CleaverBrooks 4WI Manuals

CleaverBrooks 4WI Manuals

Manuals and User Guides for CleaverBrooks 4WI. We have 1 CleaverBrooks 4WI manual available for free PDF download: Operation, Service And Parts Manual

CleaverBrooks 4WI Operation, Service And Parts Manual

CleaverBrooks 4WI Operation, Service And Parts Manual (216 pages)

Promethean Boilers

Brand: CleaverBrooks | Category: Boiler | Size: 8 MB

Table of Contents

Table of Contents
7
CHAPTER 1 Firetube Operation Basics

15
- Overview
  15
- The Boiler
  17
- Construction
  18
- Steam Controls (All Fuels)
  19
  - Controls
    19
  - Low Water Cutoff
    19
  - Water Column
    20
  - Steam Pressure Gauge and ALWCO
    20
  - Safety Valve(S)
    20
- Hot Water Controls (All Fuels)
  21
  - Pressure and Temperature Gauges
    21
  - Controls
    21
  - Low Water Cutoff and ALWCO
    22
  - Safety Valve(S)
    22
- IFGR Components
  22
CHAPTER 2 Burner Operation and Control

25
- The Burner
  25
- Controls Common to All Boilers
  26
- Control and Component Function
  27
- Components Common to All Boilers
  27
- Controls for Gas Firing
  30
- Controls Common to Oil-Fired Boilers (Including Combination)
  32
- Additional Controls for Heavy Oil
  35
- Controls for Combination Burners Only
  37
- Combustion Air
  38
- Automatic Ignition
  38
- Atomizing Air
  39
- Oil Fuel Flow: Light Oil
  40
- Oil Fuel Flow: Heavy Oil
  41
- Gas Fuel Flow
  43
- Modulating Firing
  44
CHAPTER 3 Waterside Care and Requirements

47
- Overview
  47
- Water Requirements
  48
  - Hot Water Boilers
    48
    
    Air Removal
    48
    
    Minimum Water Temperature
    48
    
    Rapid Replacement of Boiler Water
    48
    
    Continuous Flow through the Boiler
    49
    
    Water Circulation
    50
    
    Multiple Boiler Installations
    50
    
    Pump Location
    51
    
    Pump Operation
    51
    
    Pressure
    51
  - Steam Boiler
    52
    
    Feed Pump Operation
    52
    
    Water Feeder (Optional) Operation
    52
- Water Treatment
  52
- Cleaning
  53
  - Hot Water and Steam Piping
    53
  - Pressure Vessel
    53
- Boil-Out of a New Unit
  54
- Washing out
  56
  - Hot Water Boiler
    56
  - Steam Boiler
    56
- Blowdown: Steam Boiler
  57
- Periodic Inspection
  59
- Preparation for Extended Layup
  60
CHAPTER 4 Sequence of Operation

63
- Overview
  63
- Circuit and Interlock Controls
  64
- Sequence of Operation: Gas or Oil
  65
  - Pre-Purge Cycle
    65
  - Ignition Cycle
    66
  - Run Cycle
    66
- Flame Loss Sequence
  67
CHAPTER 5 Starting and Operating Instructions

71
- General Preparation for Startup: All Fuels
  71
- Control Settings: Steam and Hot Water
  72
- Gas Pilot
  74
- Revised 2009)
  74
- Atomizing Air
  74
- Firing Preparations for No. 2 Oil (Series 100-200)
  75
- Firing Preparation for No. 6 Oil (Series 400-600)
  77
  - Oil Flow
    78
  - Oil Pressure
    78
  - Oil Temperature
    79
- Firing Preparations for Gas (Series 200-400-700)
  80
- IFGR Setup
  81
- Startup, Operating, and Shutdown: All Fuels
  82
  - Operating
    85
  - Shutdown
    85
- Control Operational Test and Checks
  85
CHAPTER 6 Adjustment Procedures

87
CHAPTER 7 Troubleshooting

115
- Introduction
  115
CHAPTER 8 Inspection and Maintenance

119
- Overview
  119
  - Periodic Inspection
    120
- Fireside Cleaning
  121
- Water Level Controls
  122
  - Steam Boiler
    122
  - Hot Water Boiler
    123
- Water Gauge Glass
  123
- Electrical Controls
  124
- Flame Safety Control
  126
  - Checking Pilot Flame Failure
    127
  - Checking Failure to Light Main Flame
    128
  - Checking Loss of Flame
    128
- Oil Burner Maintenance
  129
  - Light Oil Strainers
    129
  - Heavy Oil Strainers
    129
  - Cleaning the Oil Nozzle
    130
  - Cleaning Air Purge Nozzle (No. 6 Oil) and Back Pressure Orifice Nozzle (No. 2 Oil)
    130
  - Ignition System
    131
- Gas Burner Maintenance
  132
- Motorized Gas Valve
  133
- Solenoid Valves
  133
- Air Control Damper, Linkage and Cam Spring
  134
- Fan/Motor Cassette Removal
  135
- Inspection and Adjustment
  136
- Fan/Motor Cassette Installation
  137
- Safety Valves
  138
- Fuel Oil Metering Valve, Adjusting and Relief Valves
  139
- Air Pump and Lubricating System
  141
  - Air Pump
    141
  - Lubricating Oil
    141
  - Lubricating Oil Strainer and Cooling Coil
    142
  - Air-Oil Tank
    142
  - Air Cleaner
    142
  - Lube Oil Cooling Coil
    143
  - Flexible Coupling Alignment
    143
  - Air Compressor Replacement
    144
    
    Dismantling
    144
    
    Reassembly
    145
- Refractory
  145
  - Furnace Liner
    146
  - Throat Tile and Liner
    147
  - Installation
    147
  - Rear Door
    149
- Opening and Closing Doors
  149
  - Opening Front or Rear Door
    149
  - Rear Access Plug
    150
  - Closing and Sealing Doors
    150
- Lubrication
  151
  - Electric Motors
    151
  - Control Linkage
    151
  - Solenoid and Motorized Valves
    152
  - IFGR Lubrication
    152
- Oil Heaters: Electric, Steam, Hot Water
  152
- Combustion
  153
CHAPTER 9 Parts

155
- Ordering Parts
  155
- Revised 2009)
  156
- Parts
  156
  - Front Door Insulated Head
    156
  - Front Door Exterior Insulation Component List
    157
  - Rear Door Insulated Assembly
    158
  - Rear Door Insulation Component List
    159
  - Rear Door Insulated Access Plug
    160
  - Front Head Assembly 60" Diameter
    161
  - Front Davit Assembly
    162
  - Rear Door Davit Parts List
    163
Refractory Throat Materials for 60

164

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