Flextube Operating and Maintenance Guide
Flextube Operating and Maintenance Guide
Flextube Operating and Maintenance Guide
PACKAGED BOILER
10/2009
MODEL FLX
PACKAGED BOILER
Cleaver-Brooks 2009
Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative
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 OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY
UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.
FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
TABLE OF CONTENTS
Chapter 1
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. The Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Steam Controls (All Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Hot Water Controls (All Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2
1-2
1-2
1-4
Chapter 2
ProFire V Burner
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Startup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Burner Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Chapter 3
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Hot Water Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Water Requirements (Steam Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Boilout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H. Washing Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J. Preparation For Extended Lay-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-3
3-4
3-4
3-6
3-6
3-8
3-8
3-9
Chapter 4
Sequence Of Operation
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Circuit And Interlock Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Sequence Of Operation - Oil Or Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Flame Loss Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
4-1
4-1
4-2
4-3
TABLE OF CONTENTS(continued)
Chapter 5
Adjustment Procedures
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
B. Linkage - Modulating Motor & Air Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
C. Modulating Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
D. Modulating Motor Switches Low Fire and High Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
E. Burner Operating Controls - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
F. Modulating Pressure Control (Steam). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
G. Operating Limit Pressure Control (Steam). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
H. High Limit Pressure Control (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
I. Modulating Temperature Control (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
J. Operating Limit Temperature Control (Hot Water). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
K. High Limit Temperature Control (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
L. Low Water Cutoff Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
M. Combustion Air Proving Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
N.Gas Pilot Flame Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
O. Gas Pressure and Flow Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
P. Gas Fuel Combustion Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Q. Low Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
R. High Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
S. Fuel Oil Pressure and Temperature - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
T. Fuel Oil Combustion Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
U. Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Chapter 6
iii
Chapter 7
TABLE OF CONTENTS(continued)
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Periodic Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Fireside Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Upper Pass Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F. Oil Burner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Gas Burner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H. Refractory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I. Casing Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 8
7-1
7-1
7-2
7-2
7-4
7-6
7-7
7-7
7-7
Casing HW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Casing Low Pressure Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Casing High Pressure Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Steam Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Water Level Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Water Column, Main and Aux. - 15# Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Water Column, Main and Aux. - 150# Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
iv
CHAPTER 1
GENERAL DESCRIPTION
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
B. The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
C. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
D. Steam Controls (All Fuels) . . . . . . . . . . . . . . . . . . . 1-2
E. Hot Water Controls (All Fuels) . . . . . . . . . . . . . . . . 1-4
A. General
The information in this manual applies directly to CleaverBrooks FLX Model boilers in sizes ranging from 1,500,000
to 12,000,000 Btu/hr input.
Fuel Series
700- Gas
! CAUTION
DANGER
The care taken in placing the boiler into initial
service is vital to continuous, reliable operation.
If the boiler is to be used for temporary heat (for
example in new construction), properly treated
water must be used. Failure to do so can be
detrimental to the boiler.
100-No.2 0il
200 - Combination Gas & No.2 Oil
Design Pressure
160 psig hot water
15 psig steam
150 psig steam
1-1
Chapter 1
GENERAL DESCRIPTION
B. The Boiler
The Cleaver-Brooks Model FLX is a five-pass steel boiler
with flexible watertubes formed and arranged so as to direct
the flow of combustion gases through the boiler. The pressure
vessel conforms to Section I or IV of the ASME code. The
pressure vessel consists of the formed tubes, the external
downcomer, and the top and bottom drums to which they
connect. The heated area of the pressure vessel is contained
within a gas tight insulated casing that is composed of
removable formed steel panels.
1-2
! CAUTION
DANGER
Waterside care is of prime importance. For
specific information or assistance with your
water treatment requirements, contact your
Cleaver-Brooks service and parts representative. Failure to follow these instructions
could result in equipment damage.
Feedwater equipment should be checked and ready for use.
Be sure that all valves, piping, boiler feed pumps, and
receivers are installed in accordance with prevailing codes
and practices.
Water requirements for both steam and hot water boilers are
essential to boiler life and length of service. Constant
attention to water requirements will pay dividends in the form
of longer life, less down-time, and prevention of costly
repairs. Care taken in placing the pressure vessel into initial
service is vital. The waterside of new boilers and new or
remodeled steam or hot water systems may contain oil, grease
or other foreign matter. A method of boiling out the vessel to
remove accumulations is described in Chapter 3.
The operator should be familiar with Chapter 3 before
attempting to place the unit into operation.
C. Construction
Steam boilers designed for 15 psig and hot water boilers
designed for 250F at 160 psi or less are constructed in
accordance with Section IV, Heating Boilers, of ASME Code.
Steam boilers designed for 150 psig are constructed in
accordance with Section I, Power Boilers, of the ASME
Code.
2.
750-177
GENERAL DESCRIPTION
3.
4.
Chapter 1
5.
Water Column Assembly (Figure 1-2): Houses the lowwater cutoff and pump control and includes the water
gauge glass, gauge glass shutoff cocks.
6.
7.
8.
! CAUTION
DANGER
Determine that the main and auxiliary low
water cutoffs and pump control are level after installation and throughout the equipments operating life. Failure to follow these
instructions could result in equipment damage.
HIGH LIMIT
PRESSURE
CONTROL
OPERATING LIMIT
PRESSURE
CONTROL
MODULATING LIMIT
PRESSURE
CONTROL
STEAM PRESSURE
GAUGE
WATER COLUMN
GAUGE GLASS
DRAIN VALVE
WATER COLUMN
DRAIN VALVE
CONTROL PANEL
FLAME
DETECTOR
FORCED DRAFT
FAN MOTOR
MODULATING
MOTOR
OIL SUPPLY
PRESSURE
GAUGE
OIL SOLENOID
VALVES
750-177
OIL PUMP
1-3
Chapter 1
GENERAL DESCRIPTION
! WARNING
DANGER
Only properly certified personnel such as
the safety valve manufacturers certified
representative can adjust or repair the
boiler safety valves. Failure to follow these
instructions could result in serious
personal injury or death
2.
3.
750-177
GENERAL DESCRIPTION
Chapter 1
5.
6.
7.
WATER
PRESSURE
GAUGE
WATER
TEMPERATURE
GAUGE
750-177
1-5
Chapter 1
GENERAL DESCRIPTION
remove side outlet valves by using a pipe or wrench in
the outlet.
S UP PO RT F R O M B U I L D I N G
C O NS TR U C T I O N
TO S TE AM
VENT
VENT PIPE
D R I P PA N
EXTENSION
D R I P PA N
A N D E LB O W
1 1/ 2
MIN.
! WARNING
DANGER
Only properly certified personnel such as
the relief valve manufacturers certified
representative can adjust or repair the
boiler relief valves. Failure to follow these
instructions could result in serious
personal injury or death.
D R I P PA N
D R AI N
D R I P E LL DR A I N
S A F E T Y VALVE
WAT E R L E V E L
NOTICE: BACK-PRESSURE OF STEAM
EXHAUST SYSTEM MUST BE LESS THAN 6%
OF SAFETY VALVE SETTING.
OPEN DRAIN
TO WA S T E
BOILER SHELL
1-6
750-177
CHAPTER 2
Profire V Burner
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
C. Startup and Operation . . . . . . . . . . . . . . . . . . . . . . .2-17
D. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
E. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
F. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
G. Burner Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
A. Introduction
CB Profire V/Series burners are assembled, wired, and tested
at the factory. The V/Series burner line is listed by the
Underwriters Laboratory for the U.S. and Canada, and bears
the UL and cUL markings when ordered as such by the
customer. Compliance with other regulatory agencies such as
CSD-1, I.R.I./GE GAP, F.M., etc., is available at time of
order.
Optional controls and control systems are also available. The
operator of this equipment must be familiar with the
individual functioning of all controls to understand the
operations and procedures described in this manual, and
supplementary instructions provided with optional controls.
Identify and locate each item in the illustrations as they are
described in the following sections.
! CAUTION
DANGER
2.
3.
4.
5.
6.
SIGNAL LAMPS
a. POWER ON (white) - Illuminates when the control
circuit is energized (powered).
b. IGNITION (amber) - Illuminates when the ignition
ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP, ADJUST,
OR SERVICE THIS EQUIPMENT.
DESCRIPTION
The CB Profire V/Series burners are designed to operate with
natural gas and light oil. The burners are designed for
automatic, unattended operation except for periodic
inspection and maintenance. The control panel components
require little attention except for occasional cleaning.
750-177
2-1
Chapter 2
transformer is powered, and pilot valve is energized
(open).
c. MAIN FUEL (green) - Illuminates when the main
fuel valve or valves are energized (open).
d. FLAME FAILURE (red) - Illuminates when the
flame safeguard system fails to detect pilot or main
flame.
7.
8.
MODULATING MOTOR
Operates the air damper and fuel rate valves through a
linkage system to adjust air-fuel ratios under all load
conditions.
IGNITION TRANSFORMER
Provides high voltage spark for ignition of gas pilot or
main flame direct spark models.
Profire V Burner
air flow with the fuel flow provides efficient combustion at all
firing rates.
OIL SYSTEM
Models Vl-VLG are high pressure atomizing burners using
fuel pressure for atomization. Atomized fuel is discharged
from the nozzle as a fine conical spray.
1.
Size 3 & 4
2.
NOZZLE
NOZZLE ADAPTOR
1.
4.
Air dampers are located in the air inlet housing. The dampers
are mechanically linked and actuated by a two-position motor
or hydraulic cylinder for on-off operation. Low-high-off,
low-high-low, or full modulation burners have the dampers
mechanically linked to the modulating motor.
3.
DIFFUSER
2-2
OIL FILTER
750-177
Profire V Burner
meet load demands. The low fire positions bypass oil back to
the storage tank. At high fire, the metering valve is in the
closed position. The modulating motor positions the metering
valve and the air damper simultaneously.
IGNITION SYSTEM
Oil only models VL-13 to 55 are supplied with direct spark
ignition. Models VL-60 to 168 are supplied with a gas pilot
system. Gas and combination gas-oil models are supplied
with a gas ignition system. The standard pilot gas train
consists of a manual shutoff cock, a gas pressure regulator,
and a solenoid operated gas shutoff valve.
Chapter 2
A pressure actuated switch that remains closed when gas
pressure is above a selected setting. Should the pressure drop
below this setting, the switch contacts will open, causing
main gas valve(s) to close. This switch requires manual reset
after being tripped.
B
A
750-177
2-3
Chapter 2
Profire V Burner
2-4
750-177
Profire V Burner
Chapter 2
A
B
K DIA.
4X 3/4
L B.C.
CL
CL
CL
E
G
S
R
F
H
P
656-00037
STANDARD CONFIGURATION - REAR MOUNTED PANEL, GAS PILOT LINE PANEL MOUNTED
J
G
E
F
H
I
K
L
M
N
P
BURNER
MODEL
SIZE 1
32 7/8
12 3/8
8 1/4
3 3/4
15
9 3/4
30
9 3/4
7 3/8
12 7/8
11 1/4
6 1/2
14 3/8
13
12
5 /14
7 1/4
11 3/4
SIZE 2
37 1/3
13 5/8
10
18 1/8
34 1/2
10 1/2
7 3/8
15
13 1/4
7 1/2
15 1/8
12 1/2
12 3/4
6 1/4
14 1/2
SIZE 3
44 3/8
16 1/8
11 1/2
3 3/4
17 1/2
15 3/4
41 3/4
15 1/4
7 3/8
16 3/4
15 1/4
8 3/8
17 3/8
12 1/2
14 1/8
6 1/4
10 1/4
18 5/8
SIZE 4
54 3/8
24 7/8
13 5/8
25 1/4
12
45 7/8
13 1/2
7 3/8
17 1/2
15 3/8
8 3/4
20 1/8
14 1/2
16
7 1/2
12 1/4
19 1/4
B. Installation
DRAFT CONDITIONS
! !WARNING
DANGER
CAUTION
DANGER
750-177
2-5
Chapter 2
Profire V Burner
! CAUTION
DANGER
THE GASKET MUST BE RESILIENT TO SEAL
ANY UNEVEN AREAS BETWEEN THE BURNER
FLANGE AND THE BOILER FRONT PLATE TO
PREVENT LEAKAGE OF COMBUSTION GASSES.
2-6
750-177
Profire V Burner
Chapter 2
a. Quantity of oil pumped (gph).
b. Length of suction line (feet).
c. Diameter of the suction line.
d. Number of fittings.
GAS PIPING
Gas service and house piping must supply the quantity of gas
demanded by the unit at the pressure required at the burner
gas train inlet.
All piping must be in strict accordance with applicable codes,
ordinances and regulations of the supplying utility. In the
absence of other codes, piping should be in accordance with
the following standards: National fuel Gas Code NFPA No.
54, ANSI No. Z223-1.
Gas train components upstream of the butterfly valve are
shipped loose. These components should be mounted by the
installer as close to the butterfly valve as practical.
Normally, the control train is ordered to suit a particular code
or insurance regulation - such as Underwriters Laboratories/
Canadian Underwriters Laboratories (UL/cUL), Factory
Mutual, or Industrial Risk Insurance.
2.
3.
4.
5.
6.
7.
The vertical lift from the oil level in the tank to the
pump.
2.
3.
The friction loss due to oil flow. This loss varies with:
750-177
Depending on configurations:
separate suction lines for each burner with a common
return line
multiple burners with oil supplied by a transfer pump
a pump supplies oil to the day tank
flooded loop system - the circulating pump is sized
according to the maximum burner firing rate for all
burners plus a 30% service factor
Notice: CB Profire recommends that all oil firing burners be equipped with an oil strainer (if
not included with the burner) to prevent particles from clogging the nozzle. It is essential to
follow the strainer manufacturers maintenance
schedule to ensure proper filtration.
2-7
Chapter 2
Profire V Burner
Figure 2-11: Typical UL Gas Train, Full Modulation System, Size 1 V13 to V34
Figure 2-12: Typical UL Gas Train, Low-High-Off/Low-High-Low, Size 2 V35 to V63, Full Mod System, Size 2-3-4 V35 to V168
2-8
750-177
Profire V Burner
Chapter 2
750-177
2-9
Chapter 2
Profire V Burner
2-10
750-177
Profire V Burner
Chapter 2
INSTALLATION CHECKLIST
1.
2.
3.
4.
5.
Before firing, make sure the burner firing head and dry
areas of the boiler are protected with refractory. The
burner mounting flange must be properly sealed against
the vessel front plate.
6.
750-177
! CAUTION
DANGER
BEFORE OPENING THE MANUAL GAS SHUTOFF
VALVES, READ THE REGULATOR INSTRUCTIONS CAREFULLY. THE INSTRUCTIONS ARE IN
THE REGULATOR BOX. FOLLOW THE MANUFACTURER RECOMMENDATIONS. OPEN SHUTOFF VALVE ON THE INLET SIDE OF THE
REGULATOR SLOWLY AND CAREFULLY TO
ALLOW INLET PRESSURE TO BUILD UP
SLOWLY IN THE REGULATOR UNTIL IT IS FULLY
PRESSURIZED. OPEJNING THE SHUTOFF
VALVE QUICKLY WILL DAMAGE THE REGULATOR. DO NOT EXCEED THE REGULATOR PRESSURE RATINGS.
2-11
Chapter 2
Profire V Burner
FIRING MODES
Different modulation modes are available with the Profire V burner. The Model FLX will utilize one of the
following:
Low - High -Low (60% damper purge).
Low - High -Low (open damper purge).
Full Modulation (open damper purge).
See following pages for operating descriptions of each firing mode.
2-12
750-177
Profire V Burner
Chapter 2
Operating Sequence
COMPONENTS
DESCRIPTION:
Oil
Pressure Atomization: Two solenoid type
safety shut off oil valves initiate the flow of oil
from the high pressure pump to the nozzle.
The oil pump has a built in solenoid controlled
two level pressure regulating system. Low and
high flow rates are set on the pump based on
pressure
and
the
nozzle's
flow
rating.
PRE-PURGE:
STARTUP,
IGNITION:
RUN,
MODULATE:
SHUT DOWN,
POST-PURGE:
VARIATIONS:
750-177
None
None
2-13
Chapter 2
Profire V Burner
Operating Sequence
COMPONENTS
DESCRIPTION
Oil
Pressure Atomization: Two solenoid type safety
shut off oil valves initiate the flow of oil from the high
pressure pump to the nozzle. The oil pump has a
built in solenoid controlled two level pressure
regulating system. Low and high flow rates are set
on the pump based on pressure and the nozzle's
flow
rating.
VARIATIONS
2-14
None
None
750-177
Profire V Burner
Chapter 2
Operating Sequence
COMPONENTS
DESCRIPTION
Gas
Oil
PRE-PURGE
STARTUP,
IGNITION
RUN,
MODULATE
SHUT DOWN,
POST-PURGE
VARIATIONS:
750-177
None
2-15
Chapter 2
Profire V Burner
PARALLEL POSITIONING
Combustion Air
NOTE: Parallel Positioning systems
incorporate independent actuators to
control each of the fuel and air metering
devices. Customizable "curves" can then
be created for each actuator to optimize
burner performance.
COMPONENTS
DESCRIPTION
Operating Sequence
PRE-PURGE
Gas
Safety shut off valve(s) are
provided to initiate the flow of
gas. The primary is a
diaphragm or motorized type
valve which have delayed
opening rates to prevent an "in
rush" of gas. A butterfly type
gas metering valve is directly
coupled to a parallel positioning
actuator. A manually adjusted
gas regulator limits maximum
firing rate.
Oil
Pressure Atomization: Two solenoid type safety
shut off oil valves initiate the flow of oil from the high
pressure pump to a return flow nozzle. In the return
line from the nozzle is an adjustable oil metering
valve which limits the amount of oil allowed to return
to the pump. The metering valve is direct coupled to
a parallel positioning actuator.
STARTUP,
IGNITION
RUN,
MODULATE
SHUT DOWN,
POST-PURGE
VARIATIONS
2-16
None
750-177
Profire V Burner
FIRING PREPARATIONS
Check to make certain that all plugs, connections. linkages,
etc., are tight. Prior to initial firing, oil flow and pressure
should be verified.
750-177
Chapter 2
GAS BURNERS
A representative of the gas utility should turn on the gas.
Determine by a test gauge upstream of the burner regulator
that sufficient pressure exists at the entrance to the gas train.
The gas pressure regulator must be adjusted to the pressure
required and the pressure setting recorded.
On combination fuel models, set the selector switch to gas.
On initial startup it is recommended that the main gas shutoff
cock remain closed until the programmer has cycled through
pre-purge and pilot sequences to determine that the main gas
valve opens. Turn the burner switch OFF and let the
programmer finish its cycle. Check to see that the gas valve
closes tightly.
On burners equipped with high and low gas pressure
switches, set switch pressure actuating levels and record
settings for future service reference.
See the burner specification nameplate inside the control
panel door for minimum and maximum input rate and
required manifold pressure.
When the conditions covered above and in Section 2 are
assured, the burner is ready for firing. Refer to Section E for
starting and operating information.
OIL BURNERS
Prior to initial firing, oil flow and pressure should be verified.
If the burner is a dual fuel model, make certain that the main
gas shutoff cock is closed and the fuel selector switch is set to
OIL.
OIL FLOW
If the oil supply tank is below the level of the oil fuel unit, it
is recommended that the suction line be primed with oil prior
to starting the pump to avoid the possibility of damage to the
pump through operation without lubrication.
To check for proper pump rotation, momentarily energize the
starter. With rotation verified, operate the pump to determine
that oil circulation exists. Observe the oil burner pressure
gauge. If not pressure shows after a few moments, stop the oil
pump and re-prime. If the supply tank is lower than the pump,
it is possible that the initial priming of the suction line,
followed by operation of the pump, will not establish oil flow.
This might be caused by obstruction in the suction line,
excessive lift, inadequate priming, suction line leaks, etc.
Until oil flow is established, avoid prolonged operation of the
pump. If oil flow is not established after a second priming,
investigation is required.
A vacuum (or compound pressure-vacuum) gauge should be
installed at the suction port of the pump. It is advisable that
the reading be less than 15 Hg vacuum. Vacuum in excess of
this may cause unstable firing.
2-17
Chapter 2
OIL PRESSURE AND VACUUM
Profire V Burner
6.
! !WARNING
DANGER
CAUTION
DANGER
TO PREVENT POSSIBLE SERIOUS INJURY OR
DEATH, READ THE FLAME SAFEGUARD MANUAL AND FULLY UNDERSTAND ITS CONTENT
BEFORE ATTEMPTING TO OPERATE THIS
EQUIPMENT.
! !WARNING
DANGER
CAUTION
DANGER
SHOULD A STARTING FAILURE OCCUR FOR
ANY REASON, COMBUSTIBLE FUMES MAY FILL
THE COMBUSTION CHAMBER. NEVER
ATTEMPT TO RE-LIGHT THE BURNER UNDER
THESE CONDITIONS WITHOUT PURGING THE
CHAMBER.
SEQUENCE OF OPERATION
The programming control sequences the operation of all
controls and components through the starting, ignition, firing,
and shutdown cycle. The burner and control system are in
starting condition when:
2.
3.
4.
5.
Voltmeter/Ammeter.
2-18
750-177
Profire V Burner
Chapter 2
OIL FIRED
Disconnect the electrical power to the burner. Disconnect the
electric oil safety shutoff valve. Reconnect electric power.
Close the pilot line manual gas valve, if used.
Start burner and at the time of pilot trial, with just the
electrical ignition system energized. The flame relay should
not pull in.
Upon completion of successful test, disconnect power supply.
Reconnect oil safety shutoff valve and turn on manual pilot
gas valve. Reconnect power supply and proceed with startup
procedures.
! !WARNING
DANGER
CAUTION
DANGER
FAILURE TO FOLLOW THIS PROCEDURE MAY
RESULT IN EXPLOSION, FIRE, PROPERTY DAMAGE, AND PERSONAL INJURY. THIS PROCEDURE MUST BE PERFORMED ONLY BY
AUTHORIZED AND QUALIFIED PERSONNEL.
1.
2.
3.
4.
5.
750-177
2-19
Chapter 2
Return the setpoint to its original position before proceeding.
6.
7.
Reset all manual valves to their normal setting for operation. Make sure all electric valves are operating normally. Make sure all test cocks are closed before
resuming normal operation.
8.
9.
10. Open the gas pilot cock. Check pressure. Normal setting
is 4 to 6 WC when the pilot is burning.
11. Set the ON-OFF switch to ON. The burner will start and
pre-purge. After pre-purge, the ignition transformer and
the gas pilot solenoid are energized.
On initial startup it is recommended that the main gas
shutoff cock remain closed until the programmer has
cycled through pre-purge and pilot sequence. Then
determine that the main gas valve opens. When this is
confirmed, turn the burner switch OFF and let the programmer finish its cycle. Check to see that the gas valve
has closed tightly.
If ignition does not occur, turn the burner switch OFF
and allow the programmer to recycle for a new ignition
trial.
12. Turn the burner ON and after pilot ignition when the
flame relay pulls in, the slow opening, motorized, main
gas valve is energized. Slowly open the downstream
manual shutoff gas cock. Main flame should ignite at
this time. The gas valve and air damper continue
advancing until high-fire is reached.
13. Do not repeat unsuccessful light off attempts without
rechecking burner and pilot adjustment. Vent fuel
vapors from the combustion chamber after each unsuccessful light off attempt. Set the gas low-fire rate by
adjusting butterfly valve and air linkage. Refer to the
adjustment section of this manual. Using the combustion analysis instrument, adjust the low-fire. Typical
combustion analysis for low-fire it 5% to 6% O2 on
standard turndown systems, and between 6.5% and 9%
for higher turndown systems. Verify the minimum input
rate by measuring the gas meter.
2-20
Profire V Burner
14. When low-fire is adjusted, shut down the burner. Restart
several times to be sure the low-fire setting is suitable.
Readjust if necessary. Never start the burner with fuel
vapor in the furnace. In case of emergency, open main
power switches and close all fuel valves. After combustion adjustments are satisfactorily set, allow the heating
vessel to slowly reach normal operating pressure or temperature.
15. After the boiler has reached operating temperature or
pressure, turn the potentiometer switch in small increments to the high-fire position. Check high-fire at this
point using combustion instruments. High-fire combustion analysis typically 3% to 4% O2. Verify maximum
input rate by measuring the gas meter.
16. Do not disturb established low-fire adjustment. Allow
the burner to return to low-fire position before adjusting
high or intermediate settings. CO levels should be less
than 400 ppm on an air-free basis at all firing rates with
<50 ppm as the target value.
When conditions covered above are assured, refer to Sections
F and G.
OIL BURNERS:
1.
2.
Set the ON-OFF switch to ON. The burner will start and
pre-purge. After pre-purge, the ignition transformer will
direct spark. If the flame detector proves the presence of
a satisfactory pilot, the programmer will proceed to
main flame ignition.
3.
4.
750-177
Profire V Burner
perature.
5.
6.
7.
Chapter 2
In automatic operation, the operating cycle always proceeds
sequentially through pre-purge, pilot ignition, main flame
ignition, run and post-purge. The length of purge and ignition
trial vary according to the type of programmer used.
During the run cycle, burner input is regulated to the load
demand by the modulating pressure or temperature control on
the boiler. The burner will continue to modulate until the
operating pressure or temperature is reached.
Programmer control operation should be tested when the
burner is initially placed into service, when a control is
replaced, and at scheduled intervals in the maintenance
program.
SHUTDOWN
NORMAL OPERATION
Normal operation must be with the MANUAL-AUTO switch
selector on AUTO.
750-177
2-21
Chapter 2
Profire V Burner
D. Adjustments
TEST EQUIPMENT
2-22
2.
3.
4.
5.
Voltmeter/Ammeter.
6.
750-177
Profire V Burner
Chapter 2
1.
2.
Disconnect the high voltage power supply from the oilspark-ignition electrodes (if installed).
3.
Disconnect the oil piping from the side of the blast tube.
4.
2.
3.
4.
5.
! !WARNING
DANGER
CAUTION
DANGER
AN ULTRA-VIOLET FLAME SENSOR ELECRICAL
SPARK INTERFERENCE TEST MUST BE PERFORMED AFTER FINAL ADJUSTMENT. SEE SECTION 3 OF THIS MANUAL FOR ADDITIONAL
INFORMATION.
Check the pilot electrode setting. The pilot is accessible by
loosening the four screws on the side of the blast tube and
disconnecting the gas line.
BURNER SETTINGS
To ensure reliable and safe burner performance, the location
and gap setting of the electrodes, and the relative positions of
the burner nozzle, diffuser, and air baffle components must be
set correctly. These items are preset at the factory, but must be
checked prior to placing the burner into initial service, or after
conducting any service work that may have altered their
position.
The nozzle/diffuser assembly must be removed from inside
the burner to enable measurement and readjustment:
750-177
2.
3.
4.
2-23
Chapter 2
5.
Profire V Burner
2.
3.
2-24
750-177
Profire V Burner
Chapter 2
Turn the burner switch on. This will start the blower
motor and initiate the pre-purge sequence. Make sure a
pressure gauge 0-10 W.C. or manometer is installed in
the pilot line to monitor the pilot gas pressure.
2.
750-177
3.
4.
Perform a pilot turndown test by reducing the pilot pressure very slowly until the scanner loses sight of the
flame and give a flame lockout, then reset to normal
level. Note the minimum pressure level.
5.
6.
7.
2-25
Chapter 2
Profire V Burner
diaphragm and open the valve.
5.
GAS BURNERS
On-Off gas burners are typically equipped with a pressure
regulator, and a solenoid operated diaphragm gas valve to
control the on-off operation of the burner. Adjustments are
made by matching the correct fuel/air ratios.
1.
2.
3.
4.
2-26
OIL BURNERS
On-Off burners use the Suntec B2TC-8931 oil pump model.
High-fire pressure adjustment is 200-300 PSI (solenoid
energized), and low-fire pressure adjustment is 100-200 PSI
(solenoid de-energized).
1.
2.
3.
750-177
Profire V Burner
flame is obtained and a satisfactory low-fire oil flame is
established. Turn burner off and restart to ensure smooth
ignition is obtained at the set low-fire pressure. Replace
knurled nut and hand tighten.
4.
Adjust the high-fire oil input to match the maximum rating. Turn the burner off and reconnect the wiring to the
solenoid valve. Restart the burner and allow burner to
go through ignition and low-fire. When the solenoid
energized, the oil pump discharge pressure is at high-fire
pressure. The high-fire pressure adjustment screw is
located on the oil pump body. Adjust the screw, clockwise to increase the pressure and counterclockwise to
decrease the pressure, until correct amount of oil pressure is obtained. The high-fire oil pressure should be
300 PSI. High-fire is typically 3.5% to 4.5% O2 with
less than a No. 1 smoke. The burner should be adjusted
to provide the correct amount of fuel flow at a constant
rate at high-fire position as indicated on the burner data
plate, located inside the control panel.
Chapter 2
L O W- H I G H - O F F & L O W- H I G H - L O W
BURNER ADJUSTMENTS
Refer to the burner data plate located inside the control panel
door. The data plate will list the burner information: burner
and control voltage, phase, cycle, motor amperage, maximum
and minimum fuel input settings, manifold pressure (at zero
furnace pressure). Add the furnace pressure to get the correct
manifold pressure at maximum firing rate.
These procedures assume that the pre-startup tasks, checklist,
electrical interference test, and pilot turndown tests have been
performed in accordance with the instructions in this manual.
Allow boiler to fully warm up before making adjustments for
most efficient combustion. Refer to the boiler instruction
manual for the boiler control settings.
GAS BURNERS
The gas burner adjustments on a Low-High-Off system
consist of the gas pressure regulator, gas butterfly valve, low
and high gas pressure switches, and air damper assembly.
1.
2.
3.
4.
1.
2.
3.
4.
5.
5.
750-177
6.
7.
2-27
Chapter 2
Profire V Burner
position. Adjust the gas regulator so the manifold pressure matches the rating on the burner data plate. Verify
and record the readings and pressures. High-fire is typically 3% to 4% O2 with less than 50 ppm CO.
8.
9.
Adjust the low and high gas pressure switches by turning the adjusting screw until indicator moves to a pressure slightly lower than normal operating pressure for
the low gas pressure switch, and slightly higher for the
high gas pressure switch (usually 20% below and 20%
higher than normal pressure).
4.
5.
2.
3.
4.
5.
2.
2-28
FULL
M O D U L AT I O N
ADJUSTMENTS
BURNER
Refer to the burner data plate located inside the control panel
door. The data plate will list the burner information: Burner
and control voltage, phase, cycle, motor amperage, maximum
and minimum fuel input settings, and manifold pressure (at
zero furnace pressure). Add the furnace pressure to get the
correct manifold pressure at maximum firing rate.
These procedures assume that the pre-startup tasks, checklist,
electrical interference test, and pilot turndown tests have been
performed in accordance with the instructions in this manual.
750-177
Profire V Burner
Allow the boiler to fully warm up before making adjustments
for most efficient combustion. Refer to the boiler instruction
manual for the boiler controls settings.
GAS BURNERS
The gas burners adjustments on a full modulation burner
consist of the gas pressure regulator, butterfly gas valve, low
and high gas pressure switches (Model V30-168), and air
dampers.
Chapter 2
target value.
11. Modulate the burner to low-fire. Verify the readings.
The burner should be adjusted to provide correct fuel flow at
a constant rate, at the low-fire and high-fire position as
indicated on the burner data plate. This is achieved by
clocking the gas flow at the gas meter. The gas utility or gas
meter calibration data, should be consulted to determine the
correction factors to be applied to the meter.
Natural Gas Input Calculation Using a Meter
1.
2.
3.
4.
5.
6.
7.
8.
9.
At each point, allow the burner to operate for a few minutes before recording the O2, CO, and pressure readings.
Observe that the O2 and CO levels remain within an
acceptable limit. Adjust the pressure regulator as necessary, to correct this situation. Continue to do this until
the burner reaches high-fire (the potentiometer is at the
OPEN position).
750-177
1.
2.
3.
2-29
Chapter 2
COMBUSTION AND HIGH CO EMISSIONS WILL
RESULT. Monitor O2 and CO levels during this process.
The introduction of FGR into the combustion chamber
will lower the flue O2 levels. Too much FGR may
induce high levels of CO in the flue gas. It may be necessary to adjust the air damper blades to raise the O2 to
proper low-fire values. If the proper NOx values can not
be reached by adjusting the cam screw, the FGR linkage
will have to be adjusted as well. Please see the section
on linkage adjustment for details.
4.
OIL BURNERS
The oil burner adjustments consist of the oil metering valve
and air shutters. The firing rate is regulated by a metering
valve in the nozzle return line. At low-fire, the arrow on the
valve points to approximately number 7, and at high-fire it is
in the closed position (no return flow), approximately at
number 2. The oil metering valve position will vary the oil
pressure to the nozzle. An oil pressure gauge should be
installed in the return line to monitor the oil pressure. Oil
pressure at low fire is approximately 80 to 100 PSI and 300
PSI at high-fire. Size 1 V10 to 25 uses a simplex nozzle, sizes
2 & 3 use a return flow nozzle.
1.
2.
3.
4.
5.
6.
7.
2-30
Profire V Burner
is at the OPEN position).
8.
9.
2.
3.
4.
5.
6.
7.
750-177
Profire V Burner
Chapter 2
! CAUTION
DANGER
ANY COVER PLATES, ENCLOSURES, OR
GUARDS ANCHORED TO THE BURNER, OR ANY
BURNER RELATED EQUIPMENT, MUST REMAIN
IN POSITION AT ALL TIMES. ONLY DURING
MAINTENANCE AND SERVICE SHUTDOWN CAN
THESE COVER PLATES, ENCLOSURES, OR
GUARDS BE ALLOWED TO BE REMOVED. THEY
MUST BE REPLACED, AND SECURELY
ANCHORED BEFORE TESTING, ADJUSTING, OR
RUNNING THE BURNER OR BURNER RELATED
EQUIPMENT.
E. Maintenance
A maintenance program avoids unnecessary downtime,
costly repairs, and promotes safety. It is recommended that a
record be maintained of daily, weekly, monthly, and yearly
maintenance activities.
Electrical and mechanical devices require systematic and
periodic inspection and maintenance. Any automatic
features do not relieve the operator from responsibility, but
rather frees him from certain repetitive chores, providing time
for upkeep and maintenance.
Unusual noise, improper gauge reading, leak, sign of
overheating, etc. can indicate a developing malfunction
requiring corrective action.
CONTROL SYSTEM
Most operating controls require very little maintenance
beyond regular inspection. Examine electrical connections.
Keep the controls clean. Remove any dust from the interior of
the control. Covers should be left on controls at all times.
Keep the control cabinet doors closed. Dust and dirt can
damage motor starters and relay contacts. Starter contacts are
plated with silver and are not harmed by discoloration. Never
use files or abrasive materials such as sandpaper on contact
points.
! !WARNING
DANGER
CAUTION
DANGER
ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP, ADJUST,
OR SERVICE THE EQUIPMENT.
PROGRAMMING CONTROL
! !WARNING
DANGER
CAUTION
DANGER
ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP, ADJUST,
OR SERVICE THE EQUIPMENT.
750-177
2-31
Chapter 2
Profire V Burner
MOTORS
Supply voltage to the motor must not vary more than 10%
from data plate ratings. At initial startup and regularly
thereafter, check the motor current with an ammeter while the
burner is in high-fire position. If the reading exceeds the data
plate rating plus service factor, determine the cause and
correct it. In dusty locations, clean the motor regularly to
assure adequate cooling. Lubricate in accordance with the
manufacturers instructions.
GAS SYSTEM
Check the gas train for leaks. Check the gas valves and verify
the ow and high gas pressure settings.
SOLENOID VALVES
A faint hum from the solenoid is normal when the coil is
energized. Should the valve fail to operate, check that there is
voltage at the valve coil. If there is no voltage at the coil,
check for loose wiring connections. If there is proper voltage
at the valve coil and the valve still fails to open, replace the
coil. Refer to manufacturers bulletin for correct procedure in
coil replacement.
Should it become necessary to replace the complete valve, be
sure that the flow is in the direction of the arrow on the valve
body.
Test for gas leaks and check valve action several times to
ensure proper operation before attempting to relight burner.
DRAWER ASSEMBLY
The drawer assembly may be removed for inspection and
service.
1.
2.
3.
4.
After making note of where the bolts are located in relationship to the access cover slots, remove the drawer
assembly access cover bolts. Pull the drawer partially
out of the housing. Reach inside to disconnect the ignition cables from the electrodes for direct spark applications. Pull the drawer assembly completely out of the
housing.
5.
! CAUTION
DANGER
ALL POWER MUST BE DISCONNECTED
BEFORE SERVICING VALVES.
MOTORIZED MAIN GAS VALVES
Should the valve fail to operate, check for voltage at the
valve. Make certain that the main shutoff cock is closed prior
to testing. The actuator is not field repairable nor should it be
disassembled. Replace the actuator if valve fails to operate.
After replacement, cycle the valve with the fuel shut off to
determine that it opens and closes. If the valve has a visual
indicator, observe its position for correct operation.
OIL SYSTEM
Little maintenance is required on the oil systems other than
cleaning the oil filter. This procedure should be done at
regular intervals. Increased inlet vacuum reading may
indicate a clogged filter. Follow the strainer manufacturers
maintenance schedule.
2-32
750-177
Profire V Burner
Chapter 2
FLAME SCANNER
The scanner must be clean. Even a small amount of
contamination will reduce the flame signal. Wipe the scanner
lens with a clean soft cloth. Check pilot and flame signal
strength.
EXTENDED SHUTDOWN
When shutting down the burner for an extended period of
time, the operator should use the following general guidelines
to protect the burner from its surrounding elements.
This will add to the operating life of the burner:
1.
2.
3.
750-177
2-33
Chapter 2
Profire V Burner
SERVICE BY
REMARKS
DAILY
Gauges, Monitors, and Indicators
Operator
Operator
Operator
Refer to instructions.
Operator
Igniter
Operator
Operator
Open limit switch. Make audible and visual check. Check valve
position indicators, and check fuel meters.
Operator
Close manual fuel supply for (1) pilot and (2) main fuel cock
and/or valve(s). Check safety shutdown timing. Record in log.
Operator
Read and log the flame signal for both pilot and main flame.
Notify service if readings are very high, very low, or fluctuating.
Linkages
Operator
WEEKLY
MONTHLY
Low Fan Pressure Interlock
Operator
Operator
Operator
Pilot Assembly
Operator
Operator
Handhole Covers
Operator
Operator
Operator
Impeller
Operator
QUARTERLY
ANNUALLY
2-34
Combustion Test
Service Technician
Service Technician
Operating Controls
Service Technician
Refer to instructions.
750-177
Profire V Burner
Chapter 2
F. Troubleshooting
PROBLEM
Burner Does Not Start
SOLUTION
1.
2.
3.
Limit circuit not completed - no voltage at end of limit circuit program relay terminal.
a. Pressure or temperature is above setting of operation control.
b. Water below required level.
Low-water light (and alarm horn) should indicate this condition.
Check manual reset button, if provided, on low-water control.
c. Fuel pressure must be within settings of low pressure and high pressure
switches.
d. Check burner air proving switch and high-fire limit switch.
4.
750-177
2-35
Chapter 2
Profire V Burner
PROBLEM
No Ignition
SOLUTION
1.
Lack of spark.
a. Electrode grounded or porcelain cracked.
b. Improper electrode setting.
c. Loose terminal on ignition cable, cable shorted.
d. Inoperative ignition transformer.
e. Insufficient or no voltage at pilot ignition circuit terminal.
2.
3.
4.
5.
PROBLEM
Pilot Flame, But No Main Flame
SOLUTION
1.
2.
3.
2-36
4.
5.
750-177
Profire V Burner
Chapter 2
PROBLEM
Burner Stays in Low-Fire
SOLUTION
1.
2.
3.
4.
5.
PROBLEM
Shutdown Occurs During Firing
SOLUTION
1.
2.
3.
4.
5.
If the programmer lockout switch has not tripped, check the limit circuit for an
opened safety control.
6.
7.
750-177
8.
9.
2-37
Chapter 2
Profire V Burner
PROBLEM
Modulating Motor Does Not
Operate
SOLUTION
1.
2.
3.
Motor does not drive to open or close during pre-purge or close on burner shutdown.
a. Motor defective.
b. Loose electrical connection.
c. Damper motor transformer defective.
4.
2-38
750-177
Profire V Burner
Chapter 2
G. Burner Specs
Model FLX Burner Characteristics
Model No.
Burner Maximum
Input MBH
Burner Model
FLX-150
1500
PFVLG-15
115/230/1/60
FLX-200
2000
PFVLG-20
115/230/1/60
FLX-250
2500
PFVLG-25
115/230/1/60
FLX-300
3000
PFVLG-30
115/230/1/60
FLX-350
3500
PFVLG-35
208/230/1/60
FLX-400
4000
PFVLG-40
208/230/1/60
FLX-450
4500
PFVLG-45
208-230/460/3/60
FLX-500
5000
PFVLG-50
230/460/3/60
FLX-550
5500
PFVLG-55
230/460/3/60
FLX-600
6000
PFVLG-60
460/3/60
FLX-700
7000
PFVLG-70
460/3/60
FLX-800
8000
PFVLG-80
460/3/60
FLX-900
9000
PFVLG-90
460/3/60
FLX-1000
10000
PFVLG-100
460/3/60
FLX-1100
11000
PFVLG-110
460/3/60
FLX-1200
12000
PFVLG-120
460/3/60
Notes:
1.
Burner model selection shown is subject to changed and is based on actual application (altitude, gas pressure, reduced
NOx, etc.)
2.
3.
Burner operation is Full Modulation on Elite Series and for the Econo series Low-High-Low for units 150 - 600 and modulated firing on 700 and greater.
4.
Burner models shown are for combination gas/oil firing. For straight gas, delete the letter L, and for straight oil, delete the
letter G.
750-177
2-39
Chapter 2
Profire V Burner
Burner Model
FLX-150
11.2
12.5
PFVG-15
FLX-200
19.4
21.7
PFVG-20
FLX-250
1.5
12.4
15.7
PFVG-25
FLX-300
1.5
15.9
20.7
PFVG-30
FLX-350
1.5
15.5
22.0
PFVG-35
FLX-400
1.5
18.7
27.2
PFVG-40
FLX-450
16.0
26.7
PFVG-45
FLX-500
17.6
21.0
PFVG-50
FLX-550
22.9
27.1
PFVG-55
FLX-600
20.0
24.9
PFVG-60
FLX-700
25.2
31.9
PFVG-70
FLX-800
2.5
19.9
22.2
PFVG-80
FLX-900
2.5
24.7
27.7
PFVG-90
FLX-1000
2.5
31.6
31.6
PFVG-100
FLX-1100
2.5
37.3
37.3
PFVG-110
FLX-1200
2.5
38.2
38.2
PFVG-120
Notes:
2-40
1.
Table is based on 1,000 Btu/cu. ft. natural gas and elevation of 1,000 feet.
2.
3.
As an option, the standard gas train can be replaced with an oversized design to reduce inlet gas pressure requirements.
4.
5.
750-177
Profire V Burner
Chapter 2
Serial Number
GAS
Test Conducted
Low
50%
Start-up Date
OIL
High Low
50%
High
Control Checks
Room Temp oF
Aux. LWCO
Operating Limit
O2%
High Limit
CO2%
Operating Control
CO (PPM)
NOx (PPM)
Flame Failure
Smoke (Bacharach)
Combustion Eff.%
Interlock
Oil Temperature
Inner Manifold
Manifold "W.C.
Outer Manifold
Low
50%
Voltage
Electric Motors
L1
L2
High
Adjusted by:
Amperage
L3
L1
L2
L3
Date:
Control Voltage
Blower Motor
Accepted by:
Air Compressor
Air-Oil or Metering
(Signature Required)
CB-8209
750-177
2-41
Chapter 2
2-42
Profire V Burner
750-177
CHAPTER 3
Pressure Vessel Care
A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
B. Water Requirements (Hot Water Boilers) . . . . . . . .3-1
C. Water Requirements (Steam Boilers . . . . . . . . . . . .3-3
D. Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
E. Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
F. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
G. Boilout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
H. Washing Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
I. Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . .3-8
J. Preparation for Extended Layup . . . . . . . . . . . . . . . .3-9
A. GENERAL
C
B. WATER REQUIREMENTS
(HOT WATER BOILERS)
Air Removal
Continuous Flow
The hot water outlet (Figure 3-1) is located in the top drum of
the boiler. This location reduces the possibility of released air
(which is trapped at the top of the drum) from entering the
system. Any air (or oxygen) that may be released in the boiler
will collect at the top of the upper drum, where it will escape
750-177
Chapter 3
MODEL
NO.
DT =
40F
DT =
60F
DT =
80F
DT = 100F
DP
(PSIG)
GPM
DP (PSIG)
GPM
DP (PSIG)
GPM
DP (PSIG)
GPM
DP (PSIG)
GPM
FLX-150
1.14
122.0
0.30
61.1
0.13
41.1
0.08
30.8
0.05
24.4
FLX-200
1.14
162.3
0.30
81.1
0.13
54.1
0.08
40.6
0.05
32.5
FLX-250
1.77
202.8
0.46
101.4
0.21
67.6
0.12
50.7
0.08
40.6
FLX-300
1.85
243.4
0.48
121.7
0.22
81.1
0.12
60.9
0.08
48.7
FLX-350
2.49
284.0
0.65
142.0
0.29
94.7
0.17
71.0
0.11
56.8
FLX-400
1.35
324.5
0.35
162.3
0.16
108.2
0.09
81.1
0.06
64.9
FLX-450
1.71
365.1
0.44
182.6
0.20
121.7
0.11
91.2
0.08
73.0
FLX-500
2.03
405.7
0.54
202.8
0.25
135.2
0.14
101.4
0.09
81.1
FLX-550
2.50
446.3
0.67
223.1
0.31
148.7
0.17
111.5
0.11
89.2
FLX-600
2.99
486.8
0.77
243.4
0.35
162.3
0.20
121.7
0.13
97.4
FLX-700
1.75
567.9
0.45
284.0
0.21
189.3
0.12
142.0
0.08
113.6
FLX-800
2.27
649.1
0.59
324.5
0.27
216.4
0.15
162.3
0.10
129.8
FLX-900
2.85
730.2
0.74
365.1
0.33
243.4
0.19
182.6
0.12
146.0
FLX-1000
4.08
811.4
1.02
405.6
0.42
270.4
0.25
202.8
0.15
163.6
FLX-1100
4.42
892.6
1.15
446.2
0.48
297.4
0.28
223.0
0.18
178.4
FLX-1200
6.20
973.6
1.60
486.8
0.59
324.6
0.31
243.4
0.22
194.8
! CAUTION
DANGER
The operator should determine that a circulation of water exists through the boiler before initial firing or when firing after the unit
has been drained and refilled. A reduced circulation of water or no water circulation
through the boiler when the burner is operating may result in damage to the equipment.
240
SUPPLY WATER TEMPERATURE - F
! CAUTION
DANGER
System Pressure
230
220
210
200
190
180
170
160
150
10
12
14
16
18
20
22
24
26
28
30
750-177
Pressure Drop
There will be a pressure drop of less than 4 psi through all
standardly equipped Cleaver-Brooks boilers operating in any
system that has more than the 20F temperature drop. This
drop will vary with boiler size and circulation rate. For
specific information, refer to table 3-1, Minimum Flow Rates
for Hot Water Boilers.
Chapter 3
C. WATER REQUIREMENTS
(STEAM BOILERS)
Deaeration
The most important factor in the life of a steam pressure
vessel is the proper conditioning of the boiler feed water.
Corrosive gasses, such as oxygen and carbon dioxide, must
be removed from the feed water in order to prevent
degradation of the pressure vessel. For this reason CleaverBrooks recommends the use of a deaeration system as an
integral part of a comple te bo il er i nst al la ti on . If
circumstances do not allow the implementation of a
deaeration system, then serious consideration should be given
to effective alternatives such as a feed water preheater
combined with a chemical oxygen scavenger. Complete
boiler water chemistry parameters are given in Table 3-3.
! CAUTION
DANGER
Three-way valves and system controls
should be installed or set so that the boiler
cannot be bypassed. A reduced circulation
of water or no water circulation through the
boiler when the burner is operating may result in damage to the equipment.
750-177
FEED WATER
SUPPLY PORT
3-3
Chapter 3
BOILER MODEL
150
200
250
300
350
400
450
500
550
600
700
800
900
4.9
6.6
8.2
9.9
11.6 13.2 14.9 16.5 18.2 19.8 23.1 26.4 29.7 33.0 36.3 39.6
Note: Feedwater to the boiler must be at least 60 F for minimum performance; 212 F is preferred.
Table 3-2: Minimum Boiler Feed Water Flow Rates (Steam Boiler)
Silica
150 ppm
Specific Conductance
3500 mho/cm
Total Alkalinity
Total Hardness
0 ppm as CaCO3
Oxygen (O2)
7 ppb
pH
10
Total Iron
0.05 ppm
Oily Matter
1 ppm
E. BLOWDOWN
A steam boiler requires periodic blowdown of the boiler and
water column (Figure 3-4). Blowdown is the removal of some
of the concentrated water from the boiler and the water level
D. WATER TREATMENT
Properly treated boiler water will result in maximum
effectiveness and long trouble-free life of the pressure vessel.
Contact your local Cleaver-Brooks Representative or water
management consultant for complete information on how to
prevent damage resulting from inadequate water treatment.
The objectives of water treatment in general are to:
1.
2.
3-4
750-177
! CAUTION
DANGER
Boiler and water level control blowdown
must be performed on a regular basis to ensure that concentrated solids are removed
from the boiler and in order to avoid damage
to the equipment.
Chapter 3
! CAUTION
DANGER
When initially opening the blowdown valve,
open the valve slowly to heat the discharge
piping. Failure to follow this procedure
could result in rapid expansion and damage
to the piping.
The drop of the water level in the gauge glass can be used in
determining the length of time that the blowdown valve is left
open. This is to be used as a reference only, as proper water
analysis on a regular basis will serve as an indicator of the
effectiveness of the blowdown procedures used.
! CAUTION
DANGER
Do not pump the lever action valve open
and closed when draining water during
blowdown. The hydraulic forces resulting
from this pumping action could break the
valve bodies or pipe fittings in the blowdown lines.
Blowdown Procedure
! WARNING
DANGER
Be sure that the blowdown piping is in good
condition, the discharge vents are clear of
obstruction, and that the waste is piped to a
safe point of discharge, in order to avoid
serious personal injury or death.
Frequency of Blowdown
In practice, the boiler blowdown valve(s) should be opened
periodically in accordance with a set operating schedule.
Frequency and duration of the blowdown are to be
determined by chemical analysis of boiler water and
waterside boiler condition, as observed during regular
inspections.
From an economy standpoint, frequent short blowdown is
preferred to irregularly scheduled, lengthy blowdown. This is
particularly true when the suspended solids content of the
water is high.
750-177
3-5
Chapter 3
F. CLEANING
G. BOILOUT
Pressure Vessel
Cleaning of the waterside of the pressure vessel should be
done during the course of initial installation. The waterside of
the pressure vessel must be cleansed of grease, sludge, and
foreign material. Such deposits will shorten the life of the
pressure vessel and interfere with the efficient operation and
function of control or safety devices. In addition, deposits
might cause unnecessary and expensive rework, repairs, and
downtime.
2.
3.
DOWNCOMER
300350
400600
700900
10001200
91
106
174
228
269
194
215
293
464
562
Boiler Size
3-6
SIGHT PORT
SYSTEM INLET
Boilout Procedure
1.
2.
4.
5.
6.
Fill the unit with clean water to a point just below the
access port in the upper drum. It is important that the
water used for the filling process is at a temperature of
70F or above.
7.
! WARNING
DANGER
Chapter 3
amount being equally divided among the various manual
blowdown points and continuous blowdown system.
Blow the surface and/or continuous blow-down points
first, followed by the other blowdown points lower on
the boiler. After each blowdown cycle, the water level
should be brought back to full. If the total alkalinity in
the cleaning solution falls to a level below 3000 ppm, it
may be necessary to add additional solution using a
chemical pump.
13. Allow a small amount of fresh water to enter the boiler in
order to create a slight overflow that will carry off
surface impurities. Continue to boil and overflow until
the water clears.
14. It is difficult to provide specific recommendations
regarding the duration of the cleaning process. In
general, a period of 18 to 36 hours will prove sufficient
to internally clean the water-side of the boiler. The
condition of the water blown from the boiler is the best
indicator as to whether the cleaning process is complete.
15. Discontinue firing, and allow the water to cool. After
letting the water cool to 120F or less, drain the boiler.
! WARNING
DANGER
Be sure to drain the hot water to a safe point
of discharge to avoid the possibility of
scalding, serious personal injury or death.
8.
9.
3-7
Chapter 3
H. WASHING OUT
Depending on system integrity, feedwater quality, or
operating conditions, the water side of the boiler may need to
be washed out on occasion.
In theory, a hot water system and boiler that have been
initially cleaned, filled with clean, treated water, and with no
makeup water added, will require no further cleaning or
treatment. However, minor system leaks may allow the
admission of additional water or air into the boiler.
Introduction of raw (untreated) makeup water or air to a hot
water boiler may lead to pitting, corrosion, or formation of
sludge, sediment, or scale on the pressure vessel waterside.
The waterside condition of steam boilers can be likewise
affected by feedwater quality, load demands, operating
conditions, or blowdown practices.
The waterside of a hot water or steam boiler should be
cleaned and inspected no later than three months after the
boiler is put into service. Subsequent cleaning of waterside
surfaces should be performed as indicated through periodic
inspection.
In order to thoroughly wash out the waterside of the pressure
vessel, the handhole covers at the ends of the upper and lower
drums must be removed. The interior surfaces of the drums
should be washed with a high pressure hose. Tubes should be
cleaned by directing a high pressure stream of water into the
end of each tube, first from the bottom, and then from the top
drum.
Note: A washout lance for this purpose is
available from your local Cleaver- Brooks
authorized representative.
Control and water column connections on steam boilers
should be checked for accumulated deposits, and cleaned as
required.
After waterside cleaning has been completed, replace the
handhole covers, using new gaskets.
Note: Handhole cover gaskets are installed
dry; that is, without application of a sealing
compound.
I. PERIODIC INSPECTION
Insurance regulations or local codes and good maintenance
will require that the pressure vessel be inspected periodically
by an authorized inspector. Sufficient notice is generally
required to allow removal of the boiler from service and
preparation for inspection. An internal inspection may be
required before cleaning or flushing.
Have the following information available for the inspector:
boiler design, dimensions, generating capacity, operating
pressure and temperature, time in service, defects found
previously, and any repairs or modifications made to the unit.
Reference records of previous inspections also should be
3-8
! WARNING
DANGER
To avoid the hazard of electrical shock,
which could cause serious personal injury
or death, the use of a low voltage flashlight
is recommended during an internal
inspection.
Fireside Inspection
Access for inspection of the firing chamber, or furnace, is
gained through the hinged burner door. Inspection of the
upper pass requires removal of the side casing panels and
second and fourth pass cover plates. Refer to Chapter 7,
Section C, Fireside Cleaning, for information regarding
outer and inner casing removal.
Fireside tube surfaces should be checked for corrosion or
accumulation of soot. Use a vacuum cleaner and wire brush
to remove light corrosion or soot.
Localized, heavy corrosion on fireside tube surfaces may
indicate a leaking tube or ferrule connection. If a tube or tube
ferrule leak is indicated, the source of the leakage must be
found and repaired before putting the boiler back in service.
A leak from a tube-to-drum connection may require removal
and reseating of the tube. A heavily corroded or leaking tube
must be replaced in order to assure continued reliable
operation of the boiler. Information regarding tube
replacement can be obtained from your local Cleaver-Brooks
authorized representative.
750-177
Chapter 3
Waterside Inspection
Check all water piping and valves for leaks, wear, corrosion,
and other damage. Replace or repair the piping and valves as
necessary. Inspection covers at one end of the upper and
lower drums provide access to the interior of the drums for
visual inspection or washout. The interior surfaces of the
drums should be examined for any sign of corrosion or
accumulation of deposits.
750-177
! CAUTION
DANGER
The insulating refractory covering the top of
the bottom drum must be protected from
damage when work is being done in the
boiler furnace area. Damage to the insulation may eventually cause damage to the
boiler itself.
Generally, a good brushing will clean fireside surfaces. Use a
wire brush for metal surfaces and a soft bristle brush for the
refractory. Sweep away or vacuum any accumulation.
To prevent condensation from forming in the control cabinet,
keep the control circuit energized. For extended layup
periods, especially where high humidity or large swings in
ambient temperature occur, the flame safeguard control
should be removed and stored in a dry atmosphere.
It is recommended that the burner air inlet be blocked to
prevent the flow of warm, moist air through the boiler.
! CAUTION
DANGER
A label should be affixed to the burner advising that the air inlet has been blocked.
Failure to remove the air inlet block when attempting to operate the burner may result in
damage to the equipment.
Dry Storage
Dry storage generally is used for boilers that are to be out of
service for some time or for boilers that might be subjected to
freezing conditions. With the dry storage method, the boiler
must be thoroughly dried because any moisture would cause
corrosion. Drying can be accomplished by the use of a small
stove or heater.
Both fireside and waterside surfaces must be cleaned of all
scale, deposits, soot, and other combustion products as soon
as possible after shutdown.
All openings to the pressure vessel, such as handholes or
inspection ports, should be closed tightly. Feedwater and
system valves should be closed. Dampers should be closed to
prevent air from reaching the fireside surfaces.
Steps must be taken to eliminate moisture by placing
moisture-absorbing materials on trays inside the boiler. Two
moisture-absorbing materials are: quick-lime (at 2 pounds for
3 cubic feet of volume) or silica gel (at 5 pounds for 30 cubic
feet of volume). As soon as the material is in place, close all
boiler openings and blank all connections.
3-9
Chapter 3
! WARNING
DANGER
Materials described in this section may be
considered hazardous under the U.S.
Occupational Safety and Health Act of 1970.
Material Safety Data Sheets should be
obtained and understood prior to the use of
these products to avoid the possibility of
serious personal injury or death.
Wet Storage
Note: It is always best to consult with a
water treatment consultant before
proceeding with extended layup.
Wet storage is used when the boiler will be out of service for
shorter periods of time, when a boiler is held in standby
conditions, or in cases where dry storage is not practical. The
boiler held in wet storage can be brought back into service
more quickly than one held in dry storage. However, the
3-10
750-177
CHAPTER 4
Sequence Of Operation
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
B. Circuit And Interlock Controls . . . . . . . . . . . . . . . . 4-1
C. Sequence Of Operation - Oil Or Gas. . . . . . . . . . . . 4-2
D. Flame Loss Sequence . . . . . . . . . . . . . . . . . . . . . . . 4-3
A. GENERAL
Chapter 4 outlines the electrical sequencing of various
controls through the pre-purge, ignition, run, and shutdown
cycles of the burner.
The program relay establishes the sequence of operation and
directs the operation of all other controls and components to
provide an overall operating sequence.
Note: The make or model of the program
relay provided will vary depending upon job
specifications. The following sequence
applies regardless of the make or model.
Please refer to the Wiring Diagram (WD)
prepared by Cleaver-Brooks for your
specific installation.
Abbreviations for the various electrical components are listed
in Figure 4-1. The sequences outlined in Chapter 4 employ
specific nomenclature to aid in applying the text to the wiring
diagram.
The burner and control system are in starting condition when
the following conditions exist:
Boiler water is up to the correct level, closing the lowwater cutoff switch.
The low-water light (panel) is off.
The operating limit pressure control (steam boiler) or the
operating limit temperature control (hot water boiler) and
high limit pressure or temperature control are below their
cutoff setting.
750-177
4-1
Chapter 4
Blower Motor Starter Circuit
Blower motor starter (BMS)
Running lnterlock Circuit
Blower motor starter interlock (BMSI)
Combustion air proving switch (CAPS)
Low Fire Proving Circuit
Low fire switch (LFS)
Pilot Ignition Circuit
Gas pilot valve (GPV)
Ignition transformer (IT)
Gas pilot vent valve (GPVV) (if provided)
Flame Detector Circuit
Flame detector (FD)
Main fuel valve circuit
Main gas valve (MGV)
Main gas vent valve (MGVV) (if provided)
Oil valve (OV)
Main fuel valve light (FVL)
Firing Rate Circuit
Damper motor transformer (DMT)
Modulating damper motor (MDM)
Manual-automatic switch (MAS)
Manual flame control (MFC)
Modulating control (MC)
To comply with requirements of insurance underwriters such
as Factory Mutual (FM), Industrial Risk Insurers (IRI) or
others, additional interlock devices may be used in addition to
the circuits mentioned in Section B.
High Fire Proving Circuit
High fire switch (HFS)
Running Interlock and Limit Circuit
Low oil pressure switch (LOPS)
High oil pressure switch (HOPS)
Auxiliary low-water cutoff (ALWCO)
4-2
Sequence Of Operation
750-177
Sequence Of Operation
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: Depending upon the requirements of
the regulatory body, insurer or fuel being
burned, either the 10 or 15 second pilot
ignition terminal may be used. Both provide
the same function but differ in time interval
allowed for proving main flame ignition.
Refer to the boiler wiring diagram.
With a proven pilot, the main fuel valve(s) (OV or MGV) is
energized and the main fuel valve light (FVL) in the panel is
lighted. The main flame is ignited and the trial period for
proving the main flame begins. It lasts 10 seconds for light oil
and natural gas. At the end of the proving period, if the flame
detector still detects main flame, the ignition transformer and
pilot valve are deenergized and pilot flame is extinguished.
Note: If the main flame does not light, or
stay lit, the fuel valve will close. The safety
switch will trip to lock out the control. Refer
to flame loss sequence (section D) for
description of action.
! WARNING
DANGER
The cause for loss of flame or any other
unusual condition should be investigated
and corrected before attempting to restart.
Failure to follow these instructions could
result in serious personal injury or death
Run Cycle - With main flame established, the program relay
releases the modulating damper motor (MDM) from its low
fire position to control by either the manual flame control
(MFC) or the modulating control (MC), depending upon the
position of the manual-automatic switch (MAS). This allows
operation in ranges above low fire.
Chapter 4
the pressure vessel metal and refractory to
undesirable conditions.
The burner starting cycle is now complete. The (LDL) and
(FVL) lights on the panel remain lit. Demand firing continues
as required by load conditions.
Burner Shudown-Post Purge - The burner will fire until
steam pressure or water temperature in excess of demand is
generated. With modulated firing, the modulating damper
motor (MDM) should return to the low fire position before
the operating limit control (OLC) opens. When the limit
control circuit is opened, the following sequence occurs:
The main fuel valve circuit is deenergized, causing the main
fuel valve (MGV) or (OV) to close. The flame is
extinguished. The control panel lights (LDL) and (FVL) are
turned off. The blower motor continues to run to force air
through the boiler for the post purge period.
The blower motor start circuit is deenergized at the end of the
post purge cycle and the shutdown cycle is complete.
The program relay is now ready for subsequent recycling, and
when steam pressure or water temperature drops to close the
contacts of the operating control, the burner again goes
through its normal starting and operating cycle.
! CAUTION
DANGER
No pilot flame.
The pilot flame must be ignited and proven within a 10second period after the ignition cycle begins. If not proven
within this period, the main fuel valve circuit will not be
powered and the fuel valve(s) will not be energized. The
ignition circuit is immediately deenergized and the pilot
valve closes, the reset switch lights and lockout occurs
immediately.
4-3
Chapter 4
The blower motor will continue to operate. The flame failure
light and the alarm bell (optional) are energized 10 seconds
later.
The blower motor will be deenergized. The lockout switch
must be manually reset before operation can be resumed.
(Refer to the previous caution.)
2.
Sequence Of Operation
Preventive maintenance and scheduled inspection of all
components should be followed. Periodic checking of the
relay is recommended to see that a safety lockout will occur
under conditions of failure to ignite either pilot or main flame,
or from loss of flame.
When the pilot flame is proven, the main fuel valve circuit is
energized. Depending upon the length of the trial-for-ignition
period, the pilot flame will be extinguished 10 or 15 seconds
later. The flame detecting circuit will respond to deenergize
the main fuel valve circuit within 2 to 4 seconds to stop the
flow of fuel. The reset switch lights and lockout occurs
immediately. The blower motor will continue to operate.
The flame failure light and alarm bell (optional) are energized
10 seconds later.
The blower motor will be then deenergized. The lockout
switch must be manually reset before operation can be
resumed. (Refer to the previous caution.)
3.
Loss of flame.
4-4
750-177
Sequence Of Operation
MNEMONIC
A
AAFL
AAFR
AAPL
AAPS
AAPS-B
AAPS-C
AASS
AB
ACCR
ACM
ACMCB
ACMF
ACMS
ACMSI
AH
ALFR
ALWCO
AM
AMS
AOV
APR
APV
AR
AS
ASR
ASS
ASV
AT
AWCBDS
B
BC
BDCS
BDOS
BDRS
BFPL
BFPM
BFPMCB
BFPMF
BFPMS
BFPS
BFTS
BHS
BIOL
BIOR
BM
BMCB
BMCR
BMF
BMPR
BMPS
BMR
BMS
BMSI
BMSS
Chapter 4
DESCRIPTION
A
Amber (Color Of Pilot Light)
Atomizing Air Failure Light
Atomizing Air Failure Relay
Atomizing Air Proven Light
Atomizing Air Proving Switch
Atomizing Air Proving Switch- Burner
Atomizing Air Proving Switch- Compressor
Atomizing Air Selector Switch
Alarm Bell
Air Compressor Control Relay
Air Compressor Motor
Air Compressor Motor Circuit Breaker
Air Compressor Motor Fuses
Air Compressor Motor Starter
Air Compressor Motor Starter Interlock
Alarm Horn
Assured Low Fire Relay
Auxiliary Low Water Cutoff
Ammeter
Atomizing Media Switch
Auxiliary Oil Valve
Air Purge Relay
Air Purge Valve
Alarm Relay
Auxiliary Switch (Suffix)
Alarm Silencing Relay
Alarm Silencing Switch
Atomizing Steam Valve
Annunciator Transformer
Auxiliary Water Column Blowdown Switch
B
Blue (Color of Pilot Light)
Bias Control
Breeching Damper Closed Switch
Breeching Damper Open Switch
Blowdown/Reset Switch
Boiler Feed Pump Light
Boiler Feed Pump Motor
Boiler Feed Pump Motor Circuit Breaker
Boiler Feed Pump Motor Fuses
Boiler Feed Pump Motor Starter
Boiler Feed Pump Switch
Back Flow Temperature Switch
Boiler - Header Switch
Boiler in Operation Light
Boiler In Operation Relay
Blower Motor
Blower Motor Circuit Breaker
Blower Motor Control Relay
Blower Motor Fuses
Blower Motor Power Relay
Blower Motor Purge Switch
Blower Motor Relay
Blower Motor Starter
Blower Motor Starter Interlock
Boiler Master Selector Switch
MNEMONIC
BS
BSS
BWPM
BWT
CAFL
CAFR
CAP
CAPS
CCCB
CCF
CCRS
CCT
CIPL
CL
CLS
COPS
COR
COTD
CPOL
CR
CSSS
CWPM
CWPMCB
CWPMF
CWPMS
CWPMSI
CWPR
CWPS
CWSV
D
DCVM
DG
DGHPV
DHWC
DHWL
DHWR
DISC
DLWC
DLWL
DLWR
DM
DMT
DNS
DODE
DOE
DPS
DS
EDS
ESS
ETM
FADM
FADR
FD
DESCRIPTION
Burner Switch
Boiler Selector Switch
Booster Water Pump Motor
Booster Water Thermostat
C
Combustion Air Failure Light
Combustion Air Failure Relay
Capacitor
Combustion Air Proving Switch
Control Circuit - Circuit Breaker
Control Circuit Fuse
Control Circuit Reset Switch
Control Circuit Transformer
Changeover In Progress Light
Canopy Light
Canopy Light Switch
Changeover Pressure Switch
Changeover Relay
Changeover Time Delay
Control Power on Light
Control Relay
Control System Selector Switch
Circulating Water Pump Motor
Circulating Water Pump Motor Circuit Breaker
Circulating Water Pump Motor Fuses
Circulating Water Pump Motor Starter
Circulating Water Pump Motor Starter Interlock
Circulating Water Pump Relay
Circulating Water Pump Switch
Cooling Water Solenoid Valve
D
Denotes Digester Gas Equipment (Prefix)
Direct Current Voltmeter
Draft Gauge
Digester Gas Housing Purge Valve
Deaerator High Water Control
Deaerator High Water Light
Deaerator High Water Relay
Disconnect (Entrance Switch)
Deaerator Low Water Control
Deaerator Low Water Light
Deaerator Low Water Relay
Damper Motor
Damper Motor Transformer
Day-Night Switch
Delay On Deenergization (Timer)
Delay On Energization (Timer)
Damper Positioning Switch
Door Switch
E
Emergency Door Switch
Emergency Stop Switch
Elapsed Time Meter
F
Fresh Air Damper Motor
Fresh Air Damper Relay
Flame Detector
4-5
Chapter 4
MNEMONIC
FDJB
FDPS
FFA
FFL
FFR
FGR
FGRCDTD
FGRCPS
FGRFM
FGRFMS
FGRFMSI
FGRMVLS
FGRTD
FORS
FPM
FPMS
FPR
FPS
FRI
FRP
FS
FSS
FSSM
FVEL
FVL
FVR
FWC
FWVT
G
GGL
GOL
GOR
GOS
GOR
GPS
GPV
GPVV
GR
GSSV
GVEL
GVTS
HATC
HBWTC
HBWTL
HFAV
HFGV
HFL
HFOV
HFPS
HFS
HFS-A
HGPL
HGPR
HGPS
HHFL
Sequence Of Operation
DESCRIPTION
Flame Detector Junction Box
Flow Differential Pressure Switch
Flame Failure Alarm
Flame Failure Light
Flame Failure Relay
Flue Gas Recirculation
Flue Gas Recirculation Cool Down Time Delay
Flue Gas Recirculation Cam Position Switch
Flue Gas Recirculation Fan Motor
Flue Gas Recirculation Fan Motor Starter
Flue Gas Recirculation Fan Motor Starter Interlock
Flue Gas Recirculation Manual Valve Limit Switch
Flue Gas Recirculation Time Delay
First Out Reset Switch
Feed Pump Motor
Feed Pump Motor Starter
Feed Pump Relay
Feed Pump Switch
Firing Rate Interface
Firing Rate Potentiometer (O2 Trim)
Flow Switch
Fuel Selector Switch
Flame Signal Strength Meter
Fuel Valve Energized Light
Fuel Valve Light
Fuel Valve Relay
Feed Water Control
Feed Water Valve Transformer
G
Green (Color Of Pilot Light)
Gauge Glass Light
Gas Operation Light
Gas-Oil Relay
Gas-Oil Switch
Gas-Oil Relay
Gas Pressure Sensor
Gas Pilot Valve
Gas Pilot Vent Valve
Gas Relay
Gas Sensor Solenoid Valve
Gas Valve Energized Light
Gas Valve Test Switch
H
High Ambient Temperature Control
High Boiler Water Temperature Control
High Boiler Water Temperature Light
High Fire Air Valve
High Fire Gas Valve
High Fire Light
High Fire Oil Valve
High Furnace Pressure Switch
High Fire Switch
High Fire Switch - Air
High Gas Pressure Light
High Gas Pressure Relay
High Gas Pressure Switch
Header High Fire Light
MNEMONIC
H/LWA
HLC
HLFC
HLPC
HLTC
HMC
HOPL
HOPR
HOPS
HOLC
HOTL
HOTR
HOTS
HPCO
HSPC
HSPL
HSPR
HSTC
HSTL
HSTS
HWAR
HWC
HWCO
HWL
(I.C.)
(I.O.)
IL
INT
IR
IT
JPP
LAMPS
LASPS
LDL
LDPS
LDS
LFAV
LFGV
LFHTD
LFL
LFOV
LFPS
LFR
LFS
LFS-A
LFS-F
LFS-G
LFS-O
LFTC
LGPL
LGPR
LGPS
LIAPS
LLPC
DESCRIPTION
High Low Water Alarm
High Limit Control
High-Low Fire Control
High Limit Pressure Control
High Limit Temperature Control
Header Modulating Control
High Oil Pressure Light
High Oil Pressure Relay
High Oil Pressure Switch
Header Operating Limit Control
High Oil Temperature Light
High Oil Temperature Relay
High Oil Temperature Switch
High Pressure Cutoff
High Steam Pressure Control
High Steam Pressure Light
High Steam Pressure Relay
High Stack Temperature Control
High Stack Temperature Light
High Stack Temperature Switch
High Water Alarm Relay
High Water Control
High Water Cutoff
High Water Light
I
Instantaneously Closed
Instantaneously Open
Ignition Light
Interval (Timer)
Ignition Relay
Ignition Transformer
J
Jackshaft Position Potentiometer
L
Low Atomizing Media Pressure Switch
Low Atomizing Steam Pressure Switch
Load Demand Light
Low Differential Pressure Switch
Low Draft Switch
Low Fire Air Valve
Low Fire Gas Valve
Low Fire Hold Time Delay
Low Fire Light
Low Fire Oil Valve
Low Fire Pressure Switch
Low Fire Relay
Low Fire Switch
Low Fire Switch - Air
Low Fire Switch - Fuel
Low Fire Switch - Gas
Low Fire Switch - Oil
Low Fire Temperature Control
Low Gas Pressure Light
Low Gas Pressure Relay
Low Gas Pressure Switch
Low Instrument Air Pressure Switch
Low Limit Pressure Control
750-177
Sequence Of Operation
MNEMONIC
LLPR
LLR
LLTC
LLTR
LOPL
LOPR
LOPS
LOTL
LOTR
LOTS
LPAPS
LPCO
LPS
LSPAR
LSPC
LSPL
LSPR
LSPS
LTS
LWA
LWAR
LWCO
LWFL
LWL
LWR
LWRR
MA
MAS
MAM
MC
MCS
MDM
MDMAS
MFC
MFGRTS
MFVL
MFWV
MGV
MGVAS
MGVEL
MGVV
MLC
(MOM)
MOV
MOVAS
MOVEL
MPC
MPCB
MPP
(MR)
MTC
MVA
N
(N.C.)
(N.O.)
NFL
Chapter 4
DESCRIPTION
MNEMONIC
NFR
NGHPV
ODA
ODM
ODMAS
ODMT
ODS
OH
OHCB
OHF
OHR
OHS
OHT
OLC
OLPC
OLS
OLTC
OMPM
OMPMF
OOL
OPM
OPMCB
OPMF
OPMS
OPPM
OPR
OPRL
OPRS
OPS
OPSPM
OPV
OR
ORV
OSOV
OSPS
OSS
OT
OTS
OV
OVAS
OVEL
P
PAASV
PAPS
PC
PCL
PCR
PFCC
PFFL
PFFR
PFPS
PHGPS
PIPL
PIS
PLC
PLGPS
DESCRIPTION
No Flow Relay
Natural Gas Housing Purge Valve
O
Outlet Damper Actuator
Outlet Damper Motor
Outlet Damper Motor Auxiliary Switch
Outlet Damper Motor Transformer
Oil Drawer Switch
Oil Heater
Oil Heater Circuit Breaker
Oil Heater Fuses
Oil Heater Relay
Oil Heater Switch
Oil Heater Thermostat
Operating Limit Control
Operating Limit Pressure Control
Thermal Overloads
Operating Limit Temperature Control
Oil Metering Pump Motor
Oil Metering Pump Motor Fuse
Oil Operation Light
Oil Pump Motor
Oil Pump Motor Circuit Breaker
Oil Pump Motor Fuses
Oil Pump Motor Starter
Oil Purge Pump Motor
OIl Purge Relay
Oil Pump Running Light
Oil Pressure Sensor
Oil Pump Switch
Oil Pump Supply Pump Motor
Oil Purge Valve
Oil Relay
Oil Return Valve
Oil Shutoff Valve
O2 Set Point Switch
Oil Selector Switch
Outdoor Thermostat
Oil Temperature Sensor
Oil Valve
Oil Valve Auxiliary Switch
Oil Valve Energized Light
P
Denotes Propane Gas Equipment (Prefix)
Plant Air Atomizing Solenoid Valve
Purge Air Proving Switch
Pump Control
Purge Complete Light
Pump Control Relay
Power Factor Correction Capacitor
Pilot Flame Failure Light
Pilot Flame Failure Relay
Positive Furnace Pressure Switch
Pilot High Gas Pressure Switch
Purge in Progress Light
Pilot Ignition Switch
Programmable Logic Controller
Pilot Low Gas Pressure Switch
4-7
Chapter 4
MNEMONIC
POL
POV
PPL
PPR
PPTD
PR
PRL
PRPTD
PR
PRPTD
PS
PSF
PSS
PSV
PT
PTS
PUCR
PUR
R
RAR
RATD
RES
RML
RMR
RS
RSR
RTD
SBFPL
SBFPM
SBFPMCB
SBFPMF
SBFPMS
SBOV
SBPS
SBR
SC
SCTS
SDL
SHT
SHV
SLCL
SPIR
SPS
SS
SSC
SSL
SSR
SSV
STHWC
STHWL
STHWR
STLWC
STLWL
Sequence Of Operation
DESCRIPTION
MNEMONIC
Power On Light
Pilot Oil Valve
Pre-Purging Light
Post Purge Relay
Post Purge Time Delay
Program Relay
Purge Ready Light
Pre-Purge Time Delay
Program Relay
Per-Purge Time Delay
Power Supply
Power Supply Fuse
Pump Selector Switch
Purge Solenoid Valve
Purge Timer
Pump Transfer Switch
Purge Complete Relay
Purge Relay
STLWR
R
Red (Color of Pilot Light)
Remote Alarm Relay
Remote Alarm Time Delay
Resistor
Run Mode Light
Release To Modulate Relay
Range Switch
Remote Start Relay
Resistance Temperature Detector
S
Stand By Feed Pump Light
Stand By Feed Pump Motor
Stand By Feed Pump Motor Circuit Breaker
Stand By Feed Pump Motor Fuses
Stand By Feed Pump Motor Starter
Surface Blow Off Valve
Sootblower Pressure Switch
Sootblower Relay
Scanner
Supervisory Cock Test Switch
Steam Demand Light
Steam Heater Thermostat
Steam Heater Valve
Safety Limits Complete Light
System Pump Interlock Relay
Steam Pressure Sensor
Selector Switch
Sequencing Step Controller
Safety Shutdown Light
Solid State Relay
SpanSolenoid Relay
Surge Tank High Water Control
Surge Tank High Water Light
Surge Tank High Water Relay
Surge Tank Low Water Control
Surge Tank Low Water Light
UVFD
(T.C.)
(T.O.)
TB
T/C
TC
TCR
TD
TDAS
TFWR
TPL
TPM
TPMCB
TPMF
TPMS
TPS
V
VDR
W
WC
WCBDS
WF
WFNL
WLC
WO
WTS
Y
DESCRIPTION
Surge Tank Low Water Relay
T
Timed Closed
Timed Open
Terminal Block
Thermocouple
Time Clock
Time Clock Relay
Time Delay
Time Delay Auxiliary Switch
Transistorized Feedwater Relay
Transfer Pump Light
Transfer Pump Motor
Transfer Pump Motor Circuit Breaker
Transfer Pump Motor Fuses
Transfer Pump Motor Starter
Transfer Pump Switch
U
Ultra-Violet Flame Detector
V
Voltmeter
Voltage Differential Relay
W
White (Color of Pilot Light)
Water Column
Water Column Blow Down Switch
Water Feeder
Water Flow Normal Light
Water Level Control
Denotes Waste Oil Equipment (Prefix)
Water Temperature Sensor
Y
Yellow (Color of Pilot Light)
4-8
750-177
CHAPTER 5
Adjustment Procedures
A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
B. Linkage - Modulating Motor & Air Damper . . . . . .5-1
C. Modulating Motor . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
D. Modulating Motor Switches Low Fire and High Fire . . . . . . . . . . . . . . . . . . . . . .5-2
E. Burner Operating Controls - General. . . . . . . . . . . .5-2
F. Modulating Pressure Control (Steam) . . . . . . . . . . .5-5
G. Operating Limit Pressure Control (Steam) . . . . . . .5-5
H. High Limit Pressure Control (Steam) . . . . . . . . . . .5-5
I. Modulating Temperature Control (Hot Water). . . . .5-5
J. Operating Limit Temperature Control (Hot Water) .5-5
K. High Limit Temperature Control (Hot Water) . . . .5-5
A. GENERAL
Each Cleaver-Brooks boiler is tested for correct operation
before shipment from the factory. However, variable
conditions such as burning characteristics of the fuel and
operating load conditions may require further adjustment
after installation to assure maximum operating efficiency and
economy.
A combustion efficiency analysis made during the initial
start-up will help to determine what additional adjustments
are required in a particular installation.
Prior to placing the boiler into service, a complete inspection
should be made of all controls, connecting piping, wiring, and
all fastenings such as nuts, bolts and setscrews to be sure that
no damage has occurred, or that adjustments have not
changed during shipment and installation.
The adjustment procedures in Chapter 6 apply to standard
components furnished on steam or hot water boilers fired
with gas and/or the various grades of oil.
750-177
! CAUTION
DANGER
Do not restrict the full travel of the modulating motor. Failure to follow these instructions could result in equipment damage.
5-1
Chapter 5
Adjustment Procedures
2.
3.
C. MODULATING MOTOR
The modulating motor has a 90 shaft rotation. The motor
manufacturer also provides a 160 stroke model for other
applications. If a replacement is obtained from someone other
than a Cleaver-Brooks Service or Parts representative, it may
have an incorrect stroke. To prevent damage, verify the 90
stroke prior to installing a replacement.
The stroke may be determined by powering the motor and
connecting terminals R-B to actually determine the stroke as
motor drives to an open position.
5-2
750-177
Adjustment Procedures
Chapter 5
! CAUTION
DANGER
Excessive cycling increases the potential
and severity of internal condensation. OnOff cycling should be limited to eight (8) cycles or less per hour to keep the blower motor from overheating and excessive wear on
the switch gear and pilot. Failure to follow
these instructions could result in damage
and premature failure of the equipment.
750-177
5-3
Chapter 5
Adjustment Procedures
100%
Increasing
Firing Rate
Minimum Input
(Low Fire)
Falling Temp.
or Pressure
Modulated Firing
Range
ON - OFF
Differential
Rising Temp.
or Pressure
Burner Off
(Burner ON)
0%
(Burner OFF)
(Burner OFF)
Increasing
5-4
6-4
750-177
Adjustment Procedures
settings and should not exceed 90% of the valve setting. The
control requires manual resetting after it shuts off the burner.
In the setting of the controls, consideration must be given to
the time required for a burner restart. Each start, requires a
prepurge period, plus the fixed time required for proving the
pilot and main flame. In addition, approximately one-half
minute is required for the damper motor to travel from low to
high fire. The time lag may allow pressure or temperature to
drop below desirable limits.
F. MODULATING PRESSURE
CONTROL (Steam)
Turn the adjusting screw until the indicator is opposite the
low point of the desired modulating range. Modulated firing
will range between the low point and a higher point equal to
the modulating range of the particular control. In 0-15 psi
controls the range is 1/2 psi.
! CAUTION
DANGER
To prevent burner shutdown at other than
low-fire setting, adjust the modulating pressure control to modulate to low fire BEFORE
the operating limit pressure control shuts
off the burner. Failure to follow these instructions could result in damage to the
equipment
750-177
Chapter 5
on a pressure increase. To reset, allow pressure to return to
normal and then press the reset button.
I. MODULATING TEMPERATURE
CONTROL (Hot Water)
Turn the knob on the front of the case until the pointer
indicates the desired setpoint temperature. The desired set
point is the center point of a proportional range. The control
has a 3 to 30 differential and may be adjusted to vary the
temperature range within which modulating action is desired.
With the cover off, turn the adjustment wheel until pointer
indicates desired range.
! CAUTION
DANGER
To prevent burner shutdown at other than
low-fire setting adjust modulating temperature control to modulate low fire BEFORE
operating limit temperature control shuts
off burner. Failure to follow these instructions could result in damage to the equipment.
J. OPERATING LIMIT
TEMPERATURE CONTROL
(Hot Water)
Set cut-out (burner off) temperature on the scale by
inserting a screwdriver through the cover opening to engage
the slotted head adjusting screw. The cut-in (burner on)
temperature is the cut-out temperature MINUS the
differential. The differential is adjusted from 5 to 30 F.
5-5
Chapter 5
Adjustment Procedures
5-6
Pressure
The gas supplied must provide not only the quantity of gas
demanded by the unit, but must also be at a pressure high
enough to overcome the pressure-loss due to the frictional
resistance imposed by the burner system and the control
valves.
The pressure required at the entrance to the burner gas train
for rated boiler output is termed inlet pressure. The gas
pressure regulator must be adjusted to achieve the pressure to
assure full input.
The inlet pressure requirement varies with boiler size, and
types of gas train. Refer to Table 6-3 for pressure requirements.
The pressures listed are based on 1000 Btu/cu-ft natural gas
at elevations up to 700 feet above sea level.
The volume of gas flow is measured in terms of cubic feet and
is determined by a meter reading. The gas flow rate required
for maximum boiler output depends on the heating value
(Btu/cu-ft) of the gas supplied (Table 6-1).
750-177
Adjustment Procedures
Pressure Correction
The flow rate outlined in Section P is based on a base
pressure, which is usually atmospheric or 14.7 psia.
Meters generally measure gas in cubic feet at line or supply
pressure. The pressure at which each cubic foot is measured
and the correction factor for the pressure must be known in
order to convert the quantity indicated by the meter into the
quantity which would be measured at base pressure.
To express the volume obtained from an actual meter reading
into cubic feet at base pressure, it is necessary to multiply the
meter index reading by the proper pressure factor obtained
from Table 6-2
As An Example:
Assume that a 500Flextube boiler is rated for 5MMBtu/hr
input is installed and equipped with a standard gas train; and
that 1,000 Btu natural gas is available with an incoming gas
pressure of 3 psig. The flow requirements can be determined
as follows:
Flow
Since the gas flow rate is based on standard conditions of
flow, correction must be made for the supply pressure through
the meter of 3 psig. Determine the flow rate by dividing the
Btu content of the gas into the burner input (Table 6-1) and
correct this answer by applying the correction factor for 3
psig (Table 6-2).
Btu/hr Input = CFH (Cubic feet/hour) Required
Btu/cu-ft
OR
5,000,000
1,000
THEN
5,000 = 4237 CFH
1.18
This is the CFH (at line pressure) that must pass through the
meter so that the equivalent full input requirement of 5,000
CFH (at base pressure) will be delivered.
Checking Gas Flow
Your gas supplier can generally furnish a gas meter flow chart
from which gas flow can be determined. After a short
observation period, the information aids in adjusting the
regulator to increase or decrease flow as required to obtain the
rating.
Final adjustment of the gas fuel is carried out by means of
Fine tuning the linkage adjustments, while performing a
combustion efficiency analysis. See Section O for details.
Chapter 5
Note: The information given in this section
is for all practical purposes sufficient to set
and adjust controls for gas input. Your gas
supplier can, if necessary, furnish exact
correction factors that take into
consideration Btu content, exact base
pressure, specific gravity, temperature, etc.,
of the gas used.
750-177
5-7
Chapter 5
maximum CO level standardly allowed is less than 400 ppm.
However, this may change subject to local regulations.
The percent O2 recorded on an instrument equates to percent
excess air, I.E. 3% O2 is approximately 15% excess air and
4% O2 is approximately 20% excess air. The exact percentage
of excess air is a mathematical calculation based on an
ultimate fuel analysis of the fuel being fired.
It is generally recommended that O2 readings of between 3%
to 5% be attained with less than 400 ppm CO, at high fire.
Using information from Section O of Chapter 6, determine
the standard conditions of gas pressure and flow for the size
boiler and the gas train on it. Calculate the actual pressure and
flow through the use of correction factors that compensate for
incoming gas pressure and altitude.
Basically, gas adjustments are made with a gas pressure
regulator, which controls the pressure and with the butterfly
gas valve which directly controls the rate of flow.
The low fire setting should be regarded as tentative until the
proper gas pressure for high fire operation is established.
To reach the high fire rate, turn the manual flame control
switch toward OPEN in minor increments while
monitoring combustion for overly rich or lean conditions.
At high fire, the gas butterfly valve should be open as wide as
indicated by the slot on the end of the shaft.
Determine the actual gas flow from a meter reading. (See
Section O of Chapter 6.) With the butterfly valve open and
with regulated gas pressure set at the calculated pressure, the
actual flow rate should be close to the required input. If
corrections are necessary, increase or decrease the gas
pressure by adjusting the gas pressure regulator, following
the manufacturer's directions for regulator adjustment.
When proper gas flow is obtained, take a flue gas reading.
The O2 should be between 3% and 5% at high fire.
If the fuel input is correct, but the O2 values do not fall within
this range, the air damper settings may need to be adjusted.
Adjustment of the air damper linkage is described in Section
B of Chapter 6.
With the high-fire air/fuel ratio established, the gas pressure
regulator needs no further adjusting.
After being certain 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 adjustment can be made, if necessary obtain a constant
air/fuel ratio throughout the entire firing range.
Adjustment Procedures
If the air damper needs to be adjusted in order to provide the
correct low fire air/fuel ratio, combustion must be rechecked
at higher firing rates and adjusted as required.
750-177
Adjustment Procedures
MODEL NO.
Fuel Consumption
Chapter 5
150
200
250
300
350
400
450
500
550
600
700
800
900
1000
1100
1200
2000
2500
3000
3500
4000
4500
5000
5500
6000
7000
8000
BURNER
MODEL
REGULATOR INLET
PRESSURE (PSIG)
PRESSURE FACTOR
FLX-150
11.2
12.5
PFVG-15
1.05
FLX-200
19.4
21.7
PFVG-20
1.11
FLX-250
1.5
12.4
15.7
PFVG-25
1.18
FLX-300
1.5
15.9
20.7
PFVG-30
FLX-350
1.5
15.5
22.0
PFVG-35
FLX-400
1.5
18.7
27.2
PFVG-40
3
4
1.25
1.32
FLX-450
16.0
26.7
PFVG-45
1.39
FLX-500
17.6
21.0
PFVG-50
1.45
FLX-550
22.9
27.1
PFVG-55
FLX-600
20.0
24.9
PFVG-60
FLX-700
25.2
31.9
PFVG-70
7
8
1.53
1.59
FLX-800
2.5
19.9
22.2
PFVG-80
10
1.66
FLX-900
2.5
24.7
27.7
PFVG-90
11
1.72
FLX-1000
2.5
31.6
31.6
PFVG-100
FLX-1100
2.5
37.3
37.3
PFVG-110
FLX-1200
2.5
38.2
38.2
PFVG-120
12
1.81
13
1.86
14
1.93
15
2.00
Notes:
1. Table is based on 1,000 Btu/cu.ft natural gas and elevation to 1000
feet.
2. Minimum gas pressure also applies to 200 fuel series.
3. As an option, the standard gas train can be replaced with an
oversized design to reduce inlet gas pressure requirements.
4. Use this column for all U.S. Installations.
5. Use this column for all Canadian Installations.
Chapter 5
Adjustment Procedures
12
11
10
9
60
8
5
4
7
6
PER CENT O2 IN FLUE GAS
50
20
40
30
PER CENT EXCESS AIR
15
10
3
4
5
PER CENT CO
5-10
Pressure Switches
750-177
CHAPTER 6
Troubleshooting
! WARNING
DANGER
Troubleshooting should be performed only
by personnel who are familiar with the
equipment and who have read and
understand the contents of this manual.
Failure to follow these instructions could
result in serious personal injury or death.
! WARNING
DANGER
Disconnect and lock out the main power
supply in order to avoid the hazard of
electrical shock.Failure to follow these
instructions could result in serious
personal injury or death.
Chapter 7 assumes that the unit has been properly installed
and adjusted, and that it has been running for some time. It is
further assumed that the operator has become thoroughly
familiar with both burner and manual by this time. The points
under each heading are set down briefly as possible causes,
suggestions or clues to simplify locating the source of
trouble. Methods of correcting the trouble, once it has been
identified, may be found elsewhere in this manual.
If the burner will not start or operate properly, the trouble
shooting chapter should be referred to for assistance in
pinpointing problems that may not be readily apparent.
The program relay has the capability to self-diagnose and to
display a code or message that indicates the failure condition.
Refer to the control bulletin for specifics and suggested
remedies.
Familiarity with the programmer and other controls in the
system may be obtained by studying the contents of this
manual. Knowledge of the system and its controls will make
trouble shooting much easier. Costly down-time or delays can
be prevented by systematic checks of actual operation against
the normal sequence to determine the stage at which
performance deviates from normal. Following a routine may
750-177
6-1
Chapter 6
Troubleshooting
Problem
Solution
1.
2.
3.
Limit circuit not completedno voltage at end of limit circuit program relay
terminal.
A. Pressure or temperature is above setting of operation control. (Load demand
light will not glow.)
B. Water below required level.
1). Low-water light (and alarm horn)should indicate this condition.
2). Check manual reset button, if provided,
on low-water control.
C. Fuel pressure must be within settings of low pressure and high pressure
switches.
4.
NO IGNITION
1.
Lack of spark.
A. Electrode grounded or porcelain cracked.
B. Improper electrode setting.
C. Loose terminal on ignition cable; cable shorted.
D. Inoperative ignition transformer.
E. Insufficient or no voltage at pilot ignition circuit terminal.
2.
3.
4.
5.
6-2
750-177
Troubleshooting
Chapter 6
Problem
PILOT FLAME, BUT NO
MAIN FLAME
Solution
1.
2.
3.
SHUTDOWN OCCURS
DURING FIRING
4.
5.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
If the programmer lockout switch has not tripped, check the limit circuit for an
opened safety control.
6.
750-177
6-3
Chapter 6
Troubleshooting
Problem
SHUTDOWN OCCURS
DURING FIRING
Solution
7.
MODULATING MOTOR
DOES NOT OPERATE
8.
1.
2.
3.
Motor does not drive to open or close during pre-purge or close on burner shutdown.
A. Motor defective.
B. Loose electrical connection.
C. Damper motor transformer defective.
4.
Water On Base
1. A cold environment and/or intermittent firing may allow inner casing to heat up above
the condensation temperature of the flue gasses.
A. Increase temperature of the cold boiler room if possible.
B. Verify insulation is in place between inner and outer casing and replace if missing.
C. Reset controls for less cycling to allow boiler to run for longer periods of time to heat
inner casing above condensation temperature.
6-4
750-177
Troubleshooting
Chapter 6
Problem
Solution
2. Cold system startup.
A. Any time a boiler is started with a cold system, it will produce condensate until
internal surface temperatures exceed 130 F. Internal condensation will not be produced
once a boiler has warmed up. Condensate will dry up after a short time. Limit number
of cold starts.
3. Cold return temperatures.
A. Return temperatures below 120 F. will continually produce condensation. Raise
return temperatures above 120 F.
4. Gasket leaks allow gases to escape and condence on relatively cool base.
A. Gasket may need to be replaced or inner casing not installer per instructions. Install
inner casing and gasket per instructions outlined in Chapter 8, SectionD.
750-177
6-5
Chapter 6
6-6
Troubleshooting
750-177
CHAPTER 7
Inspection and Maintenance
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
B. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
C. Fireside Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
D. Upper Pass Cleaning. . . . . . . . . . . . . . . . . . . . . . . . 7-2
E. Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
F. Oil Burner Maintenance . . . . . . . . . . . . . . . . . . . . . 7-6
G. Gas Burner Maintenance. . . . . . . . . . . . . . . . . . . . . 7-7
H. Refractory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
I. Casing Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
A. GENERAL
A well-planned maintenance program will help to avoid
unnecessary downtime or costly repairs, promote safety, and
aid boiler inspectors in performing required periodic
inspections. An inspection schedule with a listing of
procedures should be established. It is recommended that a
boiler room log or record be maintained. Recording of daily,
weekly, monthly, and yearly maintenance activities provides
a valuable guide and aids in obtaining safe, economical and
lengthy service from your Cleaver-Brooks equipment. It is
important to realize that the frequency of inspection will
depend on variable conditions such as load, fuel, system
requirements, boiler environment, etc.
! WARNING
DANGER
! WARNING
DANGER
B. PERIODIC INSPECTION
750-177
Chapter 7
C. FIRESIDE CLEANING
Soot and other noncombustible deposits are effective
insulators and, if allowed to accumulate on boiler heat
exchanger surfaces, will reduce heat transfer to the water and
increase fuel consumption. Soot and other deposits can
absorb moisture and may attract moisture in the form of
corrosive acids that will deteriorate fireside metal.
Inspection and cleanout should be performed at frequent
intervals, depending upon the boiler's load, type and quality
of fuel, internal boiler temperature, and combustion
efficiency. Stack temperature can be used as a guide to
determine cleanout intervals, since an accumulation of soot
deposits will raise the stack temperature.
Access to the furnace for tube and refractory cleaning is
provided through a hinged burner door at the front of the
boiler. When opening the burner door, first shut off the
electrical and fuel supplies and then disconnect all fuel lines
at the burner watching to see that there is no interference with
field installed piping, wiring, or other obstructions. A
temporary platform must be placed inside the furnace in order
to protect the bottom drum insulating refractory when
working inside the furnace.
! WARNING
DANGER
To avoid the hazard of electrical shock,
which could cause serious personal injury
or death, the use of a low voltage flashlight
Is recommended when working Inside the
boiler furnace area.
7-2
Chapter 7
750-177
7-3
Chapter 7
E. CONTROLS
Relief Valves
The relief valve is a very important safety device and
deserves attention accordingly. Proper removal, installation
or handling of a relief valve is of primary importance.
Exercise care when removing, installing or handling a relief
valve to ensure proper operation, long service life, and to
ensure that the valve functions as designed.
! WARNING
DANGER
Improper removal, handling or installation
of a relief valve may adversely affect the
valve's operation, resulting in serious
personal injury or death.
Observe the following precautions when removing, handling
or installing relief valves.
! WARNING
DANGER
Only properly certified personnel such as
the relief valve manufacturer's
representative should adjust or repair the
boiler relief valves. Failure to heed this
warning could result in serious personal
injury or death.
Relief valves should be operated only often enough to assure
t h a t t h e y a r e i n g o o d w o r k i n g o r d e r. F o l l o w t h e
recommendations of your boiler inspector regarding valve
inspection and testing. The frequency and method of testing
should be based on the recommendation of your boiler
inspector and/or the valve manufacturer, and should be in
7-4
! WARNING
DANGER
Safe operation of your boiler demands
periodic inspection and maintenance of all
low water cutoff devices. If controls do not
shut off the burner when the water level
drops below the safe operating level, or if
controls appear in poor physical condition,
or become erratic in operation, they must be
repaired or replaced at once. Failure to heed
this warning could result in serious
personal injury or death.
If test-n-check valves are installed on the float style low water
cutoff devices, these controls can be tested by opening the
blow down valve. The test-n-check valves restrict water flow
750-177
Chapter 7
! CAUTION
DANGER
If a control does not break the circuit to stop
the burner at the proper point then shut
down the burner immediately. Failure to do
so may result in damage to the equipment.
Do not restart until all cross-connecting piping is checked for
obstructions. Also check the float bowl. If these are clean,
repair or replace the control. Repeat the above test to ensure
proper operation prior to returning the boiler to service.
On a steam boiler, the head mechanism of the low water
cutoff device(s) should be removed from the bowl at least
once a month to check and clean the float ball, the internal
moving parts, and the bowl or water column.
Remove the pipe plugs from the tees or crosses and make
certain the cross- connecting piping is clean and free of
obstructions. Controls must be mounted in a plumb position
for proper performance. Determine that piping is vertically
aligned after shipment and installation and throughout the life
of the equipment.
A scheduled blowdown of the water controls on a steam
boiler should be maintained.
750-177
7-5
Chapter 7
Electrical Controls
The operating controls should be inspected monthly.
Examine the tightness of electrical connections and keep the
controls clean. Remove any dust that accumulates on the
interior of the controls using low pressure air that is free of
moisture and oil. Take care not to damage the mechanism.
Examine any mercury tube switches for damage or cracks.
Dark scum over the normally bright surface of the mercury
indicates a damaged tube that may lead to erratic switching
action. Make certain that controls are correctly leveled.
Covers should remain on controls and panels at all times.
Dust and dirt can cause excessive wear or overheating of the
motor stator and the relay contacts, and affect operation of
other controls. The power supply to the boiler must be
protected with dual element fuses (fusetrons) or circuit
breakers. Similar fuses should be used in branch circuits.
Standard one-shot fuses are not recommended.
! WARNING
DANGER
When replacing a control, be sure to lock
out the main power supply, since the control
is hot even though the burner switch is
off. Failure to heed this warning could result
in serious personal injury or death.
Your spare control should be wrapped in plastic and stored in
a dry atmosphere. During an extended shutdown (for
example, a seasonal shutdown), the active control should be
removed and stored in a dry atmosphere. Moisture can cause
problems with control operation.
The flame detector lens should be cleaned as often as
operating conditions demand. Use a soft cloth moistened with
detergent to clean the lens.
A safety check procedure should be established to test the
complete flame safeguard system at least once a month. Tests
should verify safety shutdown and a safety lockout upon
failure to ignite the main flame and upon loss of flame. Each
of these conditions should be checked on a scheduled basis.
7-6
Strainer Servicing
The fuel oil strainer element must be removed and cleaned or
replaced at regular intervals, or when a rising trend in the
burner supply pump suction indicates blockage. When
servicing the strainer, fuel supply and return line valves
should be shut off. The strainer should be drained of oil and
any sediment collected at the bottom of the canister. Remove
the cover and withdraw the strainer element. Replaceable
elements should be disposed of properly. Reusable elements
may be cleaned by immersing them in solvent until attached
deposits have been loosened, and then shaking them dry.
! WARNING
DANGER
Use only safety type solvents such as
C l e a v e r - B r o o k s S a f e ty S o l v e n t f o r
cleaning strainers or other components.
Work only in a well ventilated area. Do not
use gasoline or other flammable liquids as a
solvent. Do not dry the strainer elements
with compressed air. Failure to heed this
warning could result in serious personal
Injury or death.
Reassemble the strainer, taking care to seal the canister
properly to avoid air infiltration and resulting loss of suction.
Open the fuel supply and the return line valves.
750-177
Solenoid Valves
Foreign matter between the valve seat and the seat disc will
cause leakage. Valves are readily disassembled; however,
care must be taken to see that internal parts are not damaged
during removal and that reassembly is in the proper order.
A low hum or buzzing will normally be audible when the
solenoid coil is energized. If the valve emits a loud buzzing
or a chattering noise, check for proper voltage. If voltage is
correct, clean the plunger assembly and interior plunger tube
thoroughly. Do not use any oil. Make sure that the plunger
tube and solenoid are tight when assembled. Take care not to
nick, dent, or damage the plunger tube.
Solenoid coils can be replaced without removing the valve
from the line.
! WARNING
DANGER
Be sure to disconnect the main power
supply to the boiler in order to prevent the
possibility of electrical shock, which could
result in serious personal injury or death.
Check the coil position and make sure that any insulating
washers or retaining springs are reinstalled in the proper
order.
H. REFRACTORY
The boiler is shipped with completely installed refractory.
High temperature refractory lines the burner door and floor of
the boiler. Front and rear walls, side casing panels, the roof
section, the bottom drum and the drum vent are protected
with high temperature insulation. Preventive maintenance
through periodic inspection will keep the operator aware of
750-177
Chapter 7
the condition of the refractory and insulation and will guard
against unexpected downtime for repairs.
I. CASING SEALS
The most obvious indication of a problem is the appearance
of discolored paint on the casing or soot and hot gases
escaping at seal joints. It is important that at start-up any
problems are noted and corrected before the boiler is put back
into operation. The following are areas requiring inspection.
Burner Door
Inspect the area around the door and look for discolored paint
or evidence of combustion gas leakage. If a problem is noted
or the door is being opened for scheduled maintenance look
for warped sealing surfaces and make sure that the insulation
on the front wall around the door has not pushed away from
the wall. Cracks may appear in the burner door refractory as
a result of expansion and contraction from operation. If
cracks are larger than 1/8 when the refractory is cooled, the
cracks should be filled with a high temperature bonding airdry mortar such as Cleaver- Brooks Corline.
! WARNING
DANGER
Disconnect main power to the boiler and the
pilot fuel supply to the burner before the
burner door is opened. Electrical power and
fuel supply must remain shut off at all times
when the burner door is open. Failure to
heed this warning could result in serious
personal Injury or death.
Access to the boiler furnace area is gained through the burner
door opening at the front of the boiler. Whenever the burner
is opened, the gasket and gasket surfaces of the burner door
should be inspected. A good seal between the burner door and
the boiler is necessary to prevent leakage of combustion gases
and loss of efficiency. Combustion gas leaks can cause hot
spots with subsequent damage to the burner door and
surrounding refractory. Damaged or hardened gaskets must
be replaced before the burner is put back in operation.
If a new gasket is necessary, remove the old gasket and clean
the gasket surface on the wall and burner door. A spray
adhesive is used to hold the rope gasket in place around the
burner opening. A high temperature silicone may be needed
to seal under the rope gasket at the wall seams. The rope
gasket should wrap around the opening at least two times.
Before the burner door is closed, inspect studs and clean
threads if necessary with 1/2"-13 die. Apply a small amount
of Cleaver-Brooks "Never-Seez" (p.n. 797-1814 or 7971816) to the studs. Any nuts that are difficult to thread on
studs should be replaced. Door fasteners should be run in and
tightened evenly to avoid distorting the door or damaging the
7-7
Chapter 7
Sight Port
Drum Seals
Inspect the areas around the drum seals and look for soot or
hot gas leaks. If a problem is noted look for the source of the
leak. Remove the old insulation and sealant from around the
drum. Using a pumpable insulation material (p.n. 872-680),
fill the void flush with the outside of the wall. Allow the area
to set up and apply a thick bead of high temperature silicone
around the drum and install the cover plates.
7-8
Inspect the area around the sight port for paint discoloration.
A hot spot around the rear sight port is caused by either a poor
seal between the sight port insulator and the wall, a cracked
insulator or a flue gas leak at the sight port cap.
750-177
CHAPTER 8
PARTS
8-2
Figure: 8-1 Typical Hot Water Flextube Casing
750-177
750-177
Part List, Hot Water
ITEM
1.
2.
3.a
3.b
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
DESCRIPTION
Base
Roof
Front wall, w/o Hinge
Front wall w Hinge
Rear wall-large piece
Outer casing panel
Outer casing strips-top
Plate, base to wall
Outer casing strips corner strip
Burner plate
Inner side panel Left Hand
Inner side panel Right Hand
Mounting Plate
Plate, Collar, Lower Outer
Plate, Collar, Upper Outer
Plate, Cover, Lug, Lifting
Cap, sight
Capscrew, hex hd. 3/8-16x 3/4lg
Capscrew, hex hd. 1/2-13x 1-1/2lg
Capscrew, hex hd. 5/8-11x 1-1/2lg
Screw, self tapping, x 1lg
Locknut, hex hd., 3/8
Nut, hex hd., brass
Nut, hex hd.,
Capscrew, Hex hd -10 x 6 LG
Washer, flat,
Washer, flat, 5/8
Never-Seez
Inner Casing Spacer Block
Inner Side Panel Mid Left
Inner Side Panel Mid Right
Inner Side Panel Mid
Retaining Plates, Lower, Inner, Small
Retaining Plates, Lower, Inner, Large
Plate, collar, upper, inner
Assembly, rear wall corner piece
Gasket, Expanded PTFE 3/8 x 3/16
Handle, Flush Mount, Snap In
250
PART #
315-1124
315-1127
315-1262
315-1128
315-1129
315-1130
315-1131
315-1132
315-1133
Note 5
315-1135
315-1136
315-1143
315-694
315-1159
315-1100
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
n/a
n/a
n/a
315-1178
315-1158
315-1204
315-1140
32-2560
865-68
350
REQ
1
1
1
1
1
6
2
4
4
1
2
2
1
2
2
1
1
26
8
8
50
118
12
24
2
44
8
1
8
3
1
2
1
70 ft
12
500
800
1100
PART #
REQ
PART #
REQ
PART #
REQ
315-1169
315-1167
315-1265
315-1166
315-1165
315-1164
315-1163
315-1132
315-1162
Note 5
315-1161
315-1160
315-1143
315-694
315-1159
315-1100
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
n/a
n/a
n/a
315-1178
315-1158
315-1204
315-1279
32-2560
865-68
1
1
1
1
1
6
2
4
4
1
2
2
1
2
2
1
1
28
8
8
50
124
12
24
2
44
8
1
8
315-1180
315-1178
n/a
315-1177
315-1176
315-1175
315-1174
315-1132
315-1173
Note 5
315-1172
315-1171
315-1143
315-695
315-1183
315-1100
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
n/a
n/a
315-1206
315-1280
315-1182
315-1207
315-1281
32-2560
865-68
1
1
315-1194
315-1192
n/a
315-1191
315-1190
315-1189
315-1188
315-1132
315-1187
Note 5
315-1186
315-1185
315-1143
315-695
315-1183
315-1099
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
315-1294
315-1208
n/a
315-1280
315-1182
n/a
315-1282
32-2560
865-68
1
1
3
1
2
1
75 ft
12
1
1
8
2
4
4
1
2
2
1
2
2
1
1
60
8
8
50
180
12
24
2
44
8
1
12
2
3
1
2
1
99 ft
16
1
1
10
2
4
4
1
2
2
1
2
4
1
1
96
8
8
50
232
12
28
2
48
8
1
16
2
2
3
1
1
127ft
16
PART #
315-1203
315-1202
n/a
315-1201
315-1190
315-1198
315-1197
315-1132
315-1187
Note 5
315-1196
315-1195
315-1143
315-695
315-1210
315-1099
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
315-1294
315-1208
315-1209
315-1280
315-1182
315-1183
315-1282
32-2560
865-68
REQ
1
1
1
1
12
4
4
4
1
2
2
1
2
2
1
1
128
8
8
54
284
12
28
2
48
8
1
20
2
2
2
3
1
2
1
149ft
24
8-3
8-4
Figure: 8-2 Typical Low Pressure Steam Flextube Casing
750-177
750-177
DESCRIPTION
Base
Roof
Front wall, w/o Hinge
Front wall w Hinge
Rear wall-large piece
Outer casing panel
Outer casing strips-top
Plate, base to wall
Outer casing strips corner strip
Burner plate
Inner side panel Left Hand
Inner side panel Right Hand
Mounting Plate
Plate, Collar, Lower Outer
Plate, Collar, Upper Outer
Plate, Cover, Lug, Lifting
Cap, sight
Capscrew, hex hd. 3/8-16x 3/4lg
Capscrew, hex hd. 1/2-13x 1-1/2lg
Capscrew, hex hd. 5/8-11x 1-1/2lg
Screw, self tapping, x 1lg
Locknut, hex hd., 3/8
Nut, hex hd., brass
Nut, hex hd.,
Capscrew, Hex hd -10 x 6 LG
Washer, flat,
Washer, flat, 5/8
Never-Seez
Inner Casing Spacer Block
Inner Side Panel Mid Left
Inner Side Panel Mid Right
Inner Side Panel Mid
Retaining Plates, Lower, Inner, Small
Retaining Plates, Lower, Inner, Large
Plate, collar, upper, inner
Ring Seal, Outlet Steam #15
Assembly, rear wall corner piece
Assembly, front wall corner piece
Gasket, Expanded PTFE 3/8 x 3/16
Handle, Flush Mount, Snap In
250
PART #
315-1124
315-1215
315-1263
315-1216
315-1217
315-1218
315-1131
315-1132
315-1219
Note 5
315-1220
315-1221
315-1143
315-694
315-1222
315-1100
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
n/a
n/a
n/a
315-1278
315-1158
315-1223
315-219
315-1286
315-1285
32-2560
865-68
350
REQ
1
1
1
1
1
6
2
4
4
1
2
2
1
2
2
1
1
28
8
8
56
128
12
28
2
48
8
1
8
3
1
2
1
1
1
79 ft
12
500
PART #
REQ
PART #
315-1169
315-1230
315-1264
315-1229
315-1228
315-1227
315-1163
315-1132
315-1226
Note 5
315-1225
315-1224
315-1143
315-694
315-1222
315-1100
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
n/a
n/a
n/a
315-1278
315-1158
315-1223
315-220
315-1287
315-1288
32-2560
865-68
1
1
1
1
1
6
2
4
4
1
2
2
2
2
2
1
1
30
8
8
56
130
12
28
2
48
8
1
8
315-1180
315-1239
n/a
315-1138
315-1237
315-1236
315-1174
315-1132
315-1235
Note 5
315-1234
315-1233
315-1143
315-695
315-1222
315-1100
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
n/a
n/a
315-1242
315-1280
315-1282
315-1223
315-221
315-1289
315-1290
32-2560
865-68
3
1
2
1
1
1
86 ft
12
800
REQ
1
1
1
1
8
2
4
4
1
2
2
2
2
2
1
1
64
8
8
56
188
12
28
2
48
8
1
12
2
3
1
2
1
1
1
110 ft
16
1100
PART NO.
REQ
315-1194
315-1250
n/a
315-1249
315-1248
315-1247
315-1188
315-1132
315-1246
Note 5
315-1245
315-1244
315-1143
315-695
315-1243
315-1099
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
315-1295
315-1253
n/a
315-1280
315-1182
351-1254
315-1057
315-1291
315-1292
32-2560
865-68
1
1
1
1
10
2
4
4
1
2
2
2
2
2
1
1
108
8
8
56
252
12
32
2
52
8
1
16
2
2
3
1
1
1
1
1
144ft
20
PART #
315-1203
315-1260
n/a
315-1249
315-1248
315-1257
315-1197
315-1132
315-1246
Note 5
315-1256
315-1255
315-1143
315-695
315-1243
315-1099
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
315-1295
315-1253
315-1261
315-1280
315-1182
315-1254
315-1058
315-1291
315-1292
32-2560
865-68
REQ
1
1
1
1
12
4
4
4
1
2
2
2
2
2
1
1
144
8
8
60
308
12
32
2
52
8
1
20
2
2
2
3
1
2
1
1
1
168ft
24
8-5
8-6
Figure: 8-3 Typical High Pressure Steam Flextube Casing
750-177
750-177
ITEM
1.
2.
3.a
3.b
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
250
PART #
315-1124
315-1215
315-1263
315-1216
315-1217
315-1218
315-1131
315-1132
315-1219
Note 5
315-1220
315-1221
315-1143
315-694
315-1222
315-1100
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
n/a
n/a
n/a
315-1178
315-1158
315-1223
315-517
315-1286
315-1285
32-2560
865-68
REQ
1
1
1
1
1
6
2
4
4
1
2
2
2
2
2
1
1
28
8
8
50
118
12
24
2
44
8
1
8
2
2
2
3
1
2
1
1
1
79 ft
12
350
PART #
315-1169
315-1230
315-1264
315-1229
315-1228
315-1227
315-1163
315-1132
315-1226
Note 5
315-1225
315-1224
315-1143
315-694
315-1222
315-1100
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
n/a
n/a
n/a
315-1278
315-1158
315-1223
315-518
315-1287
315-1288
32-2560
865-68
REQ
1
1
1
1
1
6
2
4
4
1
2
2
2
2
2
1
1
30
8
8
56
130
12
28
2
48
8
1
8
3
1
2
1
1
1
86 ft
12
500
PART #
315-1180
315-1239
n/a
315-1238
315-1237
315-1236
315-1174
315-1132
315-1235
Note 5
315-1234
315-1233
315-1143
315-695
315-1222
315-1100
550-42
868-1506
868-102
868-188
841-423
869-510
869-27
869-144
868-600
952-286
952-321
797-1816
315-1336
n/a
n/a
315-1242
315-1280
315-1282
315-1223
315-519
315-1289
315-1290
32-2560
865-68
REQ
1
1
1
1
8
2
4
4
1
2
2
2
2
2
1
1
64
8
8
56
188
12
28
2
48
8
1
12
2
3
1
2
1
1
1
110 ft
16
800
PART #
REQ
315-1194
1
315-1250
1
n/a
315-1249
1
315-1248
1
315-1247
10
315-1188
2
315-1132
4
315-1246
4
Note 5
1
315-1245
2
315-1244
2
315-1143
2
315-695
2
315-1243
2
315-1099
1
550-42
1
868-1506
108
868-102
8
868-188
8
841-423
56
869-510
252
869-27
12
869-144
32
868-600
2
952-286
52
952-321
8
797-1816
1
315-1336
16
315-1295
2
315-1253
2
n/a
315-1280
3
315-1182
1
315-1254
1
315-550
1
315-1291
1
315-1292
1
32-2560
114ft
865-68
16
1100
PART #
REQ
315-1203
1
315-1260
1
n/a
315-1249
1
315-1248
1
315-1257
12
315-1197
4
315-1132
4
315-1246
4
Note 5
1
315-1256
2
315-1255
2
315-1143
2
315-695
2
315-1243
2
315-1099
1
550-42
1
868-1506
144
868-102
8
868-188
8
841-423
60
869-510
308
869-27
12
869-144
32
868-600
2
952-286
52
952-321
8
797-1816
1
315-1336
20
315-1295
2
315-1253
2
315-1261
2
315-1280
3
315-1182
1
315-1254
2
315-221
1
315-1291
1
315-1292
1
32-2560
168ft
865-68
16
8-7
Parts
Chapter 8
Steam Pressure Controls
8-8
750-177
Chapter 8
Parts
Water Level Controls
750-177
8-9
Parts
Chapter 8
Water Level Controls continued
8-10
750-177
Chapter 8
Parts
Water Column, Main and Aux. - 15# Steam
750-177
8-11
Parts
Chapter 8
Water Column, Main and Aux. - 150# Steam
8-12
750-177
e-mail: [email protected]
Web Address: http://www.cleaverbrooks.com