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Summary of Contents for CleaverBrooks WB
- Page 1 Table Of Contents Model Electric Boilers Hot Water Operation and Maintenance Manual 750-136 07/2018...
- Page 3 CLEAVER-BROOKS Model WB Electric Boilers - Hot Water Operation and Maintenance Manual Cleaver-Brooks 2018 Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative Manual Part No. 750-136 Printed in U.S.A. 07/2018...
- 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.
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Page 5: Table Of Contents
CONTENTS General Description 1-1 CHAPTER 1 1.1 — Introduction 1-1 1.2 — Application 1-2 1.3 — Description 1-2 1.4 — Principles of Operation 1-4 Installation Instructions 2-1 CHAPTER 2 2.1 — Receiving Inspection 2-1 2.2 — Location 2-1 2.3 — Piping 2-2 2.4 —... -
Page 7: General Description
Warning indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death. Caution Caution indicates a potentially hazardous situation which, if not avoided, could result in damage to the equipment. NOTE: ”NOTE:” indicates information that is vital to the operation of the equipment. 750-136 Model WB Electric Boiler Manual... -
Page 8: Application
160 psig and temperatures to 250º F. All WB boilers carry the “H” stamp. An 11” x 15” manhole is provided on the WB models 361 through 422, smaller boilers are supplied with hand- holes as required by ASME Code, Section IV. - Page 9 500,000 duty cycles. 4. Heating Elements Standard heating elements are Incoloy sheathed and rated at 75 watts per square inch (model WB). These elements are individually replaceable hairpin type. 5. 120 Volt Control Circuit All boilers have 120 volt control circuits. Control circuit transformers with primary fusing and grounded secondary are provided on all models.
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Page 10: Principles Of Operation
Pilot lights are standardly provided to indicate “power on,” “high tempera- ture,” and “low water.” 11. Pressure/Temperature Combina- NOTE: Model WB 121 is supplied with individual pressure and tempera- tion Gauge ture gauges. Larger models include a separate pressure gauge and digital temperature read-out. - Page 11 (100º F). Pumps should operate continuously and, for the best control, the flow through the boiler should be constant. 750-136 Model WB Electric Boiler Manual...
- Page 12 General Description 750-136 Model WB Electric Boiler Manual...
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Page 13: Installation Instructions
2.1 — Receiving Inspection Every Model WB boiler is completely inspected at the factory and carefully crated for shipment. Inspect the pack- ing for signs of exterior damage. After placing the unit as close as possible to the point of actual installation, uncrate carefully and check all boxes and cartons against the packing slip. -
Page 14: Piping
2.4 — Heat Pump Systems with High Flow Rates The Model WB will accept flow rates that will give a minimum temperature rise across the boiler as low as 3º F when supplied with optional inlet baffle or oversized connections. Minimum temperature rise can also be obtained by installing a bypass piping arrangement to adjust the flow through the boiler. -
Page 15: Electrical
Electric hot water boilers are typically designed for top connection to the main supply lugs and are supplied with solderless wire connectors suitable for copper supply wires. 750-136 Model WB Electric Boiler Manual... - Page 16 To avoid the hazard of electrical shock: On boilers requiring more than one supply circuit, be sure that phasing is cor- rect and circuits are not “mixed” before energizing. Failure to observe this warning could result in serious personal injury or death. 750-136 Model WB Electric Boiler Manual...
- Page 17 Contactor, 50A res. (8AWG - load side) 40 in lbs Caution Specific components may differ between boilers. ALWAYS adhere to each component’s recommended torque setting for specific wire size and type (often located on component’s factory label). 750-136 Model WB Electric Boiler Manual...
- Page 18 Installation Instructions 750-136 Model WB Electric Boiler Manual...
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Page 19: Pre-Start Preparation
Inspect all contactors, fuse bases, and wire bundles for stray or loose metal objects (screws, bolts, metal shavings, knockout slugs, etc.) that may lodge there. All such material must be removed before startup. 750-136 Model WB Electric Boiler Manual... -
Page 20: Boiler And System Cleaning
Sodium Hydroxide (Lye) Their preference is in the order shown. Prepare the cleaning solutions as follows, do not mix different types of cleaners. a. Trisodium Phosphate: one lb. for each fifty gallons in the system. 750-136 Model WB Electric Boiler Manual... - Page 21 If system deterioration is permitted and leaks develop and water losses increase, it is possible to cause serious damage to the boiler. Therefore, it’s important to have a closed system that is clean, neutral, and water tight. 750-136 Model WB Electric Boiler Manual...
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Page 22: Boiler Water Treatment
Water treatment may vary from season to season or over a period of time; therefore, there should be a require- ment that the water treatment procedure be checked no less than four times a year, and possibly more fre- quently, as the local water conditions may require. 750-136 Model WB Electric Boiler Manual... -
Page 23: Operating Instructions
On-Off Temperature Control The differential value is adjusted using the internal potentiometers (see Figure 4-3). NOTE: Boiler controls may vary depending on boiler model. Consult the appropriate literature for information specific to your application. 750-136 Model WB Electric Boiler Manual... - Page 24 If the contactors cycle too rapidly even after increasing the proportional band, the step control may have to be adjusted to increase span, proportional band, or time delay, depending on the step control supplied. 750-136 Model WB Electric Boiler Manual...
- Page 25 Set ST1 and ST2 switches to HEAT. Set interstage (INTER) and differential (DIFF1, DIFF2) to desired settings. Position the setpoint knob at the setting for stage 1. After making adjustments, replace the On-Off Temperature Control cover. 750-136 Model WB Electric Boiler Manual...
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Page 26: Maintenance Schedule
However, if there is a low or unbalanced amp reading, further tests with an ohmmeter may be necessary to detect the open or shorted element(s) in the group. To test individual ele- ments for continuity with an ohmmeter, the jumpers between elements must first be removed. 750-136 Model WB Electric Boiler Manual... -
Page 27: Element Replacement Procedure
(35 ft. lbs. for 208 and 240 volt elements). You will feel the ferrule separate from the nut while tighten- ing. A properly tightened ferrule nut will have separated from its ferrule and the ferrule will be squeezed or compressed onto the element sheath, thus providing a tight seal. 750-136 Model WB Electric Boiler Manual... - Page 28 5 ft lb increments up to a maximum of 70 ft lb (60 ft lb for 208 and 240 Volt elements) until leaks are no longer detected. Rewire the element ends. Torque element stud nuts to 35 in lb. Element Installation Details FIGURE 4-3. 750-136 Model WB Electric Boiler Manual...
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Page 29: Troubleshooting
• Allow pressure/temperature to fall Pressure/temperature has • below setpoint less control differ- exceeded setpoint on manual ential. Depress reset button. reset limit control. Raise setting if necessary, but not above design limit. 750-136 Model WB Electric Boiler Manual... - Page 30 Check that element bussing is per • • wiring diagram. Contactors noisy (chatter). Element(s) open. Replace faulty element(s). • • • Contactors damp/dirty. • Blow out contactors with com- pressed air. Remove contactor, disassemble and clean, and replace contactor. 750-136 Model WB Electric Boiler Manual...
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Page 31: Parts
• name and description of the required part • quantity required • method of shipment • date the part(s) is needed by If repair parts are required for accessory equipment, order these parts from your local authorized Cleaver-Brooks representative. 750-136 Model WB Electric Boiler Manual... - Page 32 Operating Temperature Control, 4 SPDT Relay Outputs, Outdoor Reset, -40°F to 248°F 817-05072-000 Modulating Temperature Control, 4-20 mA Analog Output, -40°F to 248°F 817-05075-000 Modulating Temperature Control, 4-20 mA Analog Output, Outdoor Reset, -40°F to 248°F 997-10815-000 UDC2500 w/ RS-485 Modbus Communication 750-136 Models WB Electric Boiler Manual...
- Page 33 Control Transformer, 1000VA, 208V Pri, 120V Sec 832-01913-000 Control Transformer, 1000VA, 380/415V Pri, 120V Sec 832-01803-000 Control Transformer, 1000VA, 240/480V Pri, 120V Sec 832-01914-000 Control Transformer, 1000VA, 600V Pri, 120V Sec 832-00235-000 Transformer, Damper, 40VA, 120V Pri, 24V Sec 750-136 Model WB Electric Boiler Manual...
- Page 34 Safety Door Interlock, 115Vac, 60Hz, for dual door enclosures 817-00239-000 Alarm Bell, 4" 817-00468-000 Alarm Bell, 6" 817-03096-000 Alarm Horn, 4", NEMA 1 836-01461-000 Panel High-Temperature Thermostat Switch Consult factory for special/custom parts or for parts not shown on this list. 750-136 Models WB Electric Boiler Manual...