CleaverBrooks CBT Operation And Maintenance Manual
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CleaverBrooks CBT Operation And Maintenance Manual

Tubeless vertical boiler
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Model CBT
Tubeless Vertical Boiler
Operation and Maintenance Manual
CBT-M — Full Modulation
CBT — On/Off Operation
750-382
04/2019

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Summary of Contents for CleaverBrooks CBT

  • Page 1 Model CBT Tubeless Vertical Boiler Operation and Maintenance Manual CBT-M — Full Modulation CBT — On/Off Operation 750-382 04/2019...
  • Page 2 ! DANGER WARNING ! DANGER WARNING Improper installation, adjustment, service, or mainte- If the information in this manual is not followed exactly, a fire or explosion may result causing property dam- nance can cause equipment damage, personal injury, or death. Refer to the Operation and Maintenance age, personal injury or loss of life.
  • Page 3 CLEAVER-BROOKS Model CBT Tubeless Vertical Boiler Operation, Service, and Parts Manual  Cleaver-Brooks 2019 Manual Part No. 750-382 04/2019...
  • Page 4 WARNING ! DANGER DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL APPLI- CABLE SECTIONS OF THIS MANUAL. DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY UN- DERSTAND 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

    CONTENTS CHAPTER 1 INTRODUCTION 1-1 Pressure vessel 1-2 Burner 1-4 Gas train 1-5 Controls 1-6 Component/connection locations 1-9 Optional equipment 1-10 CHAPTER 2 INSTALLATION 2-1 Lifting and moving the boiler 2-2 Water treatment 2-2 Boiler room 2-4 Gas piping 2-5 Boiler water-side connections 2-10 Electrical connections 2-11 Wiring diagrams 2-12...

  • Page 7: Introduction

    Introduction CHAPTER 1 Pressure vessel 1-2 Burner 1-4 Gas train 1-5 Controls 1-6 Component/connection locations 1-9 Optional equipment 1-10 750-382...

  • Page 8: Pressure Vessel

    The Model CBT and CBT-M are UL listed for both the US and Canada. Premix technology The Model CBT-M Boiler utilizes “Premix” technology to mix both fuel and combustion air prior to entering the firing chamber. This technology provides clean, efficient combustion with very low emission levels.
  • Page 9 Refractory is limited to the burner dry oven and a bottom furnace target plate. FIGURE 1-2. ASME data Gases of combustion flow downward through the furnace (1), then upward through the 2nd pass (2) before exiting the flue (3). CBT heat flow FIGURE 1-2. 750-382...

  • Page 10: Burner

    Introduction 1.2 — Burner 1.2.1 — Full modulation (CBT-M) Full modulation units use a premix burner with a self-regulat- ing gas valve-venturi system, ECM variable regulating gas valve, variable speed blower, and Fecralloy metal fiber burner canister. • Full modulation is provided using the integral variable speed combustion air fan and Falcon control.

  • Page 11: Gas Train

    VENTURI OPTIONAL: GAS PRESSURE REGULATOR ON/OFF (CBT) FULL MODULATION (CBT-M) FIGURE 1-5. Gas train Full modulation gas train components: Single body, dual safety shutoff gas valve with integral trim regulator Low Gas Pressure Switch...

  • Page 12: Controls

    Introduction 1.4 — Controls CONTROLS ABBREVIATIONS: ALWCO - Auxiliary Low Water Cutoff HLC - High Limit Control HWA - High Water Alarm OLC - Operating Limit Control LWCO - Low Water Cutoff 1.4.1 — Full modulation controls (Optional) (Optional) (Optional) FIGURE 1-6.
  • Page 13 Controls • Outdoor temperature reset. • Remote firing rate or setpoint control • Setback/time-of-day setpoint • Built-in Lead-Lag control for multiple boiler systems • Warm standby-minimum temperature control 1.4.2 — On-off controls The Burner Control provides burner sequencing control and flame supervision. A switch/light panel provides functionality similar to full modulation units: indicator lights for demand, fuel valve open, alarm, low water, and (optional) high water;...
  • Page 14 Introduction 1.4.3 — Water level and limit controls, all boilers ALWCO probe Manual valve The pressure transmitter provides an analog steam holder pressure signal to the controller for modulated firing (full modulation units) or on/off operation. The high limit control (HLC) provides safety shutdown Steam pressure gauge when steam pressure exceeds the maximum operating range of the boiler.

  • Page 15: Component/Connection Locations

    PRESSURE RELIEF VALVE STACK OUTLET GAUGE GLASS LEVEL CONTROL BURNER CABINET FEEDWATER PIPING TRAIN INLET BLOWDOWN PIPING (OPTIONAL) FIGURE 1-9. Boiler components/connections, CBT-M ALWCO SURFACE BLOWOFF PIPING GAS TRAIN LWCO STACK OUTLET BURNER SIGHT GLASS FEEDWATER PIPING AIR INLET BOTTOM BLOWDOWN (OPTIONAL) FIGURE 1-10.

  • Page 16: Optional Equipment

    1.6 — Optional equipment Certain options are available for the Model CBT Boiler; normally these will have been specified at the time of order entry. In addition, some options may have been provided (by others) that are not part of Cleaver-Brooks scope of supply.

  • Page 17: Installation

    Installation CHAPTER 2 Lifting and Moving the Boiler 2-2 Water Treatment 2-2 Boiler Room 2-4 Gas Piping 2-5 Boiler Waterside Connections 2-10 Electrical Connections 2-11 Wiring Diagrams 2-12 Warning Caution Provisions for combustion and ventilation air must The boiler must be installed such that the gas be in accordance with UL 795, Commercial- ignition system components are protected from Industrial Gas Heating Equipment, cUL, or...

  • Page 18: Lifting And Moving The Boiler

    Properly treated boiler water will help maximize the effectiveness and lifespan 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. See Table 2-1 for CBT water quality guidelines. 750-382...
  • Page 19 Water Treatment Important The CBT boiler requires soft water. Failure to observe this requirement can lead to dangerous operating conditions, and may result in damage to the boiler. If necessary, your Cleaver-Brooks representative can provide additional information regarding your water softening requirements.

  • Page 20: Boiler Room

    Installation 2.3 — Boiler Room The boiler room must comply with all building codes and regulations. An adequate supply of combustion air and sufficient ventilation are required for safe operation. If the optional direct vent combustion air kit is not used, ventilation must be provided to meet applicable regulations for air supply.

  • Page 21: Gas Piping

    *Maximum without upstream regulator A manually operated shut-off valve is provided as standard on the CBT boiler. If dirt particles are present in the gas supply, it may be necessary to install an approved gas filter. Please inquire with the local gas supply company.
  • Page 22 Installation If building supply gas pressure is greater than 1 psig (27.8” WC), an upstream regulator with overpressure pro- tection and proper gas venting will be required and must be piped to a safe point of discharge. For multiple boil- ler installations, a dedicated gas pressure regulator is required for each boiler to ensure consistent gas pressure at the boiler.
  • Page 23 Gas Piping Table 2-4. Gas line capacity - Schedule 40 metallic pipe Pipe Size Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 1.049 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (CFH) 1,060 1,580 3,050...
  • Page 24 Installation Gas header - For multiple unit installations, a single common gas header is recommended with individual takeoffs for each boiler (See Figure 2-4). Boiler gas manifold piping should be sized based on volume requirements and lengths between each boiler and the fuel main header. Tables 2-6 through 2-10 indicate the proper sizing for multiple units of equal size, placed on the factory standard center with the indicated take off size.
  • Page 25 DRIP LEG REQUIRED FOR ANY VERTICAL RUN OF PIPING FIGURE 2-5. Typical gas piping - Example 2 Pipe sizing for multiple unit manifolds TABLE 2- 6. CBT 10 HP boilers TABLE 2- 7. CBT 15 HP boilers # of # of...

  • Page 26: Boiler Waterside Connections

    The feedwater supply should provide sufficient pressure to meet minimum flow requirements. Cleaver-Brooks offers bottom blowdown piping and valves for CBT boilers. Optional surface blowoff is also available. A qualified boiler and piping installer should make all boiler waterside connections.

  • Page 27: Electrical Connections

    - Connect optional heat request inputs per wiring diagram - Connect pump controls per wiring diagram FIGURE 2-7. CBT wiring and cable connections Caution: The blower signal wiring must be isolated from the blower power wiring and the high voltage ignition cables.

  • Page 28: Wiring Diagrams

    Installation 2.7 — Wiring Diagrams Note: Wiring diagrams shown are for example only. Installations may vary. Refer to the Cleaver-Brooks wiring diagram provided with the boiler for information specific to your installation. Basic wiring diagram - full modulation 2-12 750-382...
  • Page 29 Wiring Diagrams Basic wiring diagram - on/off boiler 2-13 750-382...
  • Page 30 Installation 2-14 750-382...
  • Page 31 Flue and Combustion Air CHAPTER 3 Venting Venting connections - general 3-2 Flue venting 3-2 Vent terminal location 3-2 Horizontal through-wall venting, inside air (Category III) 3-5 Horizontal through-wall direct venting 3-6 Horizontal through-wall flue vent termination 3-7 Vertical venting, inside combustion air (Category III) central heating 3-8 Vertical venting direct vent combustion air (Category III) 3-9 Flue and combustion air duct design using direct vent combustion 3-9 750-382...

  • Page 32: Flue And Combustion Air Venting

    • Category IV - A boiler which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent. The Model CBT will in most applications be considered a Category III boiler. In certain applications, such as with a condensing economizer, Category II or IV venting criteria may apply.
  • Page 33 Vent terminal location 3. The bottom of the vent terminal and the air intake shall be located at least 24 inches above grade, including normal snow line. 4. Un-insulated single-wall metal vent pipe shall not be used outside in cold climates for venting combustion gas.
  • Page 34 Flue and Combustion Air Venting Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness, corrosion or deterioration. 3.3.1 — Venting installation tips Where to support piping: • Horizontal runs- at least every five (5) feet. •...

  • Page 35: Horizontal Through-Wall Venting, Inside Air (Category Iii)

    Horizontal through-wall venting, inside air (Category III) 3.4 — Horizontal through-wall venting, inside air (Category III) For boilers connected to gas vents or chimneys, vent installa- tions shall be in accordance with Part 7, Venting of Equipment, of the latest edition of National Fuel Gas Code, or in Canada, the latest edition of CAN/CGA-B 149.1 and.2 Installation Code for Gas Burning Appliances and Equipment, or applicable provi- sions of local building codes.

  • Page 36: Horizontal Through-Wall Direct Venting

    Flue and Combustion Air Venting FIGURE 3-3. Horizontal through-wall direct venting system, Category III installation 3.5 — Horizontal through-wall direct venting These installations utilize the boiler mounted blower to draw combustion air from outside and vent combustion gases to the outside. Combustion air venting can be constructed of steel, stainless steel, PVC, CPVC, or material as deemed appropri- ate for the application and per local codes.

  • Page 37: Horizontal Through-Wall Flue Vent Termination

    Horizontal through-wall flue vent termination 1. The flue venting be installed with a slight upward slope of at least 1/8” per foot of horizontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes. 2.

  • Page 38: Vertical Venting, Inside Combustion Air (Category Iii) Central Heating

    Flue and Combustion Air Venting 3.7 — Vertical venting, inside combustion air (Category III) central heating Flue Vent Termination If 10’-0” (velocity cone type) or less 24” Minimum 24” Minimum FIGURE 3-4. Vertical stack with inside combustion air These installations utilize the boiler mounted blower to vent the combustion products to the outside. Combustion air is taken from inside the room and the vent is installed vertically through the roof to the outside.

  • Page 39: Vertical Venting Direct Vent Combustion Air (Category Iii)

    Vertical venting direct vent combustion air (Category III) 3.8 — Vertical venting direct vent combustion air (Category III) Flue Vent Termination (velocity cone type) 36” Air Intake Minimum (w/Screen) 24” Minimum 12” Minimum Vertical stack with direct vent combustion air FIGURE 3-5.
  • Page 40 Flue and Combustion Air Venting 3-10 750-382...

  • Page 41: Commissioning

    Commissioning CHAPTER 4 Operating conditions 4-2 Full modulation boilers 4-2 Operating conditions 4-2 Filling boiler 4-2 Control setpoints 4-2 Water level controls 4-2 CB Falcon setup 4-4 CB Falcon display/operator interface 4-5 Lockouts, Holds, and Alerts 4-9 Controller configuration 4-10 Program module 4-17 Burner sequence 4-17 Fan speed settings 4-18...

  • Page 42: Full Modulation Boilers

    Commissioning 4.1 — Full modulation boilers 4.1.1 — Operating conditions • The installation site should be as free as possible from vibration, dust, and corrosive media • The controllers should be located as far as possible from sources of electromagnetic fields, such as frequency converters or high-voltage ignition transformers •...
  • Page 43 Full modulation boilers CBT probe and WC levels FIGURE 4-1. 750-382...

  • Page 44: Cb Falcon Setup

    Commissioning FIGURE 4-2. CB Falcon controller 4.1.5 — CB Falcon setup The Model CBT boiler uses the CB Falcon boiler control system. Primary controller functions include: • Flame supervision • Burner sequencing • PID Modulation control • Operating Limit Control Additional features include: •...

  • Page 45: Cb Falcon Display/Operator Interface

    4.1.6 — CB Falcon display/operator interface The CB Falcon display/operator interface is mounted in the boiler control panel for convenient access to all operating controls. Note: CBT boilers will be equipped with the 833-05105 System Display. For more information see Appendix B. 750-382...
  • Page 46 Commissioning Home page Apply power to the boiler. The Home page will appear on the CB Falcon display. FIGURE 4-5. Home Page If the screen does not display properly when the unit is powered up: • Verify that the controller is receiving power. •...
  • Page 47 Full modulation boilers Note: The “Home” icon at the upper left of the display screen always returns to the Home Page. The “Back” icon at the upper right displays the previous screen. The camera icon will take a snapshot of the currently displayed screen. Up to 16 snapshots can be saved and loaded to a USB device.
  • Page 48 Commissioning Status page FIGURE 4-8. The Demand display will show one of the following: Burner enable off Off (burner switch on but no demand) Steam Burner state shows the currently active step in the burner operating sequence. The central portion of the display can be toggled between the following: Pumps shows the status of the pump/auxiliary relay contacts Modulation shows fan speed RPM settings for Demand, Limited, and Override rates Setpoints shows the ON, Modulation, and OFF setpoints.

  • Page 49: Lockouts, Holds, And Alerts

    Full modulation boilers Operation page FIGURE 4-9. Operation page From the Operation Page page the user can change setpoints, manually control the boiler’s firing rate, manually turn pumps on, and view annunciation information. If a password is required to change any of the settings on this page, the user can press the Login button to enter the password.

  • Page 50: Controller Configuration

    4.1.8 — Controller configuration The CB Falcon controller should be factory configured for the specific CBT boiler model. Prior to starting the boiler, verify that the factory default settings are correct for your application. Please refer to CB default settings, Table 4-1, and make any changes at this time if needed.
  • Page 51 Full modulation boilers TABLE 4- 1. CB Falcon factory parameter settings - Model CBT-M (Continued) Parameter Group Parameter Name Access Min. Default Setting Max. Parameter Units Installation Modbus Range Range Setting Register (dec) Steam Configuration Steam modulation Service C:Modulation from...
  • Page 52 Commissioning TABLE 4- 1. CB Falcon factory parameter settings - Model CBT-M (Continued) Parameter Group Parameter Name Access Min. Default Setting Max. Parameter Units Installation Modbus Range Range Setting Register (dec) Pump Configuration Auxiliary 2 pump Service 0m 0s mmm ss...
  • Page 53 Full modulation boilers TABLE 4- 1. CB Falcon factory parameter settings - Model CBT-M (Continued) Parameter Group Parameter Name Access Min. Default Setting Max. Parameter Units Installation Modbus Range Range Setting Register (dec) Annunciation Annunciator 6 long LOW GAS Configuration...
  • Page 54 Commissioning TABLE 4- 1. CB Falcon factory parameter settings - Model CBT-M (Continued) Parameter Group Parameter Name Access Min. Default Setting Max. Parameter Units Installation Modbus Range Range Setting Register (dec) Burner Control Lightoff rate Service 1000rp 2000rpm 3000rpm Ignition...
  • Page 55 Full modulation boilers TABLE 4- 1. CB Falcon factory parameter settings - Model CBT-M (Continued) Parameter Group Parameter Name Access Min. Default Setting Max. Parameter Units Installation Modbus Range Range Setting Register (dec) Lead Lag Master Lead lag D gain...
  • Page 56 Commissioning TABLE 4- 1. CB Falcon factory parameter settings - Model CBT-M (Continued) Parameter Group Parameter Name Access Min. Default Setting Max. Parameter Units Installation Modbus Range Range Setting Register (dec) Lead Lag Slave Slave mode Service Equalize runtime Configuration...

  • Page 57: Program Module

    4.1.10 — Burner sequence In addition to providing modulation control, the CB Falcon is responsible for flame supervision and burner sequencing. The CBT boiler uses direct spark ignition (no pilot) to light the main flame. Flame FIGURE 4-12. Program module sensing is accomplished using an ultraviolet (UV) flame detector.

  • Page 58: Fan Speed Settings

    Model CBT gas train. Note: The flange. Do not use the leak test cocks to measure gas maximum rated inlet pressure to the CBT gas train is 1 psig (28" WC). pressure. An upstream regulator and overpressure protection are required if building supply gas pressure is greater than 1 psig.

  • Page 59: Power-Up

    4. The burner and its gas connection must be leak tested before placing the boiler into operation. 5. Gas Pressure Regulator - Using the adjusting screw on the main gas regulator, adjust the inlet pressure to the recommended levels in Table 4-3. TABLE 4- 3. CBT Gas Pressure Requirements CBT Size Natural Gas LP Gas Min (“WC)

  • Page 60: Operation Check: Gas Valve, Gas Pressure Switches, And Combustion Air Proving Switch

    Commissioning 4.1.15 — Operation check: gas valve, gas pressure switches, and combustion air proving switch Before initial firing of the burner, the gas valve, Low Gas Pressure Switch (LGPS), High Gas Pressure Switch (HGPS), and Combustion Air Proving Switch (CAPS) should be checked for proper operation. •...

  • Page 61: Lwco And Alwco Check

    ALWCO 1. To check the ALWCO, drain the boiler (refer to Chapter 5, Section 5.2 - Blowdown). 2. Observe the ALWCO control board in the CBT electrical panel. When the ALWCO level is reached, the LED indicator should go out.

  • Page 62: Low And High Fire Adjustments

    4.1.19 — Setting Combustion Note: A Combustion Analyzer is required to properly set-up the Model CBT burner. Do not attempt to fire and adjust the burner without this equipment. Note: Ensure boiler is filled with water prior to burner startup.
  • Page 63 Full modulation boilers Manual Modulation - use the procedure below to change the burner firing rate manually. 1. On the CB Falcon Operation screen, press 2. A numeric keypad will appear, the Firing rate display. showing the current firing rate and operating mode.* 3.

  • Page 64: Limit Controls Check

    Commissioning To set combustion: FIGURE 4-18. Operation screen 1. Check inlet gas pressure and reset low gas pressure switch. 2. At Operation screen set firing rate to low fire. Review burner sequence before proceeding. 3. Turn Demand switch to LOCAL. 4.

  • Page 65: On/Off Boilers

    On/off boilers The OLC and HLC can be tested while the boiler is producing steam by adjusting the switch setting downward. A lockout should result when the switch setting is at or just below the current steam pressure. Readjust each switch (and reset HLC) after testing. 4.2 —...

  • Page 66: Post Start-Up Checkout Procedure

    Commissioning 5. All valves in the piping leading to or from the system must be closed to prevent cleaning solution from getting into the system. 6. Fill the boiler vessel with enough clean water to cover the furnace. Add the cleaning solution, then fill to the top.

  • Page 67: Falcon Control Functions And Customer Interface

    The Time-of-Day (TOD), or setback, set point is an alternative set point that is enabled when a remote contact connected to terminals J10-2 & J10-3 is closed (Refer to Figure 2-8 CBT Wiring Diagram). When the circuit is open, the boiler control reverts back to the normal set point. The TOD set point can be adjusted at either the Operation page or under the Steam Configuration parameter group.
  • Page 68 Commissioning Remote enable and remote 4-20mA input Remote enable and Remote 4-20mA input allow the boiler to be sequenced and/or controlled from a separate boiler room controller or building management system. The 3-position Demand switch at the front of the control panel determines whether the boiler is off, in local, or under remote control.

  • Page 69: Maintenance

    Maintenance CHAPTER 5 General 5-2 Bottom blowdown 5-2 Water column blowdown 5-3 Fireside cleaning procedure/disassembly 5-5 Ignition electrode 5-7 UV scanner (full modulation only) 5-8 Waterside inspection/cleaning 5-10 Safety valve 5-11 Troubleshooting 5-11 Display diagnostics 5-27 Lay-up 5-27 750-382...

  • Page 70: General

    Maintenance 5.1 — General A well-planned maintenance program will help avoid unnecessary downtime or costly repairs, and will promote safety and aid boiler inspectors. It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly, and yearly maintenance activities will help to obtain economical and lengthy service from the equipment.

  • Page 71: Water Column Blowdown

    Water column blowdown Caution • Never pump the quick-opening valve to blow down the boiler. Such action could cause water hammer and damage the piping and valves. It could also cause personal injury. • Never leave an open blowdown valve unattended. •...
  • Page 72 Maintenance Open Open Closed 1. Open Water Column blowdown valve (5 to 3. Close upper gauge glass isolation valve. 10 sec.) to discharge water from WC. 4. Open gauge glass blowdown valve to 2. Close WC blowdown valve. discharge water from gauge glass. 8.

  • Page 73: Fireside Cleaning Procedure/Disassembly

    Fireside cleaning procedure/disassembly Close the valves when replacing the glass. Slip a packing nut, packing washer, and packing ring onto each end of the glass. Insert one end of the glass into the upper gauge valve body far enough to allow the lower end to be dropped into the lower body.
  • Page 74 Maintenance DRY OVEN BURNER CAN GASKET BURNER CAN SIGHT GASKET GLASS BURNER CANISTER ADAPTER PLATE ADAPTER PLATE GASKET BLOWER UNIT UV SCANNER IGNITION ELECTRODE VENTURI FIGURE 5-3. Burner assembly - full modulation SPRING PIN ELECTRODE ORIFICE PLATE LOCK WASHER STANDOFF BAFFLE WELDMENT LOCK WASHER SCREW...

  • Page 75: Ignition Electrode

    Ignition electrode 5.5 — Ignition electrode 5.5.1 — Full modulation burners Caution The dimensions on the Ignition Electrode are not easily adjustable. Bending the rods can cause damage to the insulating material. In addition, a bent electrode will have a tendency to return to its original shape when heated. If the electrode is out of specification, replacement is generally recommended.

  • Page 76: Uv Scanner (Full Modulation Only)

    Maintenance 0.25 - 0.125 ORIFICE PLATE COVER FLAME ROD FLAME ROD BAFFLE PLATE BAFFLE PLATE ORIFICE PLATE ELECTRODE (TIP IS FLUSH WITH FACE OF BAFFLE PLATE) ELECTRODE BAFFLE PLATE ELECTRODE ORIFICE PLATE FIGURE 5-6. Ignition electrode and flame rod, on/off burners 5.6 —...
  • Page 77 UV scanner (full modulation only) FIGURE 5-7. UV Scanner 832-2326 Scanner Wiring FIGURE 5-8. 750-382...

  • Page 78: Waterside Inspection/Cleaning

    Maintenance 5.7 — Waterside inspection/cleaning Waterside inspection frequency may depend upon the local jurisdiction and inspector but it is recommended that a waterside inspection take place 2-3 months after initial startup. C-B further recommends to semiannually remove all handhole covers and thoroughly clean the water side cavity and bottom of the boiler.

  • Page 79: Safety Valve

    Safety valve 5.8 — Safety valve The safety valve is an important safety device and deserves attention accordingly. Follow the recommendations of your boiler inspector regarding valve inspection and testing. The frequency of testing, either by use of the lifting lever or by raising the steam pressure, should be based on the recommendation of your boiler inspector and/or the valve manufacturer, and should be in accordance with Sections VI and VII of the ASME Boiler and Pressure Vessel Code.
  • Page 80 Maintenance The alert (or lockout) list will appear, showing date and time for each item. Pressing an individual item in the list will display additional information. Diagnostic information available for lockouts includes annunciator status, states of system inputs, and steam pressure at time of lockout. The Falcon display touch-screen interface is a valuable tool to help identify and resolve conditions that prevent normal and safe operation of the boiler.
  • Page 81 Troubleshooting TABLE 5- 1. CBT troubleshooting Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures Boiler will not start -- A. Hold 63 LCI Off A.1. Touch Screen Check demand state Turn Demand switch to no lockout or alarm “Demand” status is in...
  • Page 82 Maintenance Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures Check blowdown valve All blowdown valves positions. should be closed during operation, except during active blowdown proce- dures. Close any blow- down valves that may be open. B.2. Feed Water (FW) Check for power to FW If no power present -- pump is not running,...
  • Page 83 Troubleshooting Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures Inspect high-temp Tighten jam nuts on wire-to-probe connec- any loose probe con- tions in boiler water nections. column connection box (Warrick) If slight corrosion pres- ent, remove terminal connection, clean crimp-on ring termi- nal, re-crimp, and replace with copper...
  • Page 84 Maintenance Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures C. Demand: Steam C.1. Steam pressure is Note Modulation set Change steam Set Burner state: Standby greater than Falcon ON point, ON and OFF Point, On hysteresis, (normal) point (SP - ON hystere- points on status screen and Off hysteresis sis)
  • Page 85 Troubleshooting Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures Check Auxiliary Low If LED remains off after Water Cut-off (ALWCO) reset and LWCO control LED inside con- “LLCO” LED is ON, trol panel. Also observe perform water column primary LWCO control and boiler bottom “LLCO”...
  • Page 86 Maintenance Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures H. Lockout 67 ILK OFF H.1. Insufficient gas Check gas supply pres- Confirm gas shut-off LOW GAS PRESSURE supply pressure or gas sure at boiler gas valve valve is open. Increase valve closed inlet during trial for gas supply to boiler...
  • Page 87 Troubleshooting Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures J.2. Combustion Air Visually inspect blower Check that blower Blower does not run or cable/harness connec- cable/harnesses are does not run to purge tions. secure on both ends: speed (4000 RPM) 3-conductor power cable to blower power circuit and 4-conductor...
  • Page 88 Maintenance Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures Check if blower is turn- Resolve draft condi- ing when not on. tion (e.g. adjust stack damper) to near neu- tral (0" w.c.) K.2. Blower running Check Firing rate and If Firing rate indicates when boiler is off Fan speed on Falcon...
  • Page 89 Troubleshooting Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures L.4. Gas supply restric- Monitor gas supply If significant fluctations tion -- improperly sized pressure at boiler gas in gas pressure (e.g. 5" high pressure regulator, valve inlet during trial to 10"...
  • Page 90 Maintenance Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures L.10. Burner canister Check for flame signal inspect burner/clean clogged surface. Replace burner canister if clogged or damaged. Clear Lockout and try again L.11. No or poor flame Check for flame sig- If flame observed, signal (less than 1 nal;...
  • Page 91 Troubleshooting Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures M.3. Flame Rod (Ion- Check flame signal and Increase the gap ization Electrode) inspect flame rod posi- between the flame rod grounding itself tion. tip to the burner canis- ter surface. Replace flame rod if damaged.
  • Page 92 Maintenance Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures O. Lockout 173 Pilot O.1. Loose wire or neu- Check fuel valve wir- Correct/secure any relay feedback error tral in fuel valve circuit ing from control panel loose wire connections to gas valve connection in fuel valve circuit.
  • Page 93 Troubleshooting Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures Q.3. Low fire (Mini- Observe if Lockout Increase Minimum mum modulation occurs at lower firing modulation speed by speed) too low rate. Compare Mini- 100-300 RPM as mum modulation needed. parameter setting to Manual commission- ing recommendation.
  • Page 94 Maintenance Problem Display Message Possible Cause/Symp- Diagnostic Check Corrective Measures S.2. Anti-short cycle Check anti-short cycle Reduce ant-short cycle time is too long time time parameter; set to 0 to disable this func- tion. Anti-short cycle is located in the "Steam Configuration"...

  • Page 95: Display Diagnostics

    Display diagnostics 5.10 — Display diagnostics The CB Falcon display/interface provides diagnostic features under the Setup menu. To access display diagnostics, beginning on the Home screen, press <Setup>, then <Display Diagnostics> If the touch screen is not working properly, it may require re-calibration. Go to Display Diagnostics as above and press <Calibrate Screen>.
  • Page 96 Maintenance 5-28 750-382...
  • Page 97 Parts CHAPTER 6 Recommended spare parts list 6-2 Safety valves 6-3 Control panel 6-4 Burner assembly 6-6 Water Column 6-12 Feedwater piping 6-13 Gas train 6-14 Direct vent kits 6-15 750-382...

  • Page 98: Parts

    Parts 6.1 — Recommended spare parts list PART NUMBER DESCRIPTION 10-15 HP 20-25 HP 30 HP Falcon controller, steam 833-03578 Falcon Display 833-05105 Power Supply, 12VDC 832-02179 Gasket, Adapter Plate To Blower 380-01037 Gasket, Burner Canister (2) 380-01136 380-00902 380-01169 Burner Canister 380-01134 380-00900...

  • Page 99: Safety Valves

    Safety valves 6.2 — Safety valves SAFETY VALVES CBT BOILERS SAFETY BOILER PRESSURE PART NO. SIZE 940-04991- x 1.50 940-04991- x 1.50 940-04991- x1.50 940-04992- x 2.00 940-04992- x 2.00 940-07988- x 1.25 940-07988- x 1.25 940-07988- x 1.25 940-02268- x 2.00...

  • Page 100: Control Panel

    Parts 6.3 — Control panel 6.3.1 — Full modulation ITEM PART NO. DESCRIPTION 119-00440-000 CABINET, ELECTRICAL W/SUB BASE, CBT DISPLAY, TOUCHSCREEN, FALCON 833-03578-000 CONTROLLER, BOILER, STEAM CONTROLLER, LWCO & PUMP CONTROL 832-00235-000 TRANSFORMER, 115v/24v IGNITION TRANSFORMER FUSE, 5 AMP, CONTROL CIRCUIT...
  • Page 101 LUG, 90 DEG FEMALE SPADE 884-00286-000 LUG, FEMALE SPADE WIRING 832-01881-000 BLOWER FUSE 6A 832-01811-000 PANEL FUSE 5A 118-04778-000 LABEL, CBT LIGHTS, ON/OFF & L-H-L 836-08918-000 SWITCH, TOGGLE, S.P.D.T. WO/CENTER OFF 881-00136 LIGHT, NEON WHITE 881-00138 LIGHT, NEON GREEN 881-00137...

  • Page 102: Burner Assembly

    Parts 6.4 — Burner assembly 6.4.1 — 10-15 HP full modulation ITEM PART NO. DESCRIPTION 279-01270-000 DRY OVEN, CBT 10HP W/UV SCANNER 380-01136-000 GASKET, BURNER CAN 380-01134-000 BURNER CANISTER, CBT 10-20HP SEE TABLE ADAPTER PLATE, BLOWER TO BURNER 380-01037-000 GASKET, ADAPTER PLATE TO BLOWER...
  • Page 103 380-00900-000 BURNER CYLINDER 868-01080-000 CAPSCREW 845-00468-000 CONNECTOR, .125" MPT. x .25" ODC ITEM 20 HP 25 HP 279-00219-000 DRY OVEN, CBT 25HP W/UV SCANNER 380-01194-000 380-00903-000 380-01172-000 ELECTRODE, IGNITION 048-00655-000 048-00660-000 380-01037-000 GASKET, ADAPTER PLATE TO BLOWER 380-00902-000 GASKET, BURNER CAN...
  • Page 104 Parts 6.4.3 — 30 HP full modulation 750-382...
  • Page 105 SUB-BASE, CONTROLS ASSEMBLY, ON/OFF BURNER 853-00348-000 ROPE, FIBERGLASS 380-00226-000 FILTER, AIR 118-03814-000 NAMEPLATE, INSTALLATION - WARNING 118-00331-000 NAMEPLATE, UL GAS FIRED BOILER 118-04743-000 LABEL, CONTROL PANEL, CBT BOILERS 118-00247-000 NAMEPLATE, "CLEAVER-BROOKS" 118-00401-000 NAMEPLATE 118-00401-000 NAMEPLATE ITEM #8 059-00021-000 059-00022-000 NEGATIVE...
  • Page 106 CLAMP, LOOP 939-00025-000 TUBING, COPPER 118-03814-000 NAMEPLATE, INSTALLATION - WARNING 118-00331-000 NAMEPLATE, UL GAS FIRED BOILER 118-04743-000 LABEL, CONTROL PANEL, CBT BOILERS 118-00247-000 NAMEPLATE, "CLEAVER-BROOKS" LOGO 118-00401-000 NAMEPLATE, CBT LABEL SHEET 832-02101-000 HARNESS, MOTOR POWER CORD ASSEMBLY NO. ITEM #8...
  • Page 107 ITEM PART NO DESCRIPTION 059-00030-000 PLATE ASSEMBLY, BURNER MOUNTING FLANGE, ON/OFF 380-01168-000 GASKET, BURNER FLANGE 279-00218-000 DRY OVEN ASSEMBLY, ON/OFF BURNER, CBT 30HP 380-00225-000 GASKET, DRAWER ASSEMBLY 429-00168-000 DRAWER ASSEMBLY 380-01037-000 GASKET, ADAPTER PLATE TO BLOWER 894-04076-000 BLOWER UNIT, G1G170, 115V...

  • Page 108: Water Column

    Parts 6.5 — Water Column 15# STEAM 150# STEAM ITEM PART NO PART NO DESCRIPTION 817-03984-000 817-03984-000 ALWCO PROBE HOLDER 941-00055-000 941-00055-000 VALVE, BALL 850-00243-000 850-00122-000 GAUGE, PRESSURE 817-04385-000 817-04386-000 SENSOR, MODULATING CONTROL 817-04095-000 817-04093-000 PRESSURE CONTROL, OP LIMIT 817-04094-000 817-04092-000 PRESSURE CONTROL, HIGH LIMIT 817-03983-000...

  • Page 109: Feedwater Piping

    Feedwater piping 6.6 — Feedwater piping ITEM 10-25 HP 30 HP DESCRIPTION 940-03010-000 940-00455-000 VALVE, CHECK, SWING 941-01886-000 941-01887-000 VALVE, GATE 6-13 750-382...

  • Page 110: Gas Train

    Parts 6.7 — Gas train 6.7.1 — Gas train, full modulation ITEM 10-15 HP 20-25 HP 30 HP DESCRIPTION 800-00092-000 800-00092-000 800-00092-000 ADAPTER, 1" NPT PIPE 800-00098-000 800-00098-000 800-00098-000 GASKET, VENTURI 940-07162-000 940-07164-000 940-07164-000 VALVE, GAS, COMBO 817-02414-000 817-02414-000 817-02414-000 LOW GAS PRESSURE SWITCH 817-02420-000 817-02420-000...

  • Page 111: Direct Vent Kits

    Direct vent kits 6.8 — Direct vent kits CBT SIZE KIT NO DESCRIPTION 10-20 HP 880-04494-000 4" DIRECT VENT KIT 880-04494-000 4" DIRECT VENT KIT 25 HP 880-02737-000 6" DIRECT VENT KIT 880-02737-000 6" DIRECT VENT KIT 30 HP 6-15...

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