper supports and

spacers

draft at

gas

outlet is not required,

gas pressure

Pa)

to a

This pressure range

where the

each

variations.

positive

boiler

0.25" does

for combustion.

breeching/stack,

with

adequate

equipment

ventilation. Air

volume

surfaces.

venting, that is,

with

the boiler (boiler

for

Section B2-17

Rev . 03-08

Model 4

room is neutral or slightly positive boiler room where of the

method,

-

NFGC)

for U.S. installations and

air is drawn

all

installations

directly

must

installations.

Engineered Design

"Engineered Design" method

the must be

A. Two

given

permanent recommended. Locate one of 7 feet. This

B. Air supply

covered

be and is

C.

A vent fan in the boiler room is n ot

with a fine

subject

vacuum under certain conditions air . This can result in

Size

forbidden

foot. the

openings

D. It is square

E. cubic feet per minute of air; fpm

Amount

F.

1.

Combustion

of air

- When

determining

may be

to the

openings

to

air supply

allows

clogging

size

of the boiler room, airflow, and air

openings

at

each end

air to

sweep

can be

mesh

louvered

wire,

with dirt and dust.

and

unsafe burner

to

have

the total

by

using

the formula

a

required

(cfm):

Air = Maximum boiler

as

=

1500 - 6000 MBTU/hr

pressure),

from the comply CAN/CSA

boiler room air

of the

the

length

for

this

cause variations

performance.

area

of the air supply

feet per minute of air.

horsepower

or with a direct vent to outside the

with

exterior

NFPA

of the building. Re

54 (National

Fue l Gas

B149/.1 and B149.2 for Canadian

used. Following

requirements

this method,

velocity

for the boiler,

consid

as follows:

in the outer walls o f the boiler room are

boiler

room,

preferably below

of the boiler .

weather protection,

type

of

covering has poor

recommended

Refer

to

Figure

but they should not

air flow qualities

as it could create a slight

in the quantity of combustion

(Area

in ft2 =

openings

cfma/fpma),

at

less

where

(bhp) times 8 cfm.

gardless

Code

eration

a height

B2-3.

than one

cfma =

2.

Ventilation

3. Total Air feet of

G.

1.

2.

added

Acceptable From Above

Example Determine

4 boilers at 750 feet air

openings

The

total boiler

From

F.3

Air

Velocity: From

Area

required: From the formula in E

Air = Maximum boiler

=

10 cfm per bhp (up to 1000 feet

horsepower

elevation).

air

velocity

in the boiler

room

floor to 7 feet high = 250 fpm.

7 feet from boiler

of

required

the

air

area

of the boiler room air supply

will be 5 feet

horsepower

above,

total air

G.1

room

floor = 500 fpm.

openings (Engineered

elevation;

above

each

have

the floor level.

(bhp): 107 x 2 = 214 bhp.

required = 214 bhp x 10 = 2140 cfm.

above = 250 fpm.

above,

(bhp) times 2 cfm. elevation,

add 3%

more

per

1000

(fpm):

Method):

openings

for [2]

size

4500 Model

a rating of 107 boiler horsepower. The

2140 cfm/250 fpm = 8.56 square

feet total. Area opening:

8.56 divided by 2 = 4.28 ft2 per

opening

(2 required).

Notice

Consult local codes, which may supersede these

See Table

B2-15 for

combustion

air and flue

requiremen

gas

flow.

ts.

Section B2-18

Rev . 03-08

Model 4

Fuel Consumpi

Combustion

Flue

Gas

FRESH

AIR OPENING

EXTERIOR

Table

B2-15.

Gas

on

Oi l

Gas

Air

Oi l

Gas

Oi l

Notes: A. Gas consumption, expressed in c ubic feet per hour, is

cfh gph

scfh lb/hr

scfh lb/hr scfh lb/hr scfh lb/hr

B.

Oil

C

. Oil supply lines must be sized for 125 gph pumping rate. Oi l pump suction press ure to be -10" Hg to 3

Figure

WALL

Model

consumption,expressed

B2-3.

4 fuel,

1500 2000 2500 3000 3500 4000 4500

1500 1500 2500 3000 3500 4000 4500

10.72 14.29 17.86 21.43 25.00 28.57 32.14 35.71 42.85

15,480 20,640 25,800 30,960 36,120 41,280 46,440 51,600 61,920

1207 1609 2012 2414 2817 3219 3621

17,049 22,733 28,414 34,098 39,782 45,463 51,147 56,831 68,196

1269 1692 2115 2538 2961 3384 3808

17,520 23,360 29,200 35,040 40,880 46,720 52,560 58,400 70,080

1,278 1,704 2,130 2,556 2,983 3,409 3,835 4,261 5,113

17,914 23,886 29,855 35,827 41,799 47,769 53,741 59,713 71,655

1,357 1,809 2,261 2,714 3,166 3,618 4,070 4,523 5,427

Boiler room air supply - “Engineered

GA

S

VE

NT

combustion

in pounds per hour, is based on 140,000 Btu/gal oil

air,

and flue gas flow

Boiler Si

ze

bas

ed on 1,000 Btu/cu.ft gas

Design”

1500 - 6000 MBTU/hr

rates

5000 6000

4024 4828

4231 5077

val ue.

value.

psig.

FRESH

AIR OPENING

EXTERIOR

WALL

Section B2-19

Rev . 03-08

Model 4

Oil Piping

Gas Piping

1500 - 6000 MBTU/hr

General

burner mounted oil pump. As the combustion of oil utilizes mechanical atomization, the

Oil

The oil flows through a primary or valve and the low fire valve are safeguard control and when

As the close to purpose balancing

High fire rating of the proper

General

for proper operation and long burner life. The gas section must be satisfied to must follow these guidelines and of the local authorities that have installation jurisdiction.

Gas Train Component s

the requirements of UL as standard. These components also comply with the recommendations gas train and its highest combustion

Gas Pressure Requirements

requires a stable gas pressure supply . The pressure requirements are listed in previous sections for standard gas train size, and available

Gas Piping

If upstream additional upstream regulator should

For buildings or boiler rooms with gas supply lockup" type In addition to the be provided upstream of the regulator for use as a service valve. This is also required tests.

Drip any dirt, weld slag, or gas train. The bottom of the drip leg should be any supports

All NFPA fittings, normally Schedule

- Oil operation of the Model 4 boiler line

sizing

suction side

of the pump.

Train Comp onent s

to the pump must be

- Oil flow to the

opened,

damper

energize

of the

oil

- The Model 4 boiler

motor

moves

in

sequence,

intermediate valve

the oil input with

burner

pressure

and

normally sized

to high fire position, the

the

is to

increasing

is

obtained

requires appropriate gas

ensure

- Model 4

of FM, XL

components

boilers

GAP

(formerly

have been

efficiency.

- For proper and safe

pressure.

- Model 4 units are pressure

regulator

to

provide positive

legs are requir ed

gas

piping. The

and not

gas

piping and

54, local

valves,

codes,

or pipe

to the standard regulator will be greater than 1 psig, an

is

recommended

regulator,

on any

debris

connected

supported

components

and utility should

standardly equipped

a plug type or

shutoff and

vertical

can deposit in the drip leg rather than into the boiler

piping to the boiler should be

by the boiler

to the boiler

requirements

be used.

40 black iron pipe and fittings.

requires

proper oil to the standard

pressure

sufficient

burner

safety

is

shutoff

controlled

energized simultaneously

to

provide

by four

valve

into a manifold block. This

125 gph of oil to

solenoid

by the flame

valves.

allow flow of oil to the low fire nozzle.

intermediate

smooth

the

damper

and then high fire oil valve. The

transition

motor end switches

from low to high fire by

flow of air.

when all

three nozzles are

firing, assuming

nozzles.

supply

requirements

pressure

and volume

specified in this

efficient and stable combustion. Installation

are

equipped

IRI/GE GAP)

designed

be

provided

pressure exceeding

along with proper

"butterball"

isolate

the boiler

piping at the

gas

train or the bottom of the drip leg.

gas

train

as a minimum. Only

Standard industry practice

with a

and

gas

train that meets

ASME

CSD-1. The

and tested to operate for the

operation,

oversized

with a

each Model 4 boiler

trains for

gas pressure

pressure

relief valve.

regulator.

28" w.c., a "full

type

gas

gas supply

removable

connection

overpressure

gas

shutoff cock should

train

to

each

without disassembl

supported

must comply

protection.

during gas

boiler so that

from pipe

gas

approved

for

gas

piping is

reduced

piping

with

ing

Section B2-20

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Gas Supply Pipe Sizing

recommend drop from the

that the gas pipe be sized to allow no more than 0.3" w.c.

source (gas header supplier (utility) should be pressure

are provided to the building at the supply pipe (for installations of new boilers into an should

A than the boiler

be

survey

measured

of all

connected

are connected made of how much flow volume (cfh one

time and the

The

total

length piping. Total to the final

pressure

of

equivalent

connection. As B2 - 20 should be used. The data in these tables is from the 2006 edition.

- For

proper operati on

or utility meter) to the final unit location. The gas

consulted

with a

manometer

gas using

to the

drop

gas

piping and all fittings must be

length should be

a minimum

to confirm that sufficient volume and normal

to

ensure sufficient pressure

devices

gas supply

=

cubic feet per hour) will be

requirements

calculated

guideline, gas

of a

single

discharge

unit or multiple units, we

side of the gas meter or

existing

building, gas pressure

should be mad e. If

line, then a

when all

determination should

appliances are

considered when sizing

from the utility meter or source

piping

Tables

pressure

is available).

appliances

demanded

operating.

the gas

B2 - 16 through

NFPA source

other

be

at

book,

Section B2-21

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Table

B2-16.

Nominal

Actual I.D.

Length

in feet

10 20 30 40 50 60 70 80

90 100 125 150 175 200

**Fuel:

**Inlet

Pressure: Less than

**Pressure Drop:

**Specific Gravity:

Table

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

Actual I.D. 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"

Length in feet **Maximum Capacity in Cubic Feet ofGas per Hour (cfh)

10

20

30

40

50

60

70

80

90 100 125 150 175 200

**Fuel: Natural Gas

**Inlet Pressure: Less than 2.0 psi

**Pressure Drop: 0.50" w.c.

**Specific Gravity: 0.60

1.049 1.380

Natural

B2-17.

Gas line capacity - Schedule

Pipe Size

1

"

1-1/4

"

1-1/2"

"

1

514 363 284 243 215 195 179 167 157 148 131 119 109 102

Gas

2.0 psi

0.30" w.c.

0.60

.610"

**

Maximum Capacity

1,060 1,580 3,050 4,860 8,580

726 1,090 2,090 3,340 5,900 583 873 1,680 2,680 4,740 499 747 1,440 2,290 4,050 442 662 1,280 2,030 3,590 400 600 1,160 1,840 3,260 368 552 1,060 1,690 3,000 343 514 989 1,580 2,790 322 482 928 1,480 2,610 304 455 877 1,400 2,470 269 403 777 1,240 2,190 244 366 704 1,120 1,980 209 336 648 1,030 1,820 185 313 602 960 1,700

2

in

Cubic Feet of Gas per Hour

Gas line capacity - Schedule

Pipe Size

678 1,390 2,090 4,020 6,400 11,300 23,100 466 957 1,430 2,760 4,400 7,780 15,900 374 768 1,150 2,220 3,530 6,250 12,700 320 657 985 1,900 3,020 5,350 10,900 284 583 873 1,680 2,680 4,740 9,600 257 528 791 1,520 2,430 4,290 8,760 237 486 728 1,400 2,230 3,950 8,050 220 452 677 1,300 2,080 3,670 7,490 207 424 635 1,220 1,950 3,450 7,030 195 400 600 1,160 1,840 3,260 6,640 173 355 532 1,020 1,630 2,890 5,890 157 322 482 928 1,480 2,610 5,330 144 296 443 854 1,360 2,410 4,910 134 275 412 794 1,270 2,240 4,560

2"

.067"

40

2-1/2"

2.469

40

metallic

"

metallic

pipe

3

"

3

.068" 4.026"

(cfh)

17,500 12,000

9,660 8,290 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460

pipe

4"

Section B2-22

Rev . 03-08

Model 4

Table

B2-18.

Gas line capacity - Schedule

Pipe

Siz

e

40

metallic

1500 - 6000 MBTU/hr

pipe

Nominal

Actual I.D.

Length

feet

10 20 30 40 50 60 70 80

90 100 125 150 175 200 500

1000 1500

1/2" 3/4"

0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068"

in

1,510 3,040 5,560 11,400 17,100 32,900 52,500 92,800 189,000 1,070 2,150 3,930 8,070 12,100 23,300 57,100 65,600 134,000

869 1,760 3,210 6,590 753 1,520 2,780 5,710 673 1,360 2,490 5,110 615 1,240 2,270 4,660 569 1,150 2,100 4,320 532 1,080 1,970 4,040 502 1,010 1,850 3,810 462

954

414

836

372

751

344

695

318

642

192

401 132 106

**Fu

**Inlet

275

221

el: Natural Gas

Pressure:

1"

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

**Maximum Capacity

1,710 3,510 1,530 3,140 1,370 2,820 1,270 2,601 1,170 2,410

717

1,470

493

1,010

396

812

2.0 psi

2"

2-1/2

"

3"

in

Cubic Feet of Gas per Hour

9,880 19,000 30,300 53,600 109,000 8,550 16,500 26,300 46,400 94,700 7,650 14,700 23,500 41,500 84,700 6,980 13,500 21,400 37,900 77,300 6,470 12,500 19,900 35,100 71,600 6,050 11,700 18,600 32,800 67,000 5,700 11,000 17,500 30,900 63,100 5,260 10,100 16,100 28,500 58,200 4,700 9,060 14,400 25,500 52,100 4,220 8,130 13,000 22,900 46,700 3,910 7,530 12,000 21,200 43,300 3,610 6,960 11,100 19,600 40,000 2,210 4,250 6,770 12,000 24,400 1,520 2,920 4,650 8,220 1,220 2,340 3,740 6,600

(cfh)

4"

4.026"

16,800 13,500

**Pressure Drop:

**

Specific

1.0 psi

Gravity:

0.60

Section B2-23

Rev . 03-08

Model 4

Table

B2-19.

Gas line capacity - Schedule

Pipe

Siz

e

40

metallic

1500 - 6000 MBTU/hr

pipe

Nominal

Actual I.D.

Length

feet

10 20 30 40 50 60 70 80

90 100 125 150 175 200 500

1000 1500

1/2" 3/4"

0.622 0.824 1.049" 1.380" 1.610" 2.067"

in

2,350 4,920 9,270 19,000 28,500 54,900 87,500 155,000 316,000 1,620 3,380 6,370 13,100 19,600 37,700 60,100 106,000 217,000 1,300 2,720 5,110 10,500 15,700 30,300 48,300 85,400 174,000 1,110 2,320 4,380 8,990 13,500 25,900 41,300 75,100 149,000

985 2,060 3,880 7,970 11,900 23,000 36,600 64,800 132,000 892 1,870 3,520 7,220 10,300 20,300 33,200 58,700 120,000 821 1,720 3,230 6,640 764 1,600 3,010 6,180 717 1,500 2,820 5,800 677 1,420 2,670 5,470 600 1,250 2,360 4,850 544 1,140 2,140 4,400 500 1,050 1,970 4,040 465

973 1,830 3,760

283

593 1,120 2,290 195 156

**Fuel:

**Inlet

407

327

Natural

Pressure:

1"

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

**Maximum Capacity

897

1,380

616

1,270

Gas

3.0 psi

2"

2-1/2"

2.46

9" 3.068"

in

Cubic Feet of Gas per Hour

9,950 19,200 30,500 54,000 110,000 9,260 17,800 28,400 50,200 102,000 8,680 16,700 26,700 47,100 8,200 15,800 25,200 44,500 7,270 14,000 22,300 39,500 6,590 12,700 20,200 35,700 6,060 11,700 18,600 32,900 5,640 10,900 17,300 30,600 3,430 6,610 10,300 18,600 2,360 4,550 1,900 3,650

7,240 5,820

(cfh)

12,000 10,300

3"

4"

4.0

26"

96,100 90,300 80,500 72,900 67,100 62,400 38,000 26,100 21,000

**Pressure Drop:

**Specific Gravity:

2.0 psi

0.60

Section B2-24

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Table

B2-20.

Gas line capacity - Schedule

Pipe

Siz

e

40

metallic

pipe

Nominal

Actual

I.D.

Length

in feet

10 20 30 40 50 60 70 80

90 100 125 150 175 200 500

1000 1500

1/2

"

3/4"

0.622

0.824

3,190 6,430 11,800 24,200 36,200 69,700 111,000 196,000 401,000 2,250 4,550 8,320 17,100 25,600 49,300 78,600 139,000 283,000 1,840 3,720 6,790 14,000 20,900 40,300 64,200 113,000 231,000 1,590 3,220 5,880 12,100 18,100 34,900 55,600 1,430 2,880 5,260 10,800 16,200 31,200 49,700 1,300 2,630 4,800 1,200 2,430 4,450 1,150 2,330 4,260 1,060 2,150 3,920

979 1,980 3,620 876 1,770 3,240 786 1,590 2,910 728 1,470 2,690 673 1,360 2,490 384 264 212

**Fuel:

**Inlet

802 551 443

Pressure:

Natural

1"

1-1/4"

1.049" 1.380" 1.

**Maximum Capacity

9,860 14,800 28,500 45,400 9,130 13,700 26,400 42,000 8,540 12,800 24,700 39,300 8,050 12,100 23,200 37,000 7,430 11,100 21,400 34,200 6,640 9,950 19,200 30,600 5,960 8,940 17,200 27,400 5,520 8,270 15,900 25,400 5,100 7,650 14,700 23,500

1,510

3,100 4,650 8,950 14,300

1,040

2,130 3,200 6,150

834

1,710 2,570 4,940

Gas

5.0 psi

1-1/2

"

2"

2-1/2"

610" 2.067" 2.469"

in

Cubic Feet of Gas per Hour

9,810 7,880

3"

3.068"

(cfh)

98,200 200,000 87,900 179,000 80,200 164,000 74,300 151,000 69,500 142,000 65,500 134,000 60,400 123,000 54,000 110,000 48,500 98,900 44,900 91,600 41,500 84,700 25,200 51,500 17,300 13,900

4.026"

35,400 28,400

4"

**Pressure Drop:

**Specific Gravity:

3.5 psi

0.60

Section B2-25

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Figure

B2-4.

Typical gas header

piping

Section B2-26

Rev . 03-08

Model 4

Model

4

Boiler

1500 - 6000 MBTU/hr

Steam Specifications

Submittals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-28

Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guarantees

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Design Product Burner Management System Shop

Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start–Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-28

Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-28

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-33

Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-34

and

Maintenance Manuals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-35

. B2-28 . B2-28

. B2-34 . B2-34 . B2-34

SAMPLE SPECIFICATIONS

The following sample specifications are provided needs

and application.

by

Cleaver-Brooks

to

assist

you in

specifying your customer ’s

specific

Section B2-27

Rev . 03-08

Model 4

PART

1

GENERAL

1.1

SUBMITTALS

A.

B.

C.

1.2

C

ODES

A.

B.

C. All

D.

E.

1.3 GUARANTEES A.

2 PRODUCTS 2.1 TYPE

A.

B.

C.

D.

2.2

DESIGN A.

B.

C. The

D.

The manufacturer indicating all

shall supply

relevant

unit

dimensions,

clearances. The manufacturer

diagram

to

include

power supply

The manufacturer

report, to the

shall supply

all

internal

requirements.

shall

supply a copy

purchaser,

upon

unit wiring,

completion

The

boiler shall be

accordance

in The

boiler shall be wired in

National

Electric Code.

electrical equipment

Laboratories requirements.

designed, construct ed,

with the

ASME

Boiler and

accordance

shall be in

conformity

The complete boiler–burner package Underwriters Laboratories

The

boiler shall be built to

.

The complete

(Factory

boiler materials and/or workmanship months from

The

boiler shall be a

membrane The

boiler shall be a

steel

duty

The

boiler shall

shipment

walls.

frame.

have

and shall

comply

with the following insurances

Mutual,

package

shall be

for a

or 12 months from unit start–up.

watertube

type

three gas pass

an

integral forced

controls. The

boiler shall be a

=

No. 2 oil, 200 = No. 2 oil and

Cleaver Brooks Model

gas,

CRITERIA

The

boiler shall be Pressure Code

and

designed

in

accordance

Section (IV for low

pressure). The

boiler shall be

The maximum operating pr essure

500).

boiler shall be

steam,

hr of lbs/hr

of

temperature

or bhp.

steam

of

Electrical power available

Hz.

designed

when

for psig (15, 150, 250, 350, or

for a

maximum

The

operating

°F.

at psig with a feedwater

will be volts, phase,

1500 - 6000 MBTU/hr

copies

boiler shall de

of a

dimensional

layout and required

of a

ladder

type wiring

external connections,

of the

authorized

and

shipment

and

hydrostatically

inspection

Pressure Vessel

with the

rules

of the

with the Underwriters

shall be

bear

approved

a UL label.

by

XL-GAP, ASME CSD–1)

warranted

period

steam

type boiler

draft

from

defects

of not

less

than

boiler with all steel

mounted

burner

and burner

4, series

700 = gas) steam

with the

pressure,

ASME

I for high

will be psig.

output of lbs/

velop

drawing

and

of the

unit.

tested

Code.

in

18

on a heavy

(

100

boiler.

Boiler

Section B2-28

Rev . 03-08

Model 4

2.3

The maximum sound level

E.

in front of the boiler.

PRODUCT A.

DESIGN

Pressure Vessel

1.

The upper

53 Gr. B

0.3 The

2.

SA–53

0.3 The generating tubes

3.

seamless

75".

lower drum shall

Gr . B

22".

178 Gr. A tubing, with a minimum wall

4.

The

boiler shall the boiler, and be totally These

shall be a minimum of 2–1/2"

SA–178 Gr . A tubing, with a minimum wall The upper

5. rear

the

of the unit, to allow internal

minimum of 4"x6".

6.

The

lower drum shall

front and

rear

be a minimum of 4-7/8" x The

7.

boiler shall

area.

8. A

feedwater

shall be

located

blend the

3/4"

9. A

head

10. A

surface

of the

"

bottom blowoff

lower drum.

Refr

1.

actory

Refractory

B.

lower drum, and to the

2. High

temperature insulation

of the furnace.

C.

Insulation

1.

2.

and

Casing

The

boiler

cover

shall The insulation

lagging. The

3.

4.

metal

removal The

front

and

head (windbox) gasket sealed, provide tile.

full

shall not

drum shall

have

a 20"

pipe, with a minimum wall

have

an 8–5/8"

seamless

pipe, with a minimum wall

shall be 2"

have

two

downcomers, located

insulated

drum shall

have

an

have inspection ope nings, located

of the unit, to allow

5-7/8".

have inspection openings

tapping and

in the

feedwater

blowoff

upper

drum.

integral feedwater

upper

drum.

with the boiler water.

connection

shall be limited to the

burner

shall be

insulation

the

lagging

installation

shall be a minimum of 2"

entire pressure

shall be

and

covered

insulation

if required.

shall be

and bolted.

access

to the

The

furnace chamber

1500 - 6000 MBTU/hr

exceed

inspection opening, located

throat tile.

vessel.

80

dBA measured

OD, manufactured

thickness

OD, manufactured

thickness

OD, manufactured

thickness

from SA–

of 0.095".

at the

from the

generating

OD, manufactured

thickness

inspection,

and shall be a

internal inspect ion, and

in the

convection

distribution pipe

The

distribution pipe shall

shall be

furnace

located

shall be

floor to

installed

in the rear

located

insulate

on the front wall

fiberglass,

with a

front

corrugated

shall be

attached

head

metal

arranged

for easy

with a davit arm,

shall swing

and

burner

3 feet

from

of

from

rear

tubes.

from

of .105".

at the

in the

open

throat

SA–

of

at

shall

the

and

to

Section B2-29

Rev . 03-08

Model 4

5.

6. Two lifting

7.

Trim

D.

1.

2. A

3.

4.

5. A

6. A

7. A high limit

8.

9. A firing

10. An

11. A

Soot Cleaning

E.

1.

2.

3.

1500 - 6000 MBTU/hr

Observation ports shall be provided visual inspection

The exhaust gases

of the pilot and main flame conditions.

eyes

shall be

shall

located

vent

centerline.

The water column It shall be piped with

gauge glass

column The

integral actuation

blowdown valve

boiler

feedwater control

item of the water column. It shall

of a motor

maintain the boiler water The primary

shall

be located

unions

set,

gauge glass blowdown valve,

shall be provided.

switch shall be

driven feedwater

level

low

water

cutoff switch shall be an the water column. It shall be wired into the circuit below the

boiler and shall include a

comply with set

manual operation

An operating provided

rate of the

type). burner operation designated safe

preventing burner operatio n

designated safe

steam pressure gauge

safety

relief

valve

shall be

ASME Code

pressure

shall be psig.

pressure

reset

type and shall be wired to

and

lockout

limit

control shall be provided. It shall be a

if

control shall be

on– off control of the

rate control

shall be provided. It shall control the firing

burner based

auxiliary

low water cutoff shall be

It shall

be

wired into the

if the boiler water

level.

stack thermometer

shall be

level.

shall be

cock

provided

requirements.

excessive steam pressure

on the boiler load.

installation.

Soot washer lances the boiler

Each lance assembly

measuring

shall be

shall be ensure complete washing boiler is

operating

Soot washer troughs boiler. shall connections

These

The soot washer troughs

at the

cleanout openings

shall be

the full

provided

length

provided

capable

of

of the

in the low fire mode.

shall be

furnished

rear

of the boiler , and shall

at the front of the boiler.

at

each end

on top of the boiler .

at the

rear

of the boiler , on the top

on the left

for

easy

removal.

provide

pump or

within normal

if the boiler water

located

at the front

and test connection.

of a

size

The safety

prevent

provided. It shall

burner

at

operating

provided (manual

burner control

level

falls below the

shipped loose

in the

of the

pressure

with a shutoff

rotating

360 degrees. This shall

convection zone

provided

shall be

at the bottom of the

for

each convection side

provided

of the

boiler

side

of the boiler .

and water

included

as an

automatic

valve

to

limits.

integral

burner

part of

control

level

end

of the

falls

and type to

relief valve

burner

occurs.

be wired

set points.

reset

circuit

preventing

for field

convection area

vessel.

valve

and the

while the

and

with 2" drain

have

inspection/

for

to

of

Section B2-30

Rev . 03-08

Model 4

1500 - 6000 MBTU/hr

Burner Design – General

F.

1.

The burner

2. All air for mounted and vibration level.

The blower

3. minimum

The impeller

4. balanced,

The combustion

5. and shall be

6.

The burner and until main flame has

7. A

combustion

adequate

G.

Burner Design – Gas

The burner

1. approved for

The burner

2. low or full position

3.

Automatic furnished. An monitor the pilot, opening

The single c ombust ion

4. butterfly valve. according control.

Burner Design

H.

The burner

1. operation

The burner

2. must return to the low fire

The burner

3. and until main flame has shall be monitored to confirm the

Automatic electric

4. provided duty electrodes.

shall be

combustion in the

motor shall be an

service

and directly

shall

air for

shall be the high radiant multi–port type

shall

modulation) principle

prior to ignition.

electric ignition of the

until the pilot flame has

to

– No. 2

shall be the

with

shall

with a minimum 10,000 volt

integral

to the windbox.

shall

be supplied

windbox, above

open

factor of

shall be an

1.15.

enclosed centrifugal

connected

air

damper

operated

remain

air

proving

pre-purge

shall be

by a

single damper

in the low fire

been

established.

switch shall be

and combustion.

operation

operate

with natural gas.

on the (low–high–

electric scanner,

preventing

The damper

system demand

Oil

the primary fuel

air

damper

motor shall

in

pressure atomizing

commercial grade

operate

on the

position

remain

presence

in the low fire

been

proven.

with an

electric scanner,

of the low fire oil flame.

ignition of the low fire oil

by a

the

burner,

drip

proof

forced

to minimize noise

draft blower

type with a

fan type, properly

to the

blower

integral

motor shaft.

to the windbox

motor.

position during

and must

premix gas

provided

return

pilot shall be

ignition

to ensure

to the low fire

of the UV principle, shall

valve

from

been

established.

motor shall

response

No. 2

oil.

low–high–low

operate

regulate

the gas

the fire

to the firing rate

type

approved

principle, and

prior to ignition.

position during

The

ignition period

of the

supply

transformer

ignition

UV

principle,

shall be and heavy

Notice

Optional insurance compliance may require a premix gas pilot in lieu of direct ignition.

for

spark

Section B2-31

Rev . 03-08

Model 4

5. [Optional] shall be furnished. An shall confirm the pilot prior to the supply.

The single c ombust ion

6. and high fire oil valves.

according

fire control.

I.

Burner Design – Gas

The burner

1. shall be the approved grade

2.

The burner must return to the low fire

The burner

3. and until main flame has

Automatic

4. furnished. An monitor the pilot, opening

The single c ombust ion

5. and

high fire oil motor shall response

J. Main

Gas Tr

The gas burner piping shall include a primary gas shutoff

1. It shall be

burner

the failure, flame failure, or a low water condition.

2. A manual shutoff gas

valve.

3. A

plugged leakage test connection and a second manual valve primary shutoff valve.

4. A

gas pressure regulator pressure regulation

Gas a.

Train

[Sizes

5.

be [Sizes

b.

be motorized gas pressure switches

[Size

c.

motorized safety shutoff valve and cock switches

Automatic electric

ignition of the

electric scanner,

air

damper

The damper

to

system demand

and No. 2

shall

be

pressure atomizing

for

operation

No. 2

oil.

shall

operate

the high

Oil

radiant multi–port type

for oil.

with either natural

on the

low–high–low

position

shall

remain

in the low fire

been

proven.

electric ignition of the

electric scanner,

preventing

of the UV principle, shall

the primary fuel

until the pilot flame has

air

damper

valves and

regulate

the fire

the

gas butterfly

according

to the firing rate control.

ain

controlled

and to

shall be

provided as a means

by the

programming relay

close automatically

valve

shall be

shall

located ahead

be factory mounted and piped

to the burner.

Components

1500–2500]

motorized

3000–5000]

with a

The proof

The

proof

primary

of

primary of

shall be provided.

6000]

The

with a

primary

proof

of

an

gas

closure

additional plugged leakage

shall be provided. High and low

shall be provided.

1500 - 6000 MBTU/hr

premix gas

of the UV principle,

delivery

motor shall

in

response

prior to ignition.

premix gas

been

motor shall

for a

closure

shutoff

of the low fire oil

operate

motor shall

regulate

to the firing rate

The burner

gas

or commercial

principle, and

position during

pilot shall be

valve

established.

operate

valve.

to

system demand

to start or stop

in the

event

of the primary

tightness check

gas

shutoff

switch.

gas

shutoff

switch. High

valve

shall be

switch. A

gas

pressure

second

must be

The

of power

valve

the low

for

gas

ignition

from

the low

damper

and

pilot

the

and

in

valve.

shutoff

of the

for

shall

low

gas

test

Section B2-32

Rev . 03-08

Model 4

2.4

K. Natural

1. A pilot piped for

The

2.

pilot

controlled

be

3. A manual shutoff pressure

L. 2.3.12 Oil

System

Pilot Tr

gas pressure regulator

ain

pressure regulation gas

train shall by the

include a safety

programming relay

valve

shall be

regulator.

Gas

1. An oil pump shall be provided. burner,

shall include a built–in relief

strainer.

The

2.

3.

oil pump shall be belt

The

fuel oil

system

shall include terminal block, an oil solenoid mounted

oil shutoff valves.

and piped on the front

pressure gauge,

BURNER MANAGEMENT SYSTEM A.

Control

1.

2.

3.

4. A terminal

5.

6. All

7. All

B.

Combustion Safeg uard Control

1. A

Panels

The

control

key

lock.

The

control

boiler and shall be The panel

fuses, control damper selector automatic

leaving

or The panel

conditions load

demand;

switches

panel

shall be a

panel

shall be

conveniently located

shall

contain

circuit

the

transformer,

switch shall be

or manual

board

the

panel

shall

selection

shall be

shall be connected.

include

four

of: red = low water; red = flame failure; white

and white = fuel

shall be

located

electrical service connections

entrance box

electrical

and shall be

to be

mounted

wiring shall be oil, heat, and number

coded.

combustion safeguard provided burner. It shall purge periods

to control ignition, starting, and

provide precombustion

and shall stop

control

ignition, pilot, or main flame failure. T rial for ig nition shall be limited to 10 seconds.

The

2.

boiler shall be

controller

that

Cleaver Brooks Model

provided

provides technology

CB120E.

1500 - 6000 MBTU/hr

shall be

of the pilot

The

driven

These

NEMA

mounted

blower

of low or high firing.

provided

indicating

on the

on the right

burner operation

with a

factory mounted

located ahead

oil pump,

valve

from the

supply

shutoff cock, and four

items shall be factory

head

(windbox).

1 rated

on the front

motor

and

control

provided

to which all

valve

open.

panel

shall be

(program relay)

combustion

and

gas

to the burner.

shutoff valve. It shall

to start the burner.

of the pilot gas

integral

with the

and self–cleaning

blower

motor.

and return tubing to a

panel

and

have

head

of the

for the boiler

starter, control

operator.

circuit

switches. A

to permit

lights to

The

selection

wires

entering

show

operating

lights and

switch ledge.

made

to an electrical

hand side

moisture

of the boiler .

resistant

shall be

stopping

of the

and postcombustion

in the

event

safeguard

functions equal

to the

a

of

=

of

Section B2-33

Rev . 03-08

Model 4

PART

3

EXECUTION

3.

4.

5.

6.

7.

3.1

SHOP A.

TESTS

The pressure vesse l with

The

B.

to

3.2

SHIPMENT A.

Pa

1.

2.

Prepar

B.

1. All boiler

2.

3. All

3.3 INSTALLATION

3.4

S

TART

A.

–UP

The representative manufacturer's

The combustion saf egu ard control based, message center Messages provide sequence status

with

self–diagnostics, non–volatile memory,

with a

shall scroll

vocabulary

across

and flame failure

The combustion safeguard control sequence incapable

include

shall

post–purge

and

start,

The controller safety

that will shut down the minimum the failure, high and low fire interlocks open, false

The controller interruptions

to

of

being manually

pre– purge,

cycles.

shall be the

following

trip

flame

shall

have a test/run

sequence

non–recycle

proving

just after ignition trial, and during run rate motor ,

damper linkages,

tests. The controller

history

of cycles; provide a constant have provisions

shall

also have

operating hours

for

remote display

and totals of

flame

communication.

ASME

shall be

requirements.

hydrostatically tested

boiler will be test fired by the

verify proper

and

safe

operation.

inting

The entire factory

The

painted,

boiler

boiler,

before

surface

base frame,

shipment,

shall be

cleaned/prepared manufacturer's specifications practices.

ation

The boiler resistant

openings

shall be skid

covering.

shall be

mounted

shipped loose components

material

and

packaged

in a

boiler

start–up

shall be

and will be

performed

done

in

recommended procedures.

1500 - 6000 MBTU/hr

shall be microprocessor

and a

of 42

different

an

alpha–numeric display

mode

shall

have

altered.

pilot and main fuel ignition run,

type for maximum

burner

functions:

and indicate as a

pilot failure, main flame

switch faults, running

signal,

and fuel

switch. It will allow pre–purge, during

cycles,

for

adjustments

and pilot flame for turndown

the

following functions:

completed

signal strength read–out;

capability and Modbus

manufactured,

and

other components

using

a hard finish enamel.

and

standard

plugged/covered

and

protected

shall

wrapped

separate

accordance

container(s).

by a

factory

with the

messages.

information.

a fixed operating

The

sequence

valve

open.

pilot

to firing

display

on–off

in

accordance

prior to shipment,

shall be

for painting using

industrial painting

prior to shipment.

with a weather

in protective

trained

and

Section B2-34

Rev . 03-08

Model 4

B.

3.5

OPERATION

Manufacturer

The

boiler

start–up

cover

boiler

unit.

AND

shall supply

shall

include

operation,

water

MAINTENANCE

copies

of the

1500 - 6000 MBTU/hr

boiler

operator

treatment,

and

MANUALS

Operating & Maintenance

training and shall

maintenance

of the

Manual.

Section B2-35

Rev . 03-08

CleaverBrooks Model 4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual