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CleaverBrooks 5 Manual

CleaverBrooks 5 Manual

Size 8000 low water volume
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$25.00 U.S.
CLEAVER-BROOKS
Model 5 Boiler
Size 8000 Low Water Volume
Manual Part No. 750-215
11/04

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Summary of Contents for CleaverBrooks 5

  • Page 1 Table Of Contents $25.00 U.S. CLEAVER-BROOKS Model 5 Boiler Size 8000 Low Water Volume Manual Part No. 750-215 11/04...
  • Page 2 SAFETY PRECAUTIONS AND Abbreviations ABBREVIATIONS Following is an explanation of the abbreviations, acronyms, and symbols used in this manual. Safety Precautions It is essential to read and understand the following safety Alternating Current precautions before attempting to operate the equipment. Failure to follow these precautions may result in damage to Automatic Reset equipment, serious personal injury, or death.
  • Page 3 CLEAVER-BROOKS Model 5 Boiler Size 8000 Low Water Volume  Cleaver-Brooks 2004 Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative Manual Part No. 750-215 Revised 11/2004 Printed in U.S.A.
  • Page 4 ! DANGER WARNING DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL AP- PLICABLE 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

    E. Burner Controls........
  • Page 6 D. Water Gauge Glass ........6-5...
  • Page 7 D.Burner Stays in Low Fire ......7-4 E.Shutdown Occurs During Firing ......7-5 F.Damper Motor Does Not Operate .
  • Page 8 Notes...

  • Page 9: General Description And Principles Of Operation

    E. Burner Controls ........

  • Page 10: The Boiler

    Feedwater valve 3) Insulated steam drum (insulated from combustibles). 4) Low fire hold Model 5 Size 8000 LWV is designated M5 P-(100, 200, 700)- 8000- 150-WV. The type of f uel used by the boil er deter mine s the classification.

  • Page 11: The Burner

    All Model 5 boilers in the above se r i e s c om p l y, whe n e q ui p pe d w i th o p ti o na l equipment, to Factory Insurance Association (F.

  • Page 12: Steam Controls

    Section 1 — General Description and Principles of Operation C. STEAM CONTROLS 1. High Limit Pressure Control (Figure 1-6): Breaks a circuit to stop burner operation on a rise of pressure above a selected setting. It is adjusted to stop the burner at a preselected pressure above the operating limit control setting.

  • Page 13: Burner Controls

    Section 1 — General Description and Principles of Operation This valve is provided to flush the gauge glass. • Auxiliary Low/High Water Cutoff - (Figure 1-7-B) (Optional equipment) The manual reset type requires resetting in order to start the burner after a low water condition. Safety Valve(s) (Figure 1-9): Prevent buildup over the design pressure of the pressure vessel.
  • Page 14 Section 1 — General Description and Principles of Operation • Load Demand Light: Illuminates (white) when the boiler operating controls indicate a demand for hot water or steam. • Burner Switch: Activates or deactivates the operating cycle of the flame safeguard control. •...

  • Page 15: Profire Burner

    D. Oil Components ........

  • Page 16: Firing Tube

    Section 2 — Profire Burner IGNITION TRANSFORMER PILOT GAS TRAIN PIPING ASSEMBLY BLOWER MOTOR BLOWER HOUSING BLAST TUBE AND MOTOR ASSEMBLY ROTARY DAMPER COMBUSTION AIR PROVING SWITCH Figure 2-1 Profire Component Location (Left Side) A. FIRING TUBE Blast Tube (Figure 2-1). The blast tube functions as a duct for combustion air, and houses the fuel nozzle(s), gas pilot assembly, diffuser, and air baffle assemblies.

  • Page 17: Gas Components

    Section 2 — Profire Burner C. GAS COMPONENTS Note: Depending upon the requirements of the insurance carrier or other governing agencies, the gas flow control system, or gas train, may consist of some, or all, of the following items. Refer to your boiler to determine those that are applicable.
  • Page 18 Section 2 — Profire Burner ratio over the entire burner operating range, high fire to low fire. Main Gas Valve (Figure 2-4):Electrically actuated shut-off valve that opens to admit gas to the burner. Depending upon boiler size and/or the applicable regulatory requirements, this may be a diaphragm valve or, more generally, a motorized type valve.

  • Page 19: Oil Components

    Section 2 — Profire Burner from starting. This switch is usually equipped with a device that must be manually reset after being tripped. High Gas Pressure Switch (Figure 2-4): A pressure actuated switch that is closed whenever main gas line pressure is below a preselected pressure.

  • Page 20: Safety And Controls

    Check the wiring diagram for your burner for information on the specific unit installed on your burner. Fuel Selector Switch (Figure 2-5, B): Allows the operator to select either gas or oil as the active fuel on combination burners.

  • Page 21: Combustion Air

    Section 2 — Profire Burner H. COMBUSTION AIR Air for the combustion of fuel is delivered by the forced draft fan of the burner. The supply of combustion air is regulated by modulating the air damper to maintain the correct ratio of air to fuel for efficient combustion throughout the range of firing rates.
  • Page 22 Section 2 — Profire Burner valve(s) to maintain the air-fuel ratio throughout the firing range. The main fuel valve(s) cannot be energized (opened) unless the combustion air proving switch is closed to indicate a sufficient supply of combustion air. Some insurance requirements specify two main fuel valves. Additional requirements call for a normally open vent valve to be placed between them for venting gas should any be present in main gas line when main gas valves are de-...

  • Page 23: The Pressure Vessel

    E. Cleaning ........

  • Page 24: General

    160 psi a n d / o r t e m p e r a t u r e s n o t e x c e e d i n g 2 5 0 ° F : a n d manufactured to the ASME heating boiler Code.

  • Page 25: Water Requirements

    If balancing cocks or orifice plates are used, a significant pressure drop (for example, 3 to 5 psi) must be taken across the balancing device to determine required flow rates. If care is not taken to insure adequate flow through the boilers this can result in wide variation of firing rate between them.

  • Page 26: Pressure

    Section 3 — The Pressure Vessel Pressure The design of the system and the usage requirements will often dictate the pressure exerted upon the boiler. Some systems are pressurized with air or with an inert gas, such as nitrogen. Caution must be exercised to make sure that the proper relationship of pressure to temperature exists within the boiler so that all of its internal surfaces are fully wetted at all times.

  • Page 27: Objectives Of Water Treatment In General Are

    Section 3 — The Pressure Vessel Objectives of water treatment in general are: 1. Prevention of hard scale deposits or soft sludge deposits which impair the rate of heat transfer and can lead to overheated metal and costly down time and repairs. 2.
  • Page 28 Section 3 — The Pressure Vessel must be removed to prevent damage to pressure vessel heating surfaces. On steam systems the condensate should be wasted until tests show the elimination of undesirable impurities. During the period that condensate is wasted, attention must be given to the treatment of the raw water used as make up so that an accumulation of unwanted materials or corrosion does not occur.

  • Page 29: Boil-Out Of A New Unit

    Section 3 — The Pressure Vessel Any oil or grease present on the heating surfaces must be removed promptly by a boil-out with an alkaline detergent solution. F. BOIL-OUT OF A NEW UNIT The internal surfaces of a newly installed boiler may have oil, Caution grease or other coatings for various reasons beyond the manufacturer’s control.
  • Page 30 Section 3 — The Pressure Vessel contaminate these valves. Use care in removing and re- installing valves. 5. All valves in the piping leading to or from the system must be closed to prevent cleaning solution from getting into the system.

  • Page 31: Washing Out

    Section 3 — The Pressure Vessel G. WASHING OUT 1. Steam Boiler No later than 3 months after initially placing the boiler into operation and thereafter as conditions warrant, the pressure vessel should be drained after being properly cooled to near ambient temperature, handhole cover or closure plate in the upper drum and handhole covers in the lower drum removed and internal waterside surfaces inspected for corrosion,...

  • Page 32: Types Of Blowdown

    Section 3 — The Pressure Vessel designed to remove unwanted substances which contribute to scale and deposit formations. However, none of these processes are in themselves capable of removing all substances and regardless of their high efficiency, a small amount of encrusting solids will be present in the boiler water.

  • Page 33: Continuous Blowdown

    Section 3 — The Pressure Vessel Continuous Blowdown Continuous blowdown is used in conjunction with a surface bl ow - o f f t a p p i n g a n d i s t h e c o n t i nu o u s re m ov a l o f concentrated water.

  • Page 34: Manual Blowdown Procedure

    Section 3 — The Pressure Vessel r e m a i n s t o b e a l e r t t o s y s t e m w a t e r l o s s e s a n d corresponding amount of raw water make-up.
  • Page 35 Section 3 — The Pressure Vessel damaging temperature differential that can cause harmful stresses. Vessels should not normally be drained until all pressure is relieved again to prevent uneven contraction and temperature differentials. Draining the unit too quickly may cause the baking of deposits that may be present on the heating surfaces.

  • Page 36: Fireside Cleaning

    Section 3 — The Pressure Vessel J. FIRESIDE CLEANING Soot and non-combustibles are effective insulators and if allowed to accumulate will reduce heat transfer to the water and increase fuel consumption. Soot and other deposits can be very moisture absorbent and may attract moisture to form corrosive acids which will deteriorate fireside metal.

  • Page 37: Water Washing - Fireside (Oil Fired Unit)

    Section 3 — The Pressure Vessel K. WATER WASHING — FIRESIDE (OIL FIRED UNIT) An oil fired boiler has water washing lances located in the passageway between the convection tube wall and the furnace tube wall on both sides of the boiler (see Figures 3- SURFACE BLOW OFF 1).

  • Page 38: Preparation For Extended Lay-Up

    Section 3 — The Pressure Vessel The front end of the water drain troughs on the under side of the drum are equipped with capped openings. These openings enable the trough to be flushed with a hose, if necessary, to remove any accumulation. When doing this, make sure that the drains are open and that water is draining away.
  • Page 39 Section 3 — The Pressure Vessel short period of time. Additional chemicals may be suggested by the water consultant to minimize corrosion. Internal water pressure should be maintained at greater than atmospheric pressure. Nitrogen is often used for this purpose. fireside surfaces must be thoroughly cleaned and refractories should be wash-coated.
  • Page 40 Section 3 — The Pressure Vessel Notes 3-18 Part No. 750-215...
  • Page 41 B. Circuit and Interlock Controls ......4-2 C. Sequence of Operation - Oil or Gas ......4-5 D.

  • Page 42: General

    The sequences do not attempt to correlate the action of the fuel supply system or feedwater system except for the interlock controls that directly relate to the action of the prog ram relay. C hapters 5 and 6 contain operating instructions and specific information on setting and adjusting the controls.
  • Page 43 Section 4 — Sequence Of Operation Limit Circuit: • Burner switch (BS) • Operating limit control (OLC) - pressure or temperature • High limit control (HLC) - pressure or temperature • Low-water cutoff (LWCO) • Gas-oil selector switch (GOS) - (Combination burner only) •...
  • Page 44 Section 4 — Sequence Of Operation • Manual flame control (MFC) • Modulating control (MC) To comply with requirements of insurance underwriters such as Factory Mutual (FM), Industrial Risk Insurers (IRI) or others, additional interlock devices may be used in addition to the circuits mentioned in Section B.

  • Page 45: Sequence Of Operation - Oil Or Gas

    Section 4 — Sequence Of Operation C. SEQUENCE OF OPERATION - OIL OR GAS Caution On a combination fuel unit, the gas/oil switch must be set The cause for loss of flame or any for the proper fuel. other unusual condition must be The following sequence occurs with power present at the investigated and corrected before program relay (PR) input terminals and with all other...
  • Page 46 , e i t h e r t h e 1 0 or 1 5 is extinguished.

  • Page 47: Flame Loss Sequence

    Section 4 — Sequence Of Operation operating limit control (OLC) opens. When the limit control circuit is opened, the following sequence occurs: The main fuel valve circuit is deenergized, causing the main fuel valve (MGV) or (OV) to close. The flame is extinguished. The control panel lights (LDL) and (FVL) are turned off.
  • Page 48 Section 4 — Sequence Of Operation The flame failure light and alar m bell (optional) are energized 10 seconds later. The blower motor will be then deenergized. The lockout switch must be manually reset before operation can be resumed. (Refer to the previous caution.) 3.
  • Page 49 Section 4 — Sequence Of Operation MNEMONIC DESCRIPTION BMSI Blower Motor Starter Interlock MNEMONIC DESCRIPTION BMSS Boiler Master Selector Switch Burner Switch Amber (Color Of Pilot Light) Boiler Selector Switch AAFL Atomizing Air Failure Light BWPM Booster Water Pump Motor AAFR Atomizing Air Failure Relay Booster Water Thermostat...
  • Page 50 Section 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 51 Section 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 52 Section 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 53: Starting And Operating Instructions

    A. General Preparation for Initial Startup ..... . 5-2 B. Startup Procedures ........5-6 C.

  • Page 54: General Preparation For Initial Startup

    Section 5 — Starting and Operating Instructions A. GENERAL PREPARATION FOR INITIAL STARTUP Instructions in Section 5 are all based upon installation being complete and all electrical, fuel, water and vent stack connections are made. Notice The operator should be familiar with the burner, boiler, and If the boiler is not equipped with all controls and components.
  • Page 55 The blower impeller rotation is counter-clockwise for the ProFire, when viewed from the Notice motor side of the burner (see Figure 5-1). All work on the burner should be performed by qualified persons 1. Fuel Supply...
  • Page 56 5. Burner Settings To ensure reliable and safe burner performance, the gas pilot assembly and gap setting of the electrode (Figure 5-3), and the relative positions of the burner nozzle, diffuser, and air baffle components must be correctly set (Figure 5-3).
  • Page 57 2. Refer to Figure 5-4 and measure the distance from the tip of the nozzle to the diffuser. If necessary, adjust the 1/2" HOLD DIMENSION FROM position of the diffuser as follows:...

  • Page 58: Startup Procedures

    • Verify that there is proper gas pressure at the gas train, if this is a gas or combination burner. See the burner specification plate (Figure 5-8) for minimum and maximum natural gas pressure requirements. • For oil burners confirm that the oil tank is adequately filled with the correct grade of fuel oil, and that any isolation valves in the supply and return lines are open.
  • Page 59 The travel, or stroke, of the rotary air damper should be checked to verify proper operation prior to any fuel adjustments. Figure 5-6 shows the recommended linkage settings at the low fire start positions for each model burner.

  • Page 60: Burner Adjustments, Single Fuel Natural Gas

    Observe the air damper travel and adjust the linkage rod clamp if the air damper does not travel to the desired position (5 to 25 degrees open) at low fire -- depending on the burner model, fuel, and turndown -- to a full open position at high fire.
  • Page 61 Section 5 — Starting and Operating Instructions Gas/Oil Fuel M5-8000 LINKAGE SETTINGS combination Oil Only Gas Only INPUT ITEM DESCRIPTION (lengths in inches) (MMBH) Main Shaft Air Damper Arm Length Air Damper Arm Length Main Shaft Air Damper Arm Angle (deg)
  • Page 62 4. Adjust the manual flame control to the "CLOSED" (or low fire) position. 5. Verify that the gas valve cam trim and linkage assembly is close to the settings listed in Table XX. Check that the Notice cam follower, linkage and gas valve arm are in the proper positions and properly tightened.
  • Page 63 Section 5 — Starting and Operating Instructions 8. After the main flame has been established, the gas manifold pressure e ntering the bur ner should be measured using the pressure tap between the butterfly valve and the firing tube. This measurement should be compared to the Min.

  • Page 64: Burner Adjustments, Single Fuel, Oil-Fired (Return Flow Pressure Atomization)

    12.Fine-tune the high fire input with the corresponding high fire cam screw to obtain the desired excess air level. Normally, the O2 level is set between 3.5 and 5 % at high fire, depending on the application and burner size..
  • Page 65 CLOSED (low-fire) position. f i n e a d j u s t m e n t f o r t h e 5. Verify that the oil metering valve, cam trim, and linkage specific application. If the assembly is close to the settings listed in Table XX. Check...

  • Page 66: Burner Adjustments, Combination Gas And Oil

    10.Check the high fire excess air level. Normally, the O2 level is set between 3.5 and 5 % at high fire, depending on the application and burner size 11.Modulate the burner with the manual flame control to the next lower cam screw position.
  • Page 67 The slot in the gas valve shaft should be 5 to 10% open at the low fire position. 6. Open the manual shut-off valve of the gas pilot.
  • Page 68 GAS. 4. Place the Manual/Auto mode switch to the MANUAL position. 5. Place the manual flame control potentiometer to the CLOSE (low-fire) position. 6. Close the downstream manual shutoff valve on the burner gas train (closest to the burner).
  • Page 69 Section 5 — Starting and Operating Instructions a representation of the acceptable O range for the gas burner. Normally, the O levels are set between 3 and 5 percent at low fire, depending on the application and burner size (see the burner specification plate for the minimum firing rate).
  • Page 70 Section 5 — Starting and Operating Instructions Figure 5-8). Natural gas flow rates are specified in cfh (cubic feet per hour), and fuel oil flow rates are specified in gph (gallons per hour). Fuel flow rate adjustment for both natural gas and oil is accomplished by regulating the fuel pressure against a fixed diameter orifice (nozzle).

  • Page 71: Startup, Operating And Shutdown - All Fuels

    Section 5 — Starting and Operating Instructions F. STARTUP, OPERATING AND SHUTDOWN - ALL FUELS Depending upon the fuel being burned, the applicable previous sections in Chapter 5 should be reviewed for preliminary instructions. The fuel selector switch should be, accordingly, set to either oil or gas.
  • Page 72 Section 5 — Starting and Operating Instructions flame control in one point increments. Operate at the increased fuel input rate for a period of time until an increase is noted in pressure or temperature. After the boiler is thoroughly warmed, turn the manual flame control to high fire.
  • Page 73 Section 5 — Starting and Operating Instructions Shutdown - When the operating limit control setting is reached to open the circuit or if the burner switch is turned “off,” the following sequence occurs. The fuel valve is deenergized and the flame is extinguished.
  • Page 74 Section 5 — Starting and Operating Instructions Chapter 8 for information on flame safety checks. Check the program relay’s annunciation for any system failure. Observe the promptness of ignition of the pilot flame and the main flame. 5-22 Part No. 750-215...
  • Page 75 D. Water Gauge Glass ........6-5...

  • Page 76: Adjustment And Maintenance

    Section 6 — Adjustment and Maintenance A. GENERAL While each boiler is tested for correct operation before shipment from the factory, variable conditions, such as burning characteristics of the fuel used and operating load conditions, require further adjustment after installation to assure maximum operating efficiency and economy.

  • Page 77: Periodic Inspection

    Section 6 — Adjustment and Maintenance B. PERIODIC INSPECTION Insurance regulations or local laws require a periodic inspection of the pressure vessel by an authorized inspector. Section 3 contains information relative to this inspection. Inspections of this type are usually, though not necessarily, scheduled for periods of normal boiler downtime such as an off-season.
  • Page 78 Section 6 — Adjustment and Maintenance Usually, the control is of the automatic reset type and will remake the limit circuit when the water level is restored. Some applications require that a control be equipped with a manual reset mechanism that must be manually reset before the burner can be restarted.

  • Page 79: Water Gauge Glass

    Section 6 — Adjustment and Maintenance more frequently, if possible, to check and clean float ball, internal moving parts, and the bowl housing. Also check the cross connecting piping to make certain that it is clean and free of obstruction. D.

  • Page 80: Setting And Adjusting

    Section 6 — Adjustment and Maintenance Examine any mercury tube switches for damage or cracks: this condition, indicated by a dark scum over the normally bright surface of the mercury, may lead to erratic switching action. Make certain that controls of this nature are correctly leveled using the leveling indicator if provided.

  • Page 81: Pressure Controls - Steam Boiler

    The high-low fire control should be set to open at 5 to 10 psi lower than the operating limit setting. The suggested setting on a low pressure steam boiler is 2 to 3 psi. The differential setting on this control may be set low, to give quite close Part No.
  • Page 82 Section 6 — Adjustment and Maintenance control of steam pressure. In any case, the control should be adjusted so that it opens and causes the burner to go to low fire at a pressure below the limit control opening point. When the pressure controls are properly set, the burner will maintain steam pressure within narrow limits.

  • Page 83: Temperature Controls - Hot Water Boiler

    The high limit control should be set 5 to 10 degrees above the operating limit temperature control setting. The high-low fire control should be adjusted so that it is below the burner “on” temperature of the operating control.

  • Page 84: Combustion Air Proving Switch

    The “cut-in” (bur ner on) temperature is the cut-out temperature MINUS the differential. The differential is adjustable from 5 to 30 degrees F . Differential is adjusted by rotating the wheel on the back of the snap switch. High Limit Temperature Control (Hot Water) (Honeywell L4008E) Set the “cut-out”...

  • Page 85: Low Gas Pressure Switch

    5. Low Gas Pressure Switch Turn adjusting screw until indicator on scale moves to a pressure setting slightly below the operating gas pressure.
  • Page 86 Section 6 — Adjustment and Maintenance The manufacturer’s bulletin also contains troubleshooting information. The flame detector lens should be cleaned as often as operating conditions demand. Use a soft cloth, moistened with detergent if necessary. The UV sensing tube within the flame detector is not field replaceable.

  • Page 87: Control Operational Test

    Section 6 — Adjustment and Maintenance Checking Loss of Flame With the burner in normal operation, shut off the main burner fuel supply to extinguish main flame. Relay 2K should drop out within 4 seconds after flame is extinguished. The blower motor runs during the post purge.

  • Page 88: Oil Burner

    Section 6 — Adjustment and Maintenance F. OIL BURNER 1. General There are relatively few adjustments that can be made to the burner drawer, however, a check should be made to see that all components are properly located and that all holding devices such as setscrews properly tightened.

  • Page 89: Oil Pump

    Section 6 — Adjustment and Maintenance pressure is adjusted by the regulator in the fuel oil pump. If smoke occurs at open damper, the pressure should be adjusted downward to clear the fire. See the later section covering oil burner combustion adjustment. Ignition System Maintain the proper gap and dimensions of the ignition electrode(s) for best ignition results.

  • Page 90: Combustion Adjustment - Oil

    Section 6 — Adjustment and Maintenance lines, valve fittings, or pump. On gravity fed installations a vacuum gauge should read zero. If not, this is evidence of restrictions being present. If the oil supply is above the level of the pump, a pressure gauge can be installed in the pump bypass port for use in determining that the head of oil is not too great.

  • Page 91: Gas Burner

    Section 6 — Adjustment and Maintenance Turn the burner to high fire and let it operate at this rate for several minutes. Observe the color and size of the flame. Color alone is a poor means of determining efficiency, although it can serve as a guide for tentative setting. If smoke or haze is visible additional combustion air is required.
  • Page 92 If the pilot does not light after several attempts, check all components of the pilot system. 5. When the pilot flame is established, remove the flame detector from the burner plate. The pilot flame can then be observed thru this opening 6.

  • Page 93: Gas Pressure And Flow Information

    Section 6 — Adjustment and Maintenance flame at high, low, and intermediate firing rate positions. Readings should be steady and in the range indicated in step 7. If there are any deviations, refer to the troubleshooting section in the technical bulletin. The gas burner housing surrounding the diffuser plate should be periodically checked for any signs of damage that might be caused by an improperly adjusted burner or by a...
  • Page 94 Table 6-5. Conversely: to determine what the meter index reading should be in order to provide the volume of gas required for input, divide the desired flow rate by the proper pressure correction factor.
  • Page 95 BTU content of the gas into the burner input (Table 6-4) and “correct” this answer by applying the correction factor for 3 psig. (Table 6-5). B T U / H R = CFH (C ubic Feet/...

  • Page 96: Combustion Adjustment - Gas

    Input (BTU/HR) ÷ Heating Value (BTU/CU. FT.) ÷ 20 = Gas input in cubic feet for 3 minutes. 5. Apply any necessary pressure correction factor to this answer to obtain the desired rate. 6. To illustrate, using circumstances from previous example, compute as follows: BTU/HR ÷...
  • Page 97 Section 6 — Adjustment and Maintenance in two complete turns. Adjust the connecting rod so that tension is released. It is not practical to list specific setting of the connection points or of the angles of the arms. The final setting should provide a coordinated movement of the damper and the gas valve.

  • Page 98: Damper Motor And Auxiliary Switches

    Section 6 — Adjustment and Maintenance Any adjustment must not cause extensive stretching of the override springs. If linkage adjustments are made, recheck to determine that high fire is not affected. The appearance or color of the gas flame is not an indication of its efficiency since an efficient gas flame will vary from transparent blue to translucent yellow.
  • Page 99 10° (motor stroke is 90°). Release the scale lock. 5. Turn cam until the cam roller of the switch lever is exactly over the outer corner of the operational cam lobe. A slight movement of the cam at this point should produce an audible click in the switch.

  • Page 100: Air Damper Adjustment

    Section 6 — Adjustment and Maintenance aligned so that the differential cam has no effect on the switch. 7. Place the second set of cams on the shaft. Make sure that the operational cam’s locking screw is on the opposite side of the shaft of the switch the cam is to operate (when the scale plate is set at zero).
  • Page 101 4. The slot on the end of the damper shaft indicates the position of the damper blade. 5. It is not practical to list specific setting of all of the connections or of the damper arm angle, since adjustment conditions must exist to meet combustion requirements or load conditions.

  • Page 102: Safety Valves

    Section 6 — Adjustment and Maintenance Periodically check for proper adjustment. Check tightness of setscrews to prevent slippage. Occasionally oil swivel joints with a graphite or silicone type lubricant. J. SAFETY VALVES The safety valve is a very important safety device and deserves attention accordingly.

  • Page 103: Motorized Gas Valve

    The actuator is not field repairable nor should it be disassembled. To remove the actuator, loosen the two 5/32" allen setscrews that hold the actuator collar to the valve bonnet. After replacement, cycle the valve with the fuel shutoff to determine that it opens and closes.
  • Page 104 Section 6 — Adjustment and Maintenance L. SOLENOID VALVES: GAS PILOT/FUEL OIL/VENT 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 105 Section 6 — Adjustment and Maintenance furnace and through the access door. Dry fit all the segments and chip to fit, if necessar y. Reinstall, using proper refractory cement. Make sure that all joints are tight and coated with cement. Mix insulating cement with refractory mortar and work the mixture into the crevices formed by the back of the tile and the boiler tube panel.
  • Page 106 3. Disconnect pressure control lines on a steam boiler. Remove the remote bulbs from the water controls on a hot water boiler. 4. Unbolt the windbox from the burner flange. 5. Swing the windbox assembly on its davit Caution Check for interference for field installed wiring or piping.
  • Page 107 Section 6 — Adjustment and Maintenance The lubricant used should be clean and equal to one of the good commercial grades of grease locally available. Some lubricants that are distributed nationally are: Gulf Oil – P reci si on Greas e No.
  • Page 108 Section 6 — Adjustment and Maintenance Notes: 6-34 Part No. 750-215...
  • Page 109 Section 7 Troubleshooting A. Burner Does Not Start ........B.
  • Page 110 Section 7 — Troubleshooting This section assumes that the unit has been properly installed and adjusted and that it has been running for some time prior to the trouble listed in the heading of each section. It is further assumed that the operator has become thoroughly familiar with both burner and manual by this time.
  • Page 111 C. Insufficient or no voltage to gas pilot solenoid valve. 3. Low fire switch open A. Damper motor not closed, slipped cam, defective switch B. Damper jammed or linkage binding 4. Check interlocks. 5. Timer switch in TEST position and timer stopped in “pre-purge” Part No. 750-215...
  • Page 112 1. Pressure or temperature above high-low fire control setting 2. Damper positioning switch in wrong position 3. Inoperative damper motor (See Section F) 4. Defective high-low fire control 5. Binding or loose linkage, cams, setscrews, etc. 6. Check appropriate relay contacts. Part No. 750-215...
  • Page 113 3. Flame detector weak or not operative 4. Lens dirty or sight tube obstructed 5. If the programmer lockout switch has not tripped, check the limit circuit controls, interlock, or blower motor. A. The flame failure light is energized by ignition failure, main flame failure, inadequate flame signal, or open control in the non-recycling interlock circuit.
  • Page 114 A. Check appropriate contacts. 4. Motor does not operate on demand. A. Damper positioning switch in wrong position B. High-low fire control improperly set or inoperative C. Check appropriate contacts. 5. Motor inoperative A. Loose electrical connection. Part No. 750-215...
  • Page 115 Section 8 Parts DESCRIPTION PART NO. L. F. INPUT -- GAS (MBH) 3200 L. F. INPUT -- OIL (MBH) 3200 AIR BOX AIR BOX ASS'Y PART NO. 427-00253 MODULAR CAM LINKAGE ASS'Y ASS'Y NUMBER EX-06372-4 MOD. MOTOR HONEYWELL MODEL 9174C-1025 PART NUMBER 894-01373 Bracket Ass'y, Cam Trim Mounting...
  • Page 116 Section 8 — Parts BLOWER MOTOR MOTOR H.P . 208-460/3/60/3450 (ODP) Part No. CB#894-1420 (575V) IMPELLER BLOWER WHEEL SIZE 18x3.0 PART NUMBER 192-00376 NLET CONE INLET CONE P/N 097-00399 Burner Housing 090-604 or Burner Housing Part No. EX-6400-4 Gas Only Part No. 021-0592 Combination Part No.
  • Page 117 SIZE 2 “ GAS VALVE Honwywell MODEL V4055D MAIN GAS REGULATOR Maxitrol MODEL 210E BUTTERFLY VALVE ECLIPSE 2.5 FP PART NUMBER 940-01230 GAS PILOT PART NUMBER 125-00001 PILOT PRESSURE 4.0” Gas Spuds Radial Spuds P/N 042-00122 Quantity LOW FIRE MANIFOLD PRESS.
  • Page 118 Section 8 — Parts Part No. 750-215...
  • Page 119 NOTES...
  • Page 120 Web Address: http://www.cleaverbrooks.com...