CleaverBrooks CB-LE Series Operation, Service And Parts Manual
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CleaverBrooks CB-LE Series Operation, Service And Parts Manual

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Model CB-LE
Packaged Boiler
125 - 200 HP
and Model CB Ohio Special 125-225 HP
Operation, Service, and Parts Manual
750-184
04/09

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Summary of Contents for CleaverBrooks CB-LE Series

  • Page 1 Model CB-LE Packaged Boiler 125 - 200 HP and Model CB Ohio Special 125-225 HP Operation, Service, and Parts Manual 750-184 04/09...
  • Page 3 CLEAVER-BROOKS Model CB-LE Packaged Boiler 125-200 HP Light Oil, Heavy Oil, Gas, or Combination Operation, Service, and Parts Manual* © Cleaver-Brooks 2009 Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative Manual Part No. 750-184 Printed in U.S.A. 04/09...
  • Page 4 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Chapter 1 Basics of Firetube Operation A. GENERAL ................1-2 B.
  • Page 6 F. MODULATING PRESSURE CONTROL (Steam) ............6-8 G.
  • Page 7 Chapter 9 Parts Insulated Front Head - CB-LE ............9-3 Insulated Front Head Interior - CB-LE .
  • Page 8 viii...
  • Page 9 Chapter 1 Basics of Firetube Operation A. GENERAL ......... . 1-2 B.

  • Page 10: Basics Of Firetube Operation

    Chapter 1 — Basics of Firetube Operation A. GENERAL Firetube boilers are available for low or high pressure steam, or for hot water applications. Firetube boilers are typically used for applications ranging from 15 to 800 horsepower. A firetube boiler is a cylindrical vessel, with horizontal tubes passing through and connected to the front and rear tube sheets.
  • Page 11 Chapter 1 — Basics of Firetube Operation The general information in this manual applies directly to Cleaver- Brooks Model CB/CB-LE Boilers in sizes ranging from 125 through 200 boiler horsepower for the following fuels:* Series 100 Light Oil (No. 2) Series 200 Light Oil (No.

  • Page 12: The Boiler

    Chapter 1 — Basics of Firetube Operation The IFGR system mixes a portion of the relatively cool flue gas from the exit of the fourth-pass tubes with the incoming combustion air to reduce the furnace flame temperature, thereby reducing NOx emissions.

  • Page 13: Construction

    Chapter 1 — Basics of Firetube Operation Steam and hot water boilers are defined according to design pressure and operating pressure. Design pressure is the maximum pressure used in the design of the boiler for the purpose of calculating the minimum permissible thickness or physical characteristics of the pressure vessel parts of the boiler.
  • Page 14 Chapter 1 — Basics of Firetube Operation 8. Oil strainer 1. Forced draft fan motor 9. Air compressor 2. Oil pressure gauge 10. C-B Level Master controls 3. Atomizing air pressure gauge 11. Low Water Cut Off/Pump Control 4. Modulating motor 12.

  • Page 15: Steam Controls (All Fuels)

    Chapter 1 — Basics of Firetube Operation D. STEAM CONTROLS (ALL FUELS) 1. Operating Limit Pressure Control (Figure 1-3): Breaks a circuit to stop burner operation on a rise of boiler pressure at a selected setting. It is adjusted to stop or start the burner at a preselected pressure setting.

  • Page 16: Hot Water Controls (All Fuels)

    Chapter 1 — Basics of Firetube Operation 7. Water Gauge Glass Drain Valve: Provided to flush the gauge glass. 8. Vent Valve: Allows the boiler to be vented during filling, and facilitates routine boiler inspection as required by ASME Code. 9.

  • Page 17: Ifgr Components

    Chapter 1 — Basics of Firetube Operation 6. Auxiliary Low-Water Cutoff (Optional): Breaks the circuit to stop burner operation if the water level in the boiler drops below the master low-water cutoff point. 7. Safety Valve(s): Relieves the boiler of pressure higher than the design pressure or a lower pressure, if designated.
  • Page 18 Chapter 1 — Basics of Firetube Operation COMBUSTION AIR INLET FLUE OUTLET FRONT DOOR AIRBOX BACKPLATE GASKET CASSETTE MOUNTING BOLTS INSULATED PARTITION AIRBOX GASKET FLUE GAS TRANSFER CASSETTE LIFTING EYES PORT WITH IFGR DAMPER FOURTH-PASS TUBES FAN/MOTOR CASSETTE DAMPER DRIVE ARM FLANGE COLLAR COMBUSTION AIR FAN OVER-TRAVEL MECHANISM...

  • Page 19: Cb Ohio Special

    Chapter 1 — Basics of Firetube Operation OVER-TRAVEL MECHANISM 30° SINGLE FUEL ARRANGEMENT JACKSHAFT LINKAGE ROD AND 60 PPM SYSTEM QUICK-DISCONNECT LINKAGE IFGR DAMPER CONTROL 60° GAS JACKSHAFT DRIVE ARM OIL JACKSHAFT DRIVE ARM NOMINAL: ACTUAL POSITION VARIES WITH NOx REQUIREMENT JACKSHAFT PROXIMITY SWITCH JACKSHAFT ARM DUAL FUEL ARRANGEMENT...
  • Page 20 Chapter 1 — Basics of Firetube Operation the head - opposite the boiler steam space - is almost completely filled with refractory. When sealing the door, follow instructions as outlined in Section 8 of this manual. Front Head The Ohio Boiler utilizes an insulated inner (intermediate) front door. Due to the two-pass design, the front head lacks the second-to-third pass baffle found on comparable CB-LE boilers.
  • Page 21 Chapter 2 Burner Operation and Control A. THE BURNER ........2-2 B.

  • Page 22: Burner Operation And Control

    Chapter 2 — Burner Operation and Control A. THE BURNER The gas burner is of the non-premix orifice type, using a spark ignited gas pilot. The pilot is of the interrupted type and is extinguished after main flame is established. The oil burner is of the low pressure, air atomizing (nozzle) type.
  • Page 23 Chapter 2 — Burner Operation and Control The burner control circuit operates on 115 volt, single phase 60 Hz (or 50 Hz when equipped) alternating current. The forced draft fan motor is generally operated on 3-phase service at the available main power supply voltage.

  • Page 24: Control And Component Function

    Chapter 2 — Burner Operation and Control B. CONTROL AND COMPONENT FUNCTION The term “control” covers the more important valves and components, including but not limited to electrical controls or those monitored by the program relay. The operator must become familiar with the individual functioning of all controls before understanding boiler operation and procedures outlined in this manual.
  • Page 25 Chapter 2 — Burner Operation and Control subsequent setting of fuel input throughout the firing range. It has no control over the firing rate when the manual-automatic switch is set on “automatic.” 11.Burner Switch (Figure 2-8): A manually operated start-stop switch for directly starting and stopping operation of burner.

  • Page 26: Controls For Gas Firing

    Chapter 2 — Burner Operation and Control 19.Program Relay and Flame Safeguard Control: Automatically programs each starting, operating and shutdown period in conjunction with operating limit and interlock devices. Includes, in a timed and proper sequence, the operation of the blower motor, ignition system, fuel valve(s), and the damper motor.

  • Page 27: Controls Common To Oil-Fired Boilers (Including Combination)

    Chapter 2 — Burner Operation and Control 10.Leakage Connection: The body of the gas valve has a plugged opening that is used whenever it is necessary to conduct a test for possible leakage across the closed valve. MAIN GAS TRAIN Main Gas Valve Gas Valve w/POC High Gas Pressure Switch...
  • Page 28 Chapter 2 — Burner Operation and Control the air pump is present for oil firing. Oil valve(s) will not open, or will not remain open, unless switch contacts are closed. 3. Atomizing Air Pressure Gauge: Indicates the atomizing air pressure at the burner gun 4.
  • Page 29 Chapter 2 — Burner Operation and Control OIL DRAWER SWITCH FUEL OIL CONTROLLER ATOMIZING AIR PROVING SWITCH OIL RELIEF VALVE ATOMIZING AIR PRESSURE GAUGE TERMINAL BLOCK OIL SOLENOID VALVE Figure 2-10 Components Common to Oil Fired Boilers Part No. 750-184...
  • Page 30 Chapter 2 — Burner Operation and Control OIL METERING VALVE GLAND OIL MODULATING CAM OIL PRESSURE REGULATOR OIL BURNER PRESSURE GAUGE OIL SUPPLY OIL RETURN BACK PRESSURE ORIFICE TO MAIN OIL SOLENOID VALVE Figure 2-11 Oil Control Valve Assembly - Light Oil OIL MODULATING CAM OIL METERING VALVE PACKING GLAND...
  • Page 31 Chapter 2 — Burner Operation and Control 7. Terminal Block 8. Fuel Oil Strainer (Not Shown): Prevents foreign matter from entering the burner system. 9. Gas Pilot: See Section D of Chapter 2 for description of the various components. 10.Light Oil Pilot Valve (Not Shown): When a light oil pilot is furnished, a solenoid valve is provided to control flow of fuel to the pilot nozzle.

  • Page 32: Additional Controls For Heavy Oil

    Chapter 2 — Burner Operation and Control G. Lube Oil Cooling Coil: Cools the lubricating oil before it enters the air pump. A fan driven by the air pump motor circulates cooling air over the coil. H. Lube Oil Fill Pipe and Strainer: Used when adding oil to the air-oil receiver tank.
  • Page 33 Chapter 2 — Burner Operation and Control properly maintain the required fuel oil temperature. The regulator and the pressure gauge are not furnished on 15 psi units. 11.Steam Heater Solenoid Valve: A normally open solenoid valve opened by the steam oil heater thermostat to allow flow of steam to the steam heater to maintain temperature of fuel oil.

  • Page 34: Controls For Combination Burners Only

    Chapter 2 — Burner Operation and Control B. Hot Water Oil Heater Thermostat: Used on a hot water boiler to sense fuel oil temperature and control the starting and stopping of the booster water pump. C. Booster Water Pump: Started and stopped by the hot water thermostat to regulate the flow of hot water through the hot water oil heater to maintain temperature of fuel oil.

  • Page 35: Automatic Ignition

    Chapter 2 — Burner Operation and Control amount of air for correct ratio of air to fuel for efficient combustion at all firing rates. I. AUTOMATIC IGNITION Oil or gas burners are ignited by an interrupted-type pilot. The pilot flame is ignited automatically by an electric spark. The series 100 burner usually is equipped with a pilot fired with light oil fuel.

  • Page 36: Oil Fuel Flow - Light Oil

    Chapter 2 — Burner Operation and Control through baffles and filters in the tank before the air passes to the burner. Some of the primary air is also used to assist the oil pressure regulators of the fuel oil controller. K.
  • Page 37 Chapter 2 — Burner Operation and Control NOZZLE AIR PRESSURE GAUGE AIR STRAINER OIL BURNER NOZZLE MANIFOLD BLOCK SWING CHECK VALVE ATOMIZING AIR AIR PUMP OIL SOLENOID VALVE ATOMIZING AIR PRESSURE FEED BACK CONTROL TUBING ATOMIZING AIR PROVING SWITCH FUEL OIL CONTROLLER LUBE OIL STRAINER...

  • Page 38: Oil Fuel Flow - Heavy Oil

    Chapter 2 — Burner Operation and Control L. OIL FUEL FLOW - HEAVY OIL The oil fuel flow and circulating system is shown in schematic diagram form in Figure 2-17. The pertinent controls are called out and the oil flow is indicated by arrows. Fuel oil is delivered into the system by the fuel oil supply pump which delivers part of its discharge to the oil heater.
  • Page 39 Chapter 2 — Burner Operation and Control AIR STRAINER NOZZLE AIR PRESSURE GAUGE OIL BURNER NOZZLE MANIFOLD BLOCK SWING CHECK VALVE ATOMIZING AIR AIR PUMP ATOMIZING AIR PRESSURE FEEDBACK CONTROL TUBING OIL SOLENOID ATOMIZING AIR VALVE PROVING SWITCH FUEL OIL CONTROLLER LUBE OIL STRAINER...

  • Page 40: Gas Fuel Flow

    Chapter 2 — Burner Operation and Control M. GAS FUEL FLOW Metered gas from the utility flows through the pressure regulator at a reduced pressure suitable to burner requirements, through the main gas shutoff cock, main gas valve(s), and modulating butterfly gas valve to the non- premix orifice-type burner.
  • Page 41 Chapter 2 — Burner Operation and Control When the resistance ratio is equal, the motor stops in a position that allows the proper fuel and combustion air flow to meet operating demands. A feature designed into the circuitry maintains the modulating motor in the low-fire position during ignition and keeps it there until the main flame is established.
  • Page 42 Chapter 2 — Burner Operation and Control 2-22 Part No. 750-184...
  • Page 43 Chapter 3 Waterside Care and Requirements A. GENERAL ......... . 3-2 B.

  • Page 44: Waterside Care And Requirements

    Chapter 3 — Waterside Care and Requirements A. GENERAL The operator should be familiar with Chapter 3 before attempting to place the unit into operation. Although it is of prime importance, the subject of water supply and treatment cannot adequately be covered in this manual. For specific information or assistance with your water treatment requirements, contact your Cleaver-Brooks service and parts representative.
  • Page 45 Chapter 3 — Waterside Care and Requirements A temperature of 170°F is also recommended in order to provide a sufficient “temperature head” when No. 6 fuel oil is to be heated to the proper atomizing temperature by the boiler water in a safety- type oil preheater.
  • Page 46 Chapter 3 — Waterside Care and Requirements If care is not taken to ensure adequate or proportional flow through the boilers, wide variations in firing rates between the boilers can result. In extreme cases, one boiler may be in the high-fire position while the other boiler or boilers may be at low fire.
  • Page 47 Chapter 3 — Waterside Care and Requirements Table 3-1 Maximum Circulating Rate SYSTEM TEMPERATURE DROP - DEGREES °F BOILER BOILER OUT- SIZE PUT (1000) (BHP) BTU/HR MAXIMUM CIRCULATING RATE - GPM 1,005 1,340 1,675 2,010 2,345 2,680 3,350 4,185 5,025 1,005 6,695 1,340...
  • Page 48 Chapter 3 — Waterside Care and Requirements Figure 3-1 Internal Boiler Pressure 2. STEAM BOILER Feed Pump Operation BEFORE turning on the pump motor be certain that all valves in the water feed line are open to prevent possible damage to the feed pump mechanism.

  • Page 49: Water Treatment

    Chapter 3 — Waterside Care and Requirements Water Feeder (optional) Operation Water feeder operation is usually applicable to boilers operating at 15 psi steam or less. It is only necessary to open the water supply line valve and the water feeder discharge valve. Note: In the event that water column isolation valves are provided or installed, it must be established that the valves are open and seated or locked in the open position.

  • Page 50: Cleaning

    Chapter 3 — Waterside Care and Requirements Objectives of water treatment in general are: 1. Prevent hard scale deposits or soft sludge deposits, which reduce heat transfer and can lead to overheated metal and costly downtime and repairs. 2. Eliminate corrosive gases in the supply or boiler water. 3.

  • Page 51: Boil-Out Of A New Unit

    Chapter 3 — Waterside Care and Requirements y o u r l o c a l C l ea v e r- B r o o k s a u th o ri z e d r ep r e s e n ta ti v e f o r recommendations, cleaning compounds, and application procedures.
  • Page 52 Chapter 3 — Waterside Care and Requirements may begin, the burner should be ready for firing. The operator must be familiar with the procedure outlined under burner operation. Warning Use of a suitable face mask, goggles, rubber gloves, and protective garments must be worn when handling or mixing caustic chemicals.
  • Page 53 Chapter 3 — Waterside Care and Requirements (6) Fill the pressure vessel with clean water until the top of the tubes are covered. Add the cleaning solution and then fill to the top. The temperature of the water used in the initial fill should be at ambient temperature.

  • Page 54: Washing Out

    Chapter 3 — Waterside Care and Requirements F. WASHING OUT 1. HOT WATER BOILER In theory, a hot water system and boiler that has been initially cleaned, filled with raw water (and water treated), and with no make-up water added, will require no further cleaning or treatment. However, since the system (new or old) can allow entrance of air and unnoticed or undetected leakage of water, introductions of raw water make-up or air may lead to pitting, corrosion and formation...
  • Page 55 Chapter 3 — Waterside Care and Requirements substances. Regardless of their high efficiency, some solids will be present in the boiler feedwater. Solids become less soluble in the high temperature of the boiler water and tend to accumulate on heating surfaces. Therefore blowdown and internal chemical treatment are required to prevent the solids from forming harmful scale and sludge.
  • Page 56 Chapter 3 — Waterside Care and Requirements purpose of skimming surface sediment, oil or other impurities from the surface of the pressure vessel water. A controlled-orifice valve is used to allow a continual, yet controlled, flow of concentrated water. Periodic adjustments are made to the valve setting to increase or decrease the amount of blowdown in accordance with the test analysis.

  • Page 57: Periodic Inspection

    Chapter 3 — Waterside Care and Requirements Be sure the blow-off piping and tank, if used, are in proper operating condition. Discharge vents should be clear of obstruction, and the waste should be piped to a point of safe discharge. Most blow-off lines are provided with two valves, generally a quick opening valve nearest the boiler and a slow opening globe type valve downstream.

  • Page 58: Preparation For Extended Lay-Up

    Chapter 3 — Waterside Care and Requirements - again to prevent uneven contraction and temperature differentials that can cause expanded tubes to leak. Draining the unit too quickly may cause the baking of deposits that may be present on the heating surfaces.
  • Page 59 Chapter 3 — Waterside Care and Requirements Whichever method is used, common sense dictates a periodic recheck of fireside and waterside conditions during lay-up to allow variations from the above methods for special area or job-site conditions. Swing open the boiler head at the stack end of the unit to prevent flow of warm, moist air through the boiler tubes.
  • Page 60 Chapter 3 — Waterside Care and Requirements Wet storage is generally used for a boiler held in stand-by condition or in cases where dry storage is not practical. The possibility of freezing temperatures must be considered. Care must again be taken to protect metal surfaces.

  • Page 61: A. General

    Chapter 4 Sequence of Operation A. GENERAL ......... . 4-2 B.

  • Page 62: Sequence Of Operation

    Chapter 4 — Sequence of Operation 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.
  • Page 63 Chapter 4 — Sequence of Operation diagram to determine the actual controls provided. The circuits and controls normally used in the circuits follow and are referred to in the following sequence of operation. Limit Circuit: • Burner switch (BS) • Operating limit control (OLC) - pressure or temperature •...

  • Page 64: Sequence Of Operation - Oil Or Gas

    Chapter 4 — Sequence of Operation • 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) •...
  • Page 65 Chapter 4 — Sequence of Operation closed at this time, or if they subsequently open, the program relay will go into a safety shutdown. At the completion of the high fire purge period, the program relay signals the modulating damper motor (MDM) to drive the air damper to its low fire position.

  • Page 66: Flame Loss Sequence

    Chapter 4 — Sequence of Operation 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).
  • Page 67 Chapter 4 — Sequence of Operation caused by failure to ignite the pilot, or the main flame, or by loss of flame. Lockout will also occur if flame or flame simulating condition occurs during the prepurge period. The control will prevent start-up or ignition if limit circuit controls or fuel valve interlocks are open.
  • Page 68 Chapter 4 — Sequence of Operation 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 program relay and other controls in the system can be obtained by studying the contents of the manual and this bulletin.
  • Page 69 Chapter 4 — Sequence of Operation Table 4-1 Electrical Nomenclature MNEMONIC DESCRIPTION BMSI Blower Motor Starter Interlock MNEMONIC DESCRIPTION BMSS Boiler Master Selector Switch Burner Switch Boiler Selector Switch Amber (Color Of Pilot Light) BWPM Booster Water Pump Motor AAFL Atomizing Air Failure Light Booster Water Thermostat AAFR...
  • Page 70 Chapter 4 — Sequence of Operation MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION FADR Fresh Air Damper Relay HGPS High Gas Pressure Switch Flame Detector HHFL Header High Fire Light FDJB Flame Detector Junction Box H/LWA High Low Water Alarm FDPS Flow Differential Pressure Switch High Limit Control Flame Failure Alarm HLFC...
  • Page 71 Chapter 4 — Sequence of Operation MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION LIAPS Low Instrument Air Pressure Switch (N.C.) Normally Closed LLPC Low Limit Pressure Control (N.O.) Normally Open LLPR Low Limit Pressure Relay No Flow Light Lead Lag Relay No Flow Relay LLTC Low Limit Temperature Control NGHPV...
  • Page 72 Chapter 4 — Sequence of Operation MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION PIPL Purge in Progress Light STLWC Surge Tank Low Water Control Pilot Ignition Switch STLWL Surge Tank Low Water Light Programmable Logic Controller STLWR Surge Tank Low Water Relay PLGPS Pilot Low Gas Pressure Switch Power On Light (T.C.)
  • Page 73 Chapter 5 Starting and Operating Instructions A. GENERAL PREPARATION FOR START-UP , ALL FUELS ... 5-2 B. CONTROL SETTINGS - STEAM AND HOT WATER ... . . 5-3 C.

  • Page 74: Starting And Operating Instructions

    Chapter 5 — Starting and Operating Instructions Note: If your boiler is equipped with a CB-HAWK ICS boiler control system, refer to CB Manual No. 750-229 for specific information regarding procedures described in section A. A. GENERAL PREPARATION FOR START-UP , ALL FUELS Instructions in Chapter 5 are all based upon installation being complete and all electrical, fuel, water and vent stack connections...

  • Page 75: Control Settings - Steam And Hot Water

    Chapter 5 — Starting and Operating Instructions for the CB-LE, when viewed from the front of the boiler (see Figure 5-1). The air pump rotation is clockwise when viewed from its drive end. When operating a standard 60” boiler the fan motor and air pump should rotate clockwise when viewed from the front of the boiler (see Figure 5-3).

  • Page 76: Gas Pilot

    Chapter 5 — Starting and Operating Instructions Note: The settings of all the above controls may require some readjustment after the boiler is started and running for a short period. The scale settings on the controls are relatively accurate, but are principally for use as guides. Final adjustment should be based on and agree with the reading of the steam pressure gauge or the water temperature thermometer.

  • Page 77: Firing Preparations For No. 2 Oil (Series 100-200)

    Chapter 5 — Starting and Operating Instructions Check the oil level of the air intake strainer. When operating a standard CB boiler, make certain that the V-belt which drives the air pump is in place and has proper tension. To verify air flow and pressure, place the burner Run/test Switch on the program relay to the test position.
  • Page 78 Chapter 5 — Starting and Operating Instructions If the oil supply tank is below the level of the oil pump, it is MANDATORY that the suction line to the pump be completely filled with oil prior to starting the pump to avoid the possibility of damage to the pump gears.

  • Page 79: Firing Preparation For No. 6 Oil (Series 400-600)

    Chapter 5 — Starting and Operating Instructions adjustable spring pressure. Since the air pump is not running at this time, only tentative adjustment can be made. Without the air supply, adjust the fuel oil pressure regulator so that the oil burner gauge registers approximately 35 psi.
  • Page 80 Chapter 5 — Starting and Operating Instructions that at maximum firing rate a minimum reading of 75 psi is obtained on the oil supply pressure gauge. The other pressure adjustments are to the regulators on the fuel oil controller. Both the pressure regulating and the back pressure relief valves are equipped with tubing that directs and adds atomizing air pressure to the adjustable spring pressure.

  • Page 81: Firing Preparations For Gas (Series 200-400-700)

    Chapter 5 — Starting and Operating Instructions 150 SSU. The actual temperature of the oil at the burner should be determined by flame appearance and good combustion based on a stack analysis. Close the manual by-pass valve after the temperature rise on the fuel oil controller thermometer is noted.

  • Page 82: Ifgr Setup

    Chapter 5 — Starting and Operating Instructions the burner “ON”. When the fuel valve light glows, slowly open the main gas cock. Main flame should ignite unless there is air present in the line. If the flame is not established within about 5 seconds, turn the burner switch “off”...

  • Page 83: Start-Up , Operating And Shutdown - All Fuels

    Chapter 5 — Starting and Operating Instructions the fuel cams, fuel and air linkages, or IFGR control linkages, the recommended approach to start-up is as follows: 3. Set all boiler components to their initial settings as discussed in the appropriate chapters of this Operation and Maintenance manual.
  • Page 84 Chapter 5 — Starting and Operating Instructions BOILER HP PPM NOX "A" "B" "C" "D" "E" "F" "G" "H" "J" "K" 3/8" 3-1/8" 11° 79° 40° 20° 10° 13/16" 3-1/8" 11° 79° 40° 20° 10° 1" 5-3/4" 11° 79° 30° 23°...
  • Page 85 Chapter 5 — Starting and Operating Instructions DOUBLE SPRINGS HOLE #1 (FAST OPENING DAMPER) HIGH-FIRE STOP SCREW LOW-FIRE STOP SCREW EXTERNAL ARM “B” HOLE #1 (SLOW -OPENING DAMPER) “A” EXTERNAL ARM INTERNAL ARM HOLE POSITION HOLE #5 (SLOW-OPENING DAMPER) HOLE # 8 (FAST OPENING DAMPER) 90∞...
  • Page 86 Chapter 5 — Starting and Operating Instructions On ignition failure, the flame failure light will glow and the blower will purge the boiler of unburned fuel vapors before stopping. After ignition failure, wait a few moments before re-setting the lockout switch.
  • Page 87 Chapter 5 — Starting and Operating Instructions adjustment of the burner over the entire firing range. When a shutdown occurs while operating in the manual position at other than low fire, the damper will not be in a closed position, thus allowing more air than desired to flow through the boiler.

  • Page 88: Control Operational Test And Checks

    Chapter 5 — Starting and Operating Instructions J. CONTROL OPERATIONAL TEST AND CHECKS Proper operation of the various controls should be verified and tested when the boiler is initially placed into service, or whenever a control is replaced. Periodic checks should be made thereafter in accordance with a planned maintenance program.
  • Page 89 Chapter 6 Adjustment Procedures A. GENERAL ............. . . 6-2 B.

  • Page 90: Adjustment Procedures

    Chapter 6 — Adjustment Procedures Note: If your boiler is equipped with a CB-HAWK ICS boiler control system, refer to Manual No. 750-229 for specific information regarding procedures described in this section. A. GENERAL Each Cleaver-Brooks boiler is tested for correct operation before shipment from the factory.
  • Page 91 Chapter 6 — Adjustment Procedures Figure 6-1 Complete Linkage Assembly - Combination Gas and Oil 3. The closer the connector is to the drive shaft, the less the arm will travel; the closer the connector is to the driven shaft, the far- ther that arm will travel.

  • Page 92: Modulating Motor

    Chapter 6 — Adjustment Procedures Burners). In this position, fuel delivery is at low fire rate. Tighten the set screws to secure the cams on the jackshaft. Refer to Figure 6-2. The stop screw in the rotary air damper limits damper travel at both closed (low fire) and fully opened (high fire) JACK SHAFT positions.

  • Page 93: Burner Operating Controls - General

    Chapter 6 — Adjustment Procedures the modulating motor) is set to make red and blue tracer leads at approximately 60° the on motor opening. Normally the settings are left as is, but job conditions may require readjustment. If the cams require adjustment or resetting, follow the instructions in the manufacturer’s technical manual.
  • Page 94 Chapter 6 — Adjustment Procedures • Eliminates frequent burner on-off cycling. Separate and independent controls affect modulated firing and burner on-off cycling. Figure 6-6 depicts a typical setting relationship of the Operating Limit Control, Modulating Control and the High Limit Control. The burner will be “on”...
  • Page 95 Chapter 6 — Adjustment Procedures As the load requirement changes, the firing rate will change accordingly. Thus it is referred to as modulated firing. Point D represents the maximum firing rate of the burner, or highfire. In the event pressure or temperature drops while the burner is firing at highfire, it indicates that the load exceeds the capacity of the boiler.

  • Page 96: Modulating Pressure Control (Steam)

    Chapter 6 — Adjustment Procedures To properly set the Modulating Control, carefully adjust it under load conditions, until the load is maintained with the burner firing at a steady rate. The firing rate at that point may be full high fire or slightly less, depending upon the relationship of the boiler size to the load.

  • Page 97: High Limit Pressure Control (Steam)

    Chapter 6 — Adjustment Procedures in” (burner-on) pressure is the cut-out pressure MINUS the differential. The cut-out pressure should not exceed 90% of the safety valve setting. H. HIGH LIMIT PRESSURE CONTROL (STEAM) Set “cut-out” (burner off) pressure on the main scale using the adjusting screw.

  • Page 98: Low Water Cutoff Devices (Steam And Hot Water)

    Chapter 6 — Adjustment Procedures L. LOW WATER CUTOFF DEVICES (STEAM AND HOT WATER) No adjustment is required since LWCO controls are preset by the original manufacturer. However, if the water level can not be properly maintained, inspect the devices immediately and replace as required.

  • Page 99: Gas Pilot Flame Adjustment

    Chapter 6 — Adjustment Procedures The adjustment screw of the Atomizing Air Proving Switch can then be adjusted until it breaks the circuit. Here, the programmer will lock out and must be manually reset before it can be restarted. Turn the adjusting screw up a half turn or so to remake the circuit.
  • Page 100 Chapter 6 — Adjustment Procedures periods with intervening purge periods than to risk prolonged fuel introduction. If the pilot does not light after several attempts, check all components of the pilot system. 5. When the pilot flame is established, and with the Pilot Adjusting Cock wide open, remove the Flame Detector from the burner plate.

  • Page 101: Gas Pressure And Flow Information

    Chapter 6 — Adjustment Procedures tions, refer to the trouble shooting section in the technical bulle- tin. P . GAS PRESSURE AND FLOW INFORMATION Because of variables in both the properties of gas and the supply system, it will be necessary to regulate the pressure of the gas to a level that produces a steady, dependable flame that yields highest combustion efficiency at rated performance yet prevents overfiring.
  • Page 102 Chapter 6 — Adjustment Procedures Table 6-1 Gas pressure requirements, CB-LE 125-200 HP* CBLE 20 PPM CBLE 30 PPM CBLE 60 PPM Gas Train Pressure Gas Train Pressure Gas Train Pressure Boiler HP Size, in Range PSI Size, in Range PSI Size, in Range PSI 0.8 - 3.0...
  • Page 103 Chapter 6 — Adjustment Procedures Table 6-4 Pressure Correction Table 6-5 Altitude Correction Factors Factors ALTITUDE REGULATOR INLET PRESSURE CORRECTION FACTOR FEET ABOVE SEA LEVEL PRESSURE (PSIG) FACTOR 1000 1.04 1.05 2000 1.07 1.11 1.18 2500 1.09 1.25 3000 1.11 1.32 4000 1.16...

  • Page 104: Gas Fuel Combustion Adjustment

    Chapter 6 — Adjustment Procedures Pressure Correction for the 2,000 feet altitude must be made since altitude has a bearing on the net regulated gas pressure. The standard gas train requires 15.5" WC gas pressure at sea level (Table 6-1). Table 6-2 indicates a correction factor of 1.07 for 2,000 feet.
  • Page 105 Chapter 6 — Adjustment Procedures Note: All adjustment should be done by a qualified boiler operator or your local Cleaver-Brooks Service representative. Burner efficiency is measured by the amount or percentage of O present in the flue gas. O readings determine the total amount or excess air in the combustion process, above the point of stoichiometric combustion or perfect combustion.
  • Page 106 Chapter 6 — Adjustment Procedures FIRST VISIBLE TRACE OF STACK HAZE PER CENT O 1/10 of 1% CO = 1,000 PPM PER CENT EXCESS AIR Figure 6-7 Flue gas analysis chart for Natural Gas Caution Turndown in excess of the burner design may damage the burner diffuser and/or the burner housing.
  • Page 107 Chapter 6 — Adjustment Procedures 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 O readings of between 3% to 4% be attained with less than 400 ppm CO, at high fire.

  • Page 108: Low-Gas-Pressure Switch

    Chapter 6 — Adjustment Procedures Since the input of combustion air is ordinarily fixed at any given point in the modulating cycle, the flue gas reading is determined by varying the input of gas fuel at that setting. The adjustment is made to the metering cam by means of adjusting screws, which are turned outward (counterclockwise from the hex-socket end) to increase the flow of fuel, and inward (clockwise from the hex-socket end) to...

  • Page 109: High-Gas-Pressure Switch

    Chapter 6 — Adjustment Procedures S. HIGH-GAS-PRESSURE SWITCH Adjust the scale setting to slightly above the normal burning pressure. The control circuit will be broken when pressure exceeds the normal operating pressure. Unnecessary shutdowns may result if the setting is too close to normal; however, regulations require that the setting may not be greater than 150% of rated pressure.

  • Page 110: Fuel Oil Combustion Adjustment

    Chapter 6 — Adjustment Procedures 20000 10000 MAXIMUM LIMIT FOR PUMPING 4000 3000 2000 1500 1000 MAXIMUM LIMIT FOR ATOMIZATION RECOMMENDED LIMIT FOR ATOMIZATION 160 180 200 220 240 260 280 300 Temperature - Degrees Fahrenheit Figure 6-9 OIl viscosity Review of the applicable maintenance instructions given in Chapter 8 will aid in maintaining an efficient fuel system.
  • Page 111 Chapter 6 — Adjustment Procedures Note: All adjustment should be done by a qualified boiler operator or your local Cleaver-Brooks Service representative. Burner efficiency is measured by the amount or percentage of O present in the flue gas. O readings determine the total amount or excess air in the combustion process, above the point of stoichiometric combustion or perfect combustion.

  • Page 112: Burner Drawer Adjustment

    Chapter 6 — Adjustment Procedures the oil modulating cam to obtain a constant fuel/air ratio through the entire firing range. Note: Be sure the to loosen the cam foot locking screws before adjusting any cam screws or the cam feet may be damaged.

  • Page 113: Oil Drawer Switch

    Chapter 6 — Adjustment Procedures BURNER BACKPLATE ASSEMBLY SPIDER OIL NOZZLE BODY FRONT EDGE OF BURNER GUN DIFFUSER SKIRT NOZZLE ROTARY DAMPER STABILIZER PRESSURE DIFFUSER GAUGE NEOPRENE “O” RING SEAL RING INLET OIL NOZZLE 7/16" ATOMIZING ” INLET ” MAX. IGNITION ”...

  • Page 114: Low-Oil-Temperature Switch

    Chapter 6 — Adjustment Procedures electrically removed from the circuit when a combination fuel burner is fired on gas (Figure 6-18). X. LOW-OIL-TEMPERATURE SWITCH The L.O.T.S. prevents the burner from starting, or stops its operation, if the temperature of the oil is below normal operating temperature.

  • Page 115: Bb. Steam Oil Heater Thermostat (No. 6 Oil) (400 And 600 Series - Steam)

    Chapter 6 — Adjustment Procedures BB. STEAM OIL HEATER THERMOSTAT (NO. 6 OIL) (400 AND 600 SERIES - STEAM) The maximum temperature setting of the control is stamped on the dial. The maximum temperature setting is attained with the adjusting knob turned to the “high” end of the scale. Lower settings are obtained by turning the adjusting knob clockwise using the thermometer in the fuel oil controller as a guide.
  • Page 116 Chapter 6 — Adjustment Procedures 6-28 Part No. 750-184...

  • Page 117: Troubleshooting

    Chapter 7 - Troubleshooting Chapter 7 Troubleshooting 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 Warning readily apparent. Trouble shooting should be performed only by The program relay has the capability to self- personnel who are familiar with the equipment diagnose and to display a code or message that...
  • Page 118 Chapter 7 - Troubleshooting Problem Solution BURNER DOES NOT START 1. No voltage at program relay power input terminals. A. Main disconnect switch open. B. Blown control circuit fuse. C. Loose or broken electrical connection. 2. Program relay safety switch requires resetting. 3.
  • Page 119 Chapter 7 - Troubleshooting Problem Solution 4. Running interlock circuit not completed. A. Combustion or atomizing air proving switches defective or not properly set. B. Motor starter interlock contact not closed. 5. Flame detector defective, sight tube obstructed, or lens dirty. PILOT FLAME, BUT NO 1.
  • Page 120 Chapter 7 - Troubleshooting 6. If the programmer lockout switch has tripped: A. Check fuel lines and valves. B. Check flame detector. C. Check for open circuit in running interlock circuit. D. The flame failure light is energized by ignition failure, main flame failure, inadequate flame signal, or open control in the running interlock circuit.
  • Page 121 Chapter 8 Inspection and Maintenance A. GENERAL ......... . 8-2 B.

  • Page 122: Inspection And Maintenance

    Chapter 8 — Inspection and Maintenance Note: For more information on your flame safeguard system, refer to the appropriate manual that was provided with your boiler Caution Inspection and maintenance should be performed only by trained personnel who are familiar with this equipment. Failure to follow these instructions could result in equipment damage.

  • Page 123: Fireside Cleaning

    Chapter 8 — Inspection and Maintenance detailed inspection and check of all components of the boiler including piping, valves, pumps, gaskets, refractory, etc. Comprehensive cleaning, spot painting or repainting, and the replacement of expendable items should be planned for and taken care of during this time. Any major repairs or replacements that may be required should also, if possible, be coordinated with the period of boiler shutdown.

  • Page 124: Water Level Controls

    Chapter 8 — Inspection and Maintenance C. WATER LEVEL CONTROLS The need to periodically check water level controls and the waterside of the pressure vessel cannot be overemphasized. Most instances of major boiler damage are the result of operating with low water, or the use of untreated (or incorrectly) treated water.

  • Page 125: Water Gauge Glass

    Chapter 8 — Inspection and Maintenance D. WATER GAUGE GLASS A broken or discolored glass should be replaced at once. Periodic replacement should be a part of the maintenance program. Always use new gaskets when replacing a glass. Use a proper size rubber packing. Do not use loose packing, which could be forced below the glass and possibly plug the valve opening.
  • Page 126 Chapter 8 — Inspection and Maintenance Part No. 750-184...

  • Page 127: Flame Safety Control

    Chapter 8 — Inspection and Maintenance F. FLAME SAFETY CONTROL The microprocessor based control requires minimal maintenance because the safety and logic timings are inaccessible. There also are not any accessible contacts. Check to see that the retaining screw is securely holding the chassis to the mounting base.

  • Page 128: Oil Burner Maintenance

    Chapter 8 — Inspection and Maintenance purge period. The main fuel valve(s) will be energized, but there should be no main flame. The fuel valve(s) deenergize within 4 seconds after the main burner ignition trial ends. The control will lock out on a safety shutdown. The flame failure light (and optional alarm) will be activated.
  • Page 129 Chapter 8 — Inspection and Maintenance discs or the cleaner blades. Wash the cartridge in solvents. Do not attempt to disassemble the cartridge. Cleaning Oil Nozzle The design of the burner, together with the oil purge system on a heavy oil burner, make it unnecessary to clean the oil nozzle during periods of operation.

  • Page 130: Gas Burner Maintenance

    Chapter 8 — Inspection and Maintenance that might be present. If there are cracks, replace the electrode since they can cause grounding of the ignition voltage. Since carbon is an electrical conductor, it is necessary to keep the insulating portion of electrode(s) wiped clean if any carbon is present.

  • Page 131: Solenoid Valves

    Chapter 8 — Inspection and Maintenance J. SOLENOID VALVES Foreign matter between the valve seat and seat disc can cause leakage. Valves are readily disassembled; however, care must be used during disassembly to be sure that internal parts are not damaged during the removal and that reassembly is in proper order.

  • Page 132: Forced Draft Fan

    Chapter 8 — Inspection and Maintenance disturbed. Failure to follow these instructions could result in equipment damage. L. FORCED DRAFT FAN The position of the fan housing and the clearance between it and the impeller is extremely important to the output capacity of the fan. The procedures for installing and adjusting are as follows: 1.

  • Page 133: Cb-Le Fan/Motor Cassette Removal

    Chapter 8 — Inspection and Maintenance M. CB-LE FAN/MOTOR CASSETTE REMOVAL Before the boiler is commissioned at the job site, the IFGR system should be visually inspected. The fan/motor cassette should be removed to expose the internal IFGR linkage and damper. Remove the fan/motor cassette as follows: Warning Disconnect and lock out electrical power to the boiler before...

  • Page 134: Cb-Le Airbox Gasket Installation

    Chapter 8 — Inspection and Maintenance 1. With the IFGR damper exposed, inspect the internal linkages for secure connections, and check for free movement of the linkage arms and the IFGR damper assembly. To check for free movement of the linkage separate the external linkage from the jackshaft drive arm(s) and cycle the exterior linkage through its range of movement.

  • Page 135: Cb-Le Fan/Motor Cassette Installation

    Chapter 8 — Inspection and Maintenance 2. Secure the gasket in position with clamps, using strips of wood on top of the gasket for a bearing surface. 3. After the silicone has dried (approximately 24 hours), remove the clamps and strips of wood. P .

  • Page 136: Fuel Oil Metering Valve

    Chapter 8 — Inspection and Maintenance R. FUEL OIL METERING VALVE In the event that a leak occurs in the packing of the metering valve, the packing nut should be snugged gradually to stop the leak. Caution Do not over tighten the metering valve packing nut. Exces- sive tightening of the packing nut prevents free movement of the metering stem.

  • Page 137: Air Pump And Lubricating System

    Chapter 8 — Inspection and Maintenance 15.Depress the valve stem and replace the cam. Mate the match-marks and secure the setscrews. Be sure the cam spring is centered in the roller. 16.Restore oil flow. Test fire the burner at various firing rates being certain that the metering stem freely follows the cam.
  • Page 138 Chapter 8 — Inspection and Maintenance Lubricating Oil Strainer and Cooling Coil Air pressure from the pump forces lubricating oil from the tank through a cooling tube to the pump. The oil lubricates the pump bearings and also provides a seal and lubrication for the pump vanes. The cooled oil flows to the pump through the strainer in the filler pipe.
  • Page 139 Chapter 8 — Inspection and Maintenance The coupling must be checked for both parallel (offset) alignment and angular (gap) alignment. Parallel misalignment exists when shaft axis are parallel but not concentric. Angular misalignment is the reverse situation - shaft axis concentric, but not parallel. Checking parallel alignment, both horizontal and vertical can be accomplished, by laying a straightedge across the coupling halves and checking with a thickness gauge to obtain the amount of misalignment.
  • Page 140 Chapter 8 — Inspection and Maintenance 5. Remove the entire heat exchange assembly, consisting of the cylinder, the finned tubing, and the oil line “B.” 6. Remove the fan from the air pump. 7. Disconnect the flexible air line from the lube tank. 8.

  • Page 141: Head Inspection And Maintenance

    Chapter 8 — Inspection and Maintenance T. HEAD INSPECTION AND MAINTENANCE Warning Disconnect and lock out electrical power and fuel to the boiler before opening either the front or rear head. Failure to follow these instructions can result in electrical shock and serious personal injury or death.
  • Page 142 Chapter 8 — Inspection and Maintenance Examine the condition of the burner housing and ensure that all necessary burner setup is correct. Be sure the oil piping and atomizing air piping are in good condition and not leaking, replace if necessary. Clean the cooling fins on both the oil and atomizing air cooling tubes.
  • Page 143 Chapter 8 — Inspection and Maintenance CB-OS ONLY CB-LE ONLY 1. Tadpole gasket 2. Rope 1-1/2” dia. 3. Blanket insulation 1/2” x 2” Figure 8-3 Rear door seal A good seal between the rear door and the pressure vessel is necessary to prevent leakage of combustion gases, loss of heat, and to aid in obtaining operating efficiency.
  • Page 144 Chapter 8 — Inspection and Maintenance After opening the rear door, clean the flange with a scraper or wire brush. Clean the surface of the refractory carefully with a fiber brush to avoid damaging the surface. Clean the mating surfaces of the baffle and the boiler shell.

  • Page 145: Refractory

    Chapter 8 — Inspection and Maintenance Door bolts should be run in snug and tightened evenly to avoid cocking the door and damaging the gasket. Start tightening at top center and alternate between the top and bottom bolts until both are tight. Do not overtighten. Tighten alternate bolts until the door is secured and gas tight.
  • Page 146 Chapter 8 — Inspection and Maintenance Liner Installation Since the thickness of the furnace metal varies with the boiler design pressure, a shim of appropriate thickness must be used to compensate for the variance. A layer or two of insulating board or equal, or a bed of refractory material, may be used to center the ring.

  • Page 147: Lubrication

    Chapter 8 — Inspection and Maintenance V. LUBRICATION Electric Motors Manufacturers of electric motors vary in their specifications for lubrication and care of motor bearings; their specific recommendations should be followed. Ball-bearing-equipped motors are pre-lubricated. The length of time a bearing can run without having grease added will depend upon many factors, including the rating of the motor, type of motor enclosure, duty, atmospheric conditions, humidity, and ambient temperatures.

  • Page 148: Oil Heaters - Electric, Steam, Hot Water

    Chapter 8 — Inspection and Maintenance Notice Note: The amount and type of grease is very important. Siemens motors require an aluminum complex high temperature grease, which may not be mixed with any other lubricant. Only enough grease should be added to replace the grease used by the bearing.

  • Page 149: Combustion

    Chapter 8 — Inspection and Maintenance X. COMBUSTION The frequency of burner adjustments depends upon several factors, including; type of burner, type of fuel, load conditions, ambient temperature, climatic variables, and general maintenance practices. The air-fuel ratio should be checked monthly in order to alert the operator to losses in efficiency, which do not produce visible flame change.

  • Page 150: Air Pump Belt (Cb-Os)

    Chapter 8 — Inspection and Maintenance Y. AIR PUMP BELT (CB-OS) The V-belt driving the air pump requires no servicing and no preservatives or dressing compounds should be used. Belts normally stretch with use and proper tension should be maintained. Do not apply excessive tension. The air pump can be moved the small distance necessary for belt adjustment without any change of piping.
  • Page 151 Chapter 9 Parts FURNISH COMPLETE INFORMATION WHEN ORDERING PARTS - When ordering parts or spares, give the description and the quantity of parts desired, together with the complete nameplate data, including all electrical requirements. W H E R E T O O R D E R PA R T S - R e p a i r a n d replacement parts should be ordered from your local Cleaver-Brooks authorized representative.
  • Page 152 Chapter 9 — Parts Table Of Contents Insulated Front Head - CB-LE ........9-3 Insulated Front Head Interior - CB-LE .

  • Page 153: Insulated Front Head - Cb-Le

    Chapter 9 — Parts Insulated Front Head - Model CB-LE Part No. 750-184...

  • Page 154: Insulated Front Head Interior - Cb-Le

    Chapter 9 — Parts Insulated Front Head Interior - Model CB-LE Part No. 750-184...

  • Page 155: Insulated Inner Door - Cb-Os

    Chapter 9 — Parts Insulated Inner Door - Model CB-OS Part No. 750-184...

  • Page 156: Insulated Rear Head Cb-Le

    Chapter 9 — Parts Insulated Rear Head CB-LE Part No. 750-184...
  • Page 157 Chapter 9 — Parts Insulated Rear Head CB-LE Part No. 750-184...

  • Page 158: Insulated Rear Head Cb-Os

    Chapter 9 — Parts Insulated Rear Head CB-OS Part No. 750-184...

  • Page 159: Dry Oven Model Cb-Le

    Chapter 9 — Parts Dry Oven Model CB-LE Part No. 750-184...

  • Page 160: Motor And Impeller

    Chapter 9 — Parts Motor and Impeller Model CB-LE, CB-OS TABLE ITEM 2 - IMPELLER 60 HZ 50 HZ BOILER H.P. 192-C-42 192-C-43 192-C-43 192-C-46 192-C-46 192-C-70 NOTE: Impeller size is based on boiler hp, ppm emission level, boiler operating pressure and alti- tude.
  • Page 161 Chapter 9 — Parts Motor & Impeller - Model CB-LE Part No. 750-184 9-11...

  • Page 162: Front Head Linkage

    Chapter 9 — Parts Front Head Linkage 9-12 Part No. 750-184...

  • Page 163: Jackshaft Retrofit Assembly Kits

    Chapter 9 — Parts Jackshaft Retrofit Assembly Kits CB PART # 274-63 CB PART # 274-220 CB PART# 274-221 Part No. 750-184 9-13...

  • Page 164: Mod Motor Linkage Kits

    Chapter 9 — Parts Mod Motor Linkage Kits CB PART # 476-53 Item REQ. Part # Description 67-16 Activation Rod 883-17 Ball Joint 10-288 Ball Joint Bushing 2-47 Modulation Motor Arm 869-21 Hex Nut, 1/4” - 20 869-22 Hex Nut, 3/8” - 24 860-39 Set Screw 868-138...

  • Page 165: Air Damper Linkage Kit

    Chapter 9 — Parts Air Damper Linkage Kit CB PART # 476-54 Item REQ. Part # Description 67-109 Damper Linkage Rod 883-17 Ball Joint 10-288 Ball Joint Bushing 869-21 Hex Nut, 1/4” - 20 869-22 Hex Nut, 3/8” - 24 Not Used 860-39 Capscrew, 1/4”...

  • Page 166: Burner Drawer-Gas Pilot Models 100-600, 125-200Hp

    Chapter 9 — Parts Burner Drawer-Gas Pilot Models 100-600, 125-200HP CB-LE 24 15 46 19 17 33 18 17" 16-1/4” 9-1/4” 1/8” 7/16” 3/16” MAX. 3/32” MIN. 1" MIN. 1/4” 44 45 9-16 Part No. 750-184...
  • Page 167 Chapter 9 — Parts Burner Drawer - Gas Pilot Models 100-600, 125-200 HP CB-LE ITEM DESCRIPTION PART NO. SEE TABLE NOZZLE-GUN ASSEMBLY 108-B-47 DAMPER 851-77 MICA, SHEET, PORT HOLE, #36 GA. X 1-1/2” DIA. 65-A-11 RETAINER SIGHT HOLE 860-176 MACHINE SCREW, RD. HD. 10-24 X 1/4” LG. 858-310 PLUG, PIPE, COUNTER SUNK, 3/4”...

  • Page 168: Burner Housing

    Chapter 9 — Parts Burner Housing TUBE SHEET BAFFLE SEAL BAFFLE (FRONT EXTENSION) STUD INNER DOOR 1/2" NOTES: BAFFLE ATTACHMENT 1. SEAL BAFFLE AT TUBE SHEET AND SHELL WITH ITEM #12. 2. PAINT WITH SYNCRON #5112 ZINCOAT PER INSTRUCTIONS ON DRAWING #876-A-73 AFTER CUTTING THREADS.
  • Page 169 Chapter 9 — Parts Burner Housing ITEM PART NO. DESCRIPTION USED ON 869-30 NUT, HEX, 3/8"-16 952-93 WASHER, 3/8" 32-A-605 GASKET, BURNER DRAWER TO HOUSING SEE TABLE BURNER DRAWER 32-A-603 GASKET, BURNER HOUSING TO FRT. HEAD 900-79 BULK PIPE, 3" X 13-1/2" LG. TBE. NAT.

  • Page 170: Control Cabinet (Hawk Ics)

    Chapter 9 — Parts Control Cabinet (Hawk ICS) 9-20 Part No. 750-184...

  • Page 171: Control Panel, Standard

    Chapter 9 — Parts Control Panel, Standard Part No. 750-184 9-21...

  • Page 172: Entrance Box

    Chapter 9 — Parts Entrance Box 9-22 Part No. 750-184...

  • Page 173: Front Head Electrical Cb-Le

    Chapter 9 — Parts Front Head Electrical CB-LE Part No. 750-184 9-23...
  • Page 174 Chapter 9 — Parts Front Head Electrical CB-LE 9-24 Part No. 750-184...

  • Page 175: Front Head Electrical Cb-Os

    Chapter 9 — Parts Front Head Electrical CB-OS Part No. 750-184 9-25...
  • Page 176 Chapter 9 — Parts Front Head Electrical CB-OS 9-26 Part No. 750-184...

  • Page 177: Straight Electric Oil Heater 60" Heavy Oil

    Chapter 9 — Parts Straight Electric Oil Heater 60” Heavy Oil - Model CB-LE NOTES: 1. ALL DIMENSIONS ARE APPROX. 2. UNLESS OTHERWISE NOTED, ALL PIPE TO BE 3/4" SCH. 40 ASTM A120 WELDED BLACK STL. AND ALL FITTINGS 150# M.I.. 3.
  • Page 178 Chapter 9 — Parts Straight Electric Oil Heater 60” Heavy Oil - Model CB-LE ITEM PART NO. DESCRIPTION USED ON OPTION 838-C-81 TANK - HEATER 3 & 5 kw U.S. 838-C-35 TANK - HEATER 3 & 5 kw CAN. 7-1/2 kw 195-B-238 TANK - HEATER QQ/QU...

  • Page 179: Heavy Oil Piping 60" Steam

    Chapter 9 — Parts Heavy Oil Piping 60” Steam CB-LE Part No. 750-184 9-29...

  • Page 180: Heavy Oil Piping 60" Steam

    Chapter 9 — Parts Heavy Oil Piping 60” Steam CB-LE SEE TABLE NEXT PAGE 9-30 Part No. 750-184...

  • Page 181: Common Oil Parts Heavy Oil

    Chapter 9 — Parts Common Oil Parts Heavy Oil Part No. 750-184 9-31...

  • Page 182: Side Mounted Air Compressor Piping

    Chapter 9 — Parts Side Mounted Air Compressor Piping 9-32 Part No. 750-184...

  • Page 183: Air Compressor Piping Cb-Os

    Chapter 9 — Parts Air Compressor Piping CB-OS Part No. 750-184 9-33...

  • Page 184: Air Line Piping

    Chapter 9 — Parts Air Line Piping ITEM PART NO. DESCRIPTION 827-8 BULK CONDUIT, 1/2" THINWALL EMT. X "B" LG. APPROX. 827-8 BULK CONDUIT, 1/2" THINWALL EMT. X "A" LG. APPROX. 8-A-2833 BRACKET 928-33 PIPE STRAP, 1/2" CONDUIT 868-136 CAPSREW, HEX HD. 1/4"-20 X 3/4" LG. 859-118 ELBOW, STREET, 1/2"...

  • Page 185: Light Oil Piping

    Chapter 9 — Parts Light Oil Piping Part No. 750-184 9-35...

  • Page 186: Light Oil/Air Piping - Front Head

    Chapter 9 — Parts Light Oil/Air Piping - Front Head 9-36 Part No. 750-184...
  • Page 187 Chapter 9 — Parts Light Oil/Air Piping - Front Head PAGE 9-31 Part No. 750-184 9-37...

  • Page 188: Pilot Gas Train 125-150Hp Cb-Le & 125-175Hp Cb-Os

    Chapter 9 — Parts Pilot Gas Train 125-150 HP CB-LE & 125-175 HP CB-OS 9-38 Part No. 750-184...

  • Page 189: Pilot Gas Train 200Hp Cb-Le & Cb-Os

    Chapter 9 — Parts Pilot Gas Train 200 HP CB-LE & CB-OS Part No. 750-184 9-39...

  • Page 190: Pilot Gas Train 225Hp Cb-Os

    Chapter 9 — Parts Pilot Gas Train 225HP CB-OS 9-40 Part No. 750-184...

  • Page 191: Gas Train 125-150 Hp

    Chapter 9 — Parts Gas Train 125-150 HP Part No. 750-184 9-41...

  • Page 192: Gas Train 175 Hp Cb-Os

    Chapter 9 — Parts Gas Train 175 HP CB-OS 3$576 /,67 ,7(0 47< 3$57 180%(5 '(6&5,37,21  1,33/( 6,'( 287/(7  [  [   9$/9( %877(5%$// %521=(   36,  1,33/( 3,3( 60/6  136 [   6&+  9$/9( %2'< *$6  ...

  • Page 193: Gas Train 200 Hp

    Chapter 9 — Parts Gas Train 200 HP Part No. 750-184 9-43...

  • Page 194: Gas Train 225 Hp Cb-Os

    Chapter 9 — Parts Gas Train 225 HP CB-OS 3DUWV /LVW ,7(0 47< &% 3DUW 1XPEHU 'ZJ /LQH  'HVFULSWLRQ  $&78$725 *$6 9$/9( :2 32&  $&78$725 5(*8$7,1* :32&   :&  635,1* <(//2: )25 6,(0(16 5(* $&78$725  7((  0,  137 ...

  • Page 195: Steam Pressure Controls

    Chapter 9 — Parts Steam Pressure Controls Part No. 750-184 9-45...

  • Page 196: Hot Water Temperature Controls

    Chapter 9 — Parts Hot Water Temperature Controls 9-46 Part No. 750-184...

  • Page 197: Water Column

    Chapter 9 — Parts Water Column Part No. 750-184 9-47...
  • Page 198 Chapter 9 — Parts Water Column 9-48 Part No. 750-184...

  • Page 199: Fireside Gaskets, Cb-Le

    Chapter 9 — Parts Fireside Gaskets, CB-LE Part No. 750-184 9-49...

  • Page 200: Fireside Gaskets, Cb-Os

    Chapter 9 — Parts Fireside Gaskets, CB-OS 9-50 Part No. 750-184...

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