Model CBLE Manuals

Model CBLE O&M manuals
125 – 200 HP
250 – 300 HP
400 – 800 HP
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
ii
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

04/09 iii Printed in U.S.A.
! 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.
TO: Owners, Operators and/or Maintenance Personnel
This operating manual presents information that will help to properly operate and care for the equipment. Study its con-
tents carefully. The unit will provide good service and continued operation if proper operating and maintenance instruc-
tions are followed. No attempt should be made to operate the unit until the principles of operation and all of the
components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe
personal injury or death.
It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who
are servicing, repairing or operating the equipment, in all safety aspects.
Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical
and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however,
proper operating techniques and maintenance procedures must be followed at all times. Although these components af-
ford a high degree of protection and safety, operation of equipment is not to be considered free from all dangers and
hazards inherent in handling and firing of fuel.
Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely
free him of certain repetitive chores and give him more time to devote to the proper upkeep of equipment.
It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instructions
can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the
responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before at-
tempting to operate, maintain, service, or repair this equipment.
Because of state, local, or other applicable codes, there are a variety of electric controls and safety devices which vary
considerably from one boiler to another. This manual contains information designed to show how a basic burner operates.
Operating controls will normally function for long periods of time and we have found that some operators become lax in
their daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to
uneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness and
deficiencies in testing and maintenance.
It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly and yearly main-
tenance activities and recording of any unusual operation will serve as a valuable guide to any necessary investigation.
Most instances of major boiler damage are the result of operation with low water. We cannot emphasize too strongly the
need for the operator to periodically check his low water controls and to follow good maintenance and testing practices.
Cross-connecting piping to low water devices must be internally inspected periodically to guard against any stoppages
which could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected
frequently to check for the presence of foreign substances that would impede float ball movement.
The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be inspected fre-
quently to check for the presence of any mud, sludge, scale or corrosion.
It is essential to obtain the services of a qualified water treating company or a water consultant to recommend the proper
boiler water treating practices.
The operation of this equipment by the owner and his or her operating personnel must comply with all requirements or
regulations of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsis-
tency between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks be-
fore proceeding.
iv
TABLE OF CONTENTS
Chapter 1
Basics of Firetube Operation
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 1-2
B. THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 1-4
C. CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 1-5
D. STEAM CONTROLS (ALL FUELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 1-7
E. HOT WATER CONTROLS (ALL FUELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 1-8
F. IFGR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 1-9
G. CB OHIO SPECIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 1-11
Chapter 2
Burner Operation and Control
A. THE BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
B. CONTROL AND COMPONENT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
C. COMPONENTS COMMON TO ALL BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
D. CONTROLS FOR GAS FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
E. CONTROLS COMMON TO OIL-FIRED BOILERS (INCLUDING COMBINATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Chapter 3
Waterside Care And Requirements
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
B. WATER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
C. WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
D. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
E. BOIL-OUT OF A NEW UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
F. WASHING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
G. BLOWDOWN STEAM BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
H. PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
I. PREPARATION FOR EXTENDED LAY-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Chapter 4
Sequence Of Operation
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... ...... ..... . 4-2
B. CIRCUIT AND INTERLOCK CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... ...... ..... . 4-2
C. SEQUENCE OF OPERATION - OIL OR GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... ...... ..... . 4-4
D. FLAME LOSS SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... ...... ..... . 4-6
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. GAS PILOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
D. ATOMIZING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
E. FIRING PREPARATIONS FOR NO. 2 OIL (SERIES 100-200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
F. FIRING PREPARATION FOR NO. 6 OIL (SERIES 400-600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
G. FIRING PREPARATIONS FOR GAS (SERIES 200-400-700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
H. IFGR SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
I. START-UP, OPERATING AND SHUTDOWN - ALL FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
J. CONTROL OPERATIONAL TEST AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Chapter 6
Adjustment Procedures
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
B. LINKAGE - MODULATING MOTOR AND AIR DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
C. MODULATING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
D. MODULATING MOTOR SWITCHES - LOW FIRE AND HIGH FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
E. BURNER OPERATING CONTROLS - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
v
F. MODULATING PRESSURE CONTROL (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
G. OPERATING LIMIT PRESSURE CONTROL (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
H. HIGH LIMIT PRESSURE CONTROL (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
I. MODULATING TEMPERATURE CONTROL (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
J. OPERATING LIMIT TEMPERATURE CONTROL (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
K. HIGH LIMIT TEMPERATURE CONTROL (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
L. LOW WATER CUTOFF DEVICES (Steam and Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
M. COMBUSTION AIR PROVING SWITCH (CAPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
N. ATOMIZING AIR PROVING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
O. GAS PILOT FLAME ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
P. GAS PRESSURE AND FLOW INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Q. GAS FUEL COMBUSTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
R. LOW-GAS-PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
S. HIGH-GAS-PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
T. FUEL OIL PRESSURE AND TEMPERATURE - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
U. FUEL OIL COMBUSTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
V. BURNER DRAWER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
W. OIL DRAWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
X. LOW-OIL-TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Y. HIGH-OIL-TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Z. LOW OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
AA. ELECTRIC OIL HEATER THERMOSTAT (400 and 600 Series - Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
BB. STEAM OIL HEATER THERMOSTAT (No. 6 Oil) (400 and 600 Series - Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
CC. HOT WATER OIL HEATER THERMOSTAT (400 and 600 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
DD. STEAM HEATER PRESSURE REGULATOR (400 and 600 Series - Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Chapter 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Chapter 8
Inspection And Maintenance
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
B. FIRESIDE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
C. WATER LEVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
D. WATER GAUGE GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
E. ELECTRICAL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
F. FLAME SAFETY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
G. OIL BURNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
H. GAS BURNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
I. MOTORIZED GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
J. SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
K. AIR CONTROL DAMPER, LINKAGE & CAM SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
L. FORCED DRAFT FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
M. CB-LE FAN/MOTOR CASSETTE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
N. CB-LE INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
O. CB-LE AIRBOX GASKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
P. CB-LE FAN/MOTOR CASSETTE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Q. SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
R. FUEL OIL METERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
S. AIR PUMP AND LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
T. HEAD INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
U. REFRACTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
V. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
W. OIL HEATERS - ELECTRIC, STEAM, HOT WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
X. COMBUSTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Y. AIR PUMP BELT (CB-OS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
vi
Chapter 9
Parts
Insulated Front Head - CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Insulated Front Head Interior - CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Insulated Inner Door - CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Insulated Rear Head CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Insulated Rear Head CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Dry Oven Model CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Motor and Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Front Head Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Jackshaft Retrofit Assembly Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Mod Motor Linkage Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Air Damper Linkage Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Burner Drawer-Gas Pilot Models 100-600, 125-200HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Burner Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Control Cabinet (Hawk ICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Control Panel, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Entrance Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Front Head Electrical CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Front Head Electrical CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Straight Electric Oil Heater 60” Heavy Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Heavy Oil Piping 60” Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Common Oil Parts Heavy Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Side Mounted Air Compressor Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Air Compressor Piping CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Air Line Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Light Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
Light Oil/Air Piping - Front Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Pilot Gas Train 125-150HP CB-LE & 125-175HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Pilot Gas Train 200HP CB-LE & CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Pilot Gas Train 225HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Gas Train 125-150 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Gas Train 175 HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
Gas Train 200 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
Gas Train 225 HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
Steam Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
Hot Water Temperature Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
Water Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
Fireside Gaskets, CB-LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
Fireside Gaskets, CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
vii
viii
Chapter 1
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
B. THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
C. CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
D. STEAM CONTROLS (ALL FUELS) . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
E. HOT WATER CONTROLS (ALL FUELS) . . . . . . . . . . . . . . . . . . . . . 1-8
F. IFGR COMPONENTS (CB-LE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
G. CB OHIO SPECIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Milwaukee, Wisconsin
www.cleaver-brooks.com
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. The vessel contains the
water and absorbs the energy generated from the flame. The front
door and rear door provide the seal to contain the hot combustion
gasses. Baffles designed into the doors serve to redirect the
combustion gasses through the various firetube passages. The
flame originates in the furnace. As the combustion gasses travel
down the furnace and through the various firetube channels, heat
from the flame and combustion gasses is transferred to the water.
Transferred energy develops into the required steam or hot water.
The primary purpose of the boiler is to supply energy to the facility’s
operations - for heat, manufacturing process, laundry, kitchen, etc.
The nature of the facility’s operation will dictate whether a steam or
hot water boiler should be used.
Notice
If your boiler is equipped with a C-B Hawk ICS boiler control
system, refer to C-B Manual No. 750-229 for information regarding
the control system.
\
Figure 1-1 Firetube Cut Away (Typical)
1-2 Part No. 750-184

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. 2) Or Gas
Series 400 Heavy Oil (No. 6) Or Gas
Series 600 Heavy Oil (No. 6) Only
Series 700 Gas Only
*For additional information on Model CB Ohio Special boilers 125-225 HP, see
Section G at the end of this chapter.
Notice
Although the Series 400 or 600 burner is designed and designated
to burn No. 6 oil, the burner will handle grades 4 and 5 equally well,
with some possible adjustments. While the manual contains
pertinent information on No. 6 fuel oil, all references to No. 6 fuel
should be considered applicable to all grades of heavy oil.
Rated Capacity: 125

through 200hp
Operating Pressure Steam 15-250 psig, or higher
if specified
Hot Water 30-250 psig or
higher if specified
Fuel Oil or Gas or Combination
Ignition Automatic
Firing Full Modulation Through
Operating Ranges
Burner (Oil) (Low Pressure) Air Atomizing
Burner (Gas) Non-premix – Orificed Type
Air Damper Rotary Type
(Electrically Modulated)
Steam Trim ASME Code
Water Trim ASME Code
The LE option reduces Nitrogen Oxide (NOx) emissions, a major

precursor to ozone pollution (smog). Carbon Monoxide (CO)
emissions also tend to be lower, due to increased turbulence caused
by the addition of the flue gases into the combustion air stream,
thereby improving combustion.
Notice
For information on IFGR when firing heavy oil, review the Operation
and Maintenance manual for Heavy Oil Isolation 750-171
The LE option is used on Cleaver-Brooks Model CB Firetube boilers
firing either natural gas and/or light oil, and is compatible with both
hot water and steam systems.
Part No. 750-184 1-3

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. In this approach, the combustion air fan handles both
the combustion air and the recirculated flue gases. Accordingly, this
method is called Induced Flue Gas Recirculation (IFGR), because
the flue gas is “induced” into the fan inlet.
The LE option, with its various levels of IFGR systems, can affect
the selection of the combustion air fan, motor, burner, and other
components. Several different system configurations are available,
depending on the requirements for NOx emissions and the fuels
used. All systems use similar primary components, but may have
different linkage controls, IFGR damper, fan, and motor sizes.
Always order genuine Cleaver-Brooks parts from your local Cleaver-
Brooks authorized representative.
The boiler and related equipment installation are to be in
compliance with the standards of the National Board of Fire
Underwriters. Installation should also conform to state and local
codes governing such equipment. Prior to installation, the proper
authorities having jurisdiction are to be consulted, permits
obtained, etc. All boilers in the above series comply, when equipped
with optional equipment, to Industrial Risk Insurers (IRI), Factory
Mutual (FM), or other insuring underwriters requirements.
B. THE BOILER
The Model CB/CB-LE boiler is a packaged firetube boiler of welded
steel construction and consists of a pressure vessel, burner, burner
controls, forced draft fan, damper, air pump, refractory, and
appropriate boiler trim.
The horsepower rating of the boiler is indicated by the numbers
following the fuel series. Thus, CB700-200 indicates a gas-fired
200 hp boiler.
The firetube construction provides some characteristics that
differentiate it from other boiler types. Because of its vessel size, the
firetube contains a large amount of water, allowing it to respond to
load changes with minimum variation in steam pressure.
Firetube boilers are rated in boiler horsepower (BHP), which should
not be confused with other horsepower measurements.
Hot water is commonly used in heating applications with the boiler
supplying water to the system at 180 °F to 220 °F. The operating
pressure for hot water heating systems usually is 30 psig to 125
psig.
Steam boilers are designed for low pressure or high pressure
applications. Low pressure boilers are limited to 15 psig design, and
are typically used for heating applications. High pressure boilers are
typically used for process loads and can have a design pressure of
75 to 350 psig.
1-4 Part No. 750-184

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. Typically,
the safety valves are set at or below design pressure. Operating
pressure is the pressure of the boiler at which it normally operates.
The operating pressure usually is maintained at a suitable level
below the setting of the pressure relief valve(s) to prevent their
frequent opening during normal operation.
The type of service that your boiler is required to provide has an
important bearing on the amount of waterside care it will require.
! Caution
Waterside care is of prime importance. For specific information or
assistance with your water treatment requirements, contact your
Cleaver-Brooks service and parts representative. Failure to follow
these instructions could result in equipment damage
Feedwater equipment should be checked and ready for use. Be sure
that all valves, piping, boiler feed pumps, and receivers are installed
in accordance with prevailing codes and practices.
Water requirements for both steam and hot water boilers are
essential to boiler life and length of service. Constant attention to
water requirements will pay dividends in the form of longer life, less
down-time, and prevention of costly repairs. Care taken in placing
the pressure vessel into initial service is vital. The waterside of new
boilers and new or remodeled steam or hot water systems may
contain oil, grease or other foreign matter. A method of boiling out
the vessel to remove accumulations is described in Chapter 3.
The operator should be familiar with Chapter 3 before attempting to
place the unit into operation.
C. CONSTRUCTION
Steam boilers designed for 15 psig and hot water boilers designed
for 250°F at 125 psi or less are constructed in accordance with
Section IV, Power Boilers, of ASME Code.
Steam boilers designed for operating pressures exceeding 15 psig
are constructed in accordance with Section 1, Power Boilers, of the
ASME code. Hot water boilers designed for operating temperatures
above 250°F or 125 psi are likewise built to ASME code.
Part No. 750-184 1-5

12
14 13 11
2
10
3
5 9
6 8
7
1. Forced draft fan motor 8. Oil strainer

2. Oil pressure gauge 9. Air compressor
3. Atomizing air pressure gauge 10. C-B Level Master controls
4. Modulating motor 11. Low Water Cut Off/Pump Control
5. Gas Train (not shown) 12. Vent Valve
6. Fuel oil controller 13. Limit Controls
7. Ignition transformer 14. Control Panel
Figure 1-2 CB-LE, Dual Fuel, Typical

(Components and component orientation may vary)
1-6 Part No. 750-184

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.
2. High Limit Pressure Control (Figure 1-3): 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. The high limit pressure control is
normally equipped with a manual reset.
3. Modulating Pressure Control (Figure 1-3): Senses changing boiler
pressures and transmits the information to the modulating motor
to change the burner firing rate when the manual-automatic
switch is set on “automatic.”
4. Low-Water Cutoff and Pump Control (Figure 1-4. 1-5): Float- Figure 1-3 Steam Controls
operated control responds to the water level in the boiler. It
performs two distinct functions:
• Stops firing of the burner if water level lowers below the safe
operating point. Energizes the low-water light in the control
panel; also causes low-water alarm bell (optional
equipment) to ring. Code requirements of some models
require a manual reset type of low-water cutoff.
• Starts and stops the feedwater pump (if used) to maintain
water at the proper operating level.
! Caution
Determine that the main and auxiliary low water cutoffs and pump
control are level after installation and throughout the equipment’s
operating life. Failure to follow these instructions could result in
equipment damage.
5. Water Column Assembly: Houses the low-water cutoff and pump
control and includes the water gauge glass, gauge glass shutoff
cocks.
6. Water Column Drain Valve: Provided so that the water column
and its piping can be flushed regularly to assist in maintaining Figure 1-4 CB Level Master (CB-LE
cross-connecting piping and in keeping the float bowl clean and high pressure steam)
free of sediment. A similar drain valve is furnished with auxiliary
low-water cutoff for the same purpose.
Part No. 750-184 1-7

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. Stack Temperature Gauge: Indicates flue gas outlet temperature.
10.Auxiliary Low-water Cutoff: Breaks the circuit to stop burner
operation in the event boiler water drops below the master low-
water cutoff point. Manual reset type requires manual resetting
in order to start the burner after a low-water condition.
11.Safety Valve(s): Prevent pressure from exceeding the design
pressure of the vessel. The size, rating and number of valves on
a boiler is determined by the ASME Boiler Code. The safety
valves and the discharge piping are to be installed to conform to
Figure 1-5 Low Water Cutoff (CB- the ASME code requirements. The installation of a valve is of
LE low pressure and CB-OS) primary importance to its service life. A valve must be mounted
in a vertical position so that discharge piping and code-required
drains can be properly piped to prevent buildup of back pressure
and accumulation of foreign material around the valve seat area.
Apply only a moderate amount of pipe compound to male threads
and avoid overtightening, which can distort the seats. Use only
flat-jawed wrenches on the flats provided. When installing a
flange-connected valve, use a new gasket and draw the mounting
bolts down evenly. Do not install or remove side outlet valves by
using a pipe or wrench in the outlet.
! Warning
Only properly certified personnel such as the safety valve
manufacturer’s certified representative can adjust or repair the
boiler safety valves. Failure to follow these instructions could result
in serious personal injury or death.
E. HOT WATER CONTROLS (ALL FUELS)

1. Water Temperature Gauge: Indicates the boiler internal water
temperature.
2. Operating Limit Temperature Control: Breaks a circuit to stop
burner operation on a rise of boiler temperature at a selected
setting. It is adjusted to stop or start the burner at a preselected
operating temperature.
3. High Limit Temperature Control: Breaks a circuit to stop burner
operation on a rise of temperature at a selected setting. It is
adjusted to stop burner at a preselected temperature above the
operating control setting. The high limit temperature control
normally is equipped with a manual reset.
4. Modulating Temperature Control: Senses changing boiler water
temperature and transmits the information to the modulating
motor to change the burner firing rate when the manual-
automatic switch is set on “automatic.”
5. Low-Water Cutoff: Breaks the circuit to stop burner operation if
the water level in the boiler drops below safe operating point,
activating low-water light and optional alarm bell if burner is so
equipped.
1-8 Part No. 750-184

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. Relief valves
and their discharge piping are to be installed to conform to ASME
Code requirements.
F. IFGR COMPONENTS (CB-LE)

1. Flue Gas Transfer Port, IFGR Damper, and Flange Collar (Figure
1-6). The flue gas transfer port is a tube that allows the flue
gases to travel from the exit of the fourth-pass tubes to the
entrance of the combustion air fan. The IFGR damper controls
the volume of flue gas induced into the combustion air stream.
The damper is located in the flue gas transfer port and is
positioned by the control linkage.
2. IFGR Damper Linkage (Figure 1-7). The IFGR damper is
positioned by the control linkage. The linkage could consist of a
single arm, or it could consist of several arms driven from the
jackshaft to provide modulating control (see Figure 1-16).
3. Over-Travel Mechanism. The over-travel mechanism has two
functions. It allows the linkage to pass through the front door,
and it allows jackshaft rotation to exceed (over travel) IFGR
linkage movement. A set of springs allows the linkage to stay in
a fixed position while the jackshaft rotates.
4. Fuel Change-Over Linkage. When a boiler is equipped to fire
either gas or oil (dual-fuel boilers), and the required NOx levels
are below 60 ppm on natural gas, a dual-linkage arrangement is
used to provide the different recirculation rates required for each
fuel. Two jackshaft drive arms are provided, one for oil and one
for gas. The linkage is manually connected to the appropriate
arm, based on the fuel being used. On dual-fuel boilers with two
jackshaft drive arms, as defined above, a proximity switch is
used to prove that the correct linkage connection is made. (Refer
to the wiring diagram provided with the boiler.)
5. Fan/Motor Cassette. The fan and motor assemblies are designed
as a cassette so that they can be removed from the front of the
boiler, without opening the front door. The front door davit arm
can be used to remove the assembly.
Part No. 750-184 1-9

COMBUSTION AIR INLET

FLUE OUTLET
FRONT DOOR
BACKPLATE GASKET AIRBOX

CASSETTE MOUNTING BOLTS INSULATED PARTITION
AIRBOX GASKET
FLUE GAS TRANSFER
CASSETTE LIFTING EYES
PORT WITH IFGR DAMPER
FOURTH-PASS TUBES
FAN/MOTOR CASSETTE
FLANGE COLLAR DAMPER DRIVE ARM
COMBUSTION AIR FAN

OVER-TRAVEL MECHANISM
IFGR DAMPER LINKAGE

QUICK DISCONNECT LINKAGE
THROAT AND LINER TILE

JACKSHAFT ARM
FURNACE
REAR BURNER DRAWER GASKET
GAS SPUDS
BURNER DRAWER
BURNER HOUSING
BURNER DRAWER SUPPORTS
INNER PLATE CLAMPS
INSULATION
(20-30 PPM NOx SYSTEMS)
WINDBOX
FRONT DOOR BOLTS
FLUE GAS FLOW
COMBUSTION AIR FLOW
Figure 1-6 Induced Flue Gas Recirculation System, General Arrangement
6. Burner Drawer . The gas spudding pattern for the IFGR system
may be different than that of a non-IFGR CB Burner of the same
horsepower (HP) model designation.
7. Combustion Air Inlet. The combustion air inlets are located at the
top of the front door. Air enters from the rear of the air inlet
shrouds, which reduces the sound level and captures heat from
the boiler and stack flue outlet.
8. Front Door Insulation. If NOx emissions are below 60 PPM, the
front door is insulated inside to control temperature build up. The
insulation is held in place with wire mesh.
1-10 Part No. 750-184

OVER-TRAVEL MECHANISM
30°*
SINGLE FUEL ARRANGEMENT
JACKSHAFT LINKAGE ROD AND 60 PPM SYSTEM
IFGR DAMPER CONTROL 60°* QUICK-DISCONNECT LINKAGE

GAS JACKSHAFT DRIVE ARM OIL JACKSHAFT DRIVE ARM
* NOMINAL: ACTUAL POSITION VARIES

WITH NOx REQUIREMENT
JACKSHAFT
PROXIMITY SWITCH JACKSHAFT ARM
DUAL FUEL ARRANGEMENT
(Except 60 ppm)
Figure 1-7 IFGR Damper Linkage
G. CB OHIO SPECIAL
The model numbers CB125S - CB225S indicate boilers built by
Cleaver-Brooks specifically for the State of Ohio market. These
boilers comply with state rules and regulations applying to boilers
with less than 359 square feet of heating surface.
The CB-OS is not a low-emission design and therefore lacks the flue
gas recirculation components found on the CB-LE. Other differences
are noted below and elsewhere throughout this manual. Unless
indicated otherwise, information in this manual regarding boiler
operation, maintenance, and parts applies equally to CB-LE and
CB-OS models.
Two Pass Design

The principal difference between the Ohio boilers and CB-LE boilers
in the corresponding size range is the construction of the pressure
vessel. Ohio Special boilers (identified by an “S” suffixed to the
model number) are of a two-pass design, as opposed to the four-
pass design of the CB-LE.
Rear Head
Due to the two-pass design of the Ohio boiler, the rear head lacks
the baffle found on comparable CB-LE boilers. The upper portion of
Part No. 750-184 1-11

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. See Section 8 for
front head sealing procedure.
Dimpled Tubes
The second-pass tubes are 2” O.D. and of dimpled design for
increased heat transfer.
1-12 Part No. 750-184

Chapter 2
A. THE BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
B. CONTROL AND COMPONENT FUNCTION . . . . . . . . . . . . . . . . . . . 2-4
C. COMPONENTS COMMON TO ALL BOILERS . . . . . . . . . . . . . . . . . . 2-4
D. CONTROLS FOR GAS FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
E. CONTROLS COMMON TO OIL-FIRED BOILERS (INCL. COMB.) . . . . 2-7
F. ADDITIONAL CONTROLS FOR HEAVY OIL. . . . . . . . . . . . . . . . . . . 2-12
G. CONTROLS FOR COMBINATION BURNERS ONLY . . . . . . . . . . . . 2-14
H. COMBUSTION AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
I. AUTOMATIC IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
J. ATOMIZING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
K. OIL FUEL FLOW - LIGHT OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
L. OIL FUEL FLOW - HEAVY OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
M. GAS FUEL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
N. MODULATING FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
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.
Note: A Series 100 boiler is usually equipped with a light oil pilot,
although a gas pilot is also available.
Burners equipped to burn oil and gas (combination burners) include
equipment for each fuel. Since the burner uses only one type of fuel
at a time, a gas/oil selector switch is incorporated.
Regardless of which fuel is used, the burner operates with full
modulation (within its rated operating range). The burner returns to
minimum firing position for ignition. High-pressure boilers (above
Figure 2-1 Burner drawer 15 psi) can be wired for both low-pressure and high-pressure
modulation, which enables the boiler to operate at lower pressure
during off-load hours, but at a somewhat reduced steam output,
dependent upon lower steam pressure and steam nozzle sizing.
The flame safeguard and program relay include a flame detector to
supervise both oil and gas flames, and to shut the burner down in
the event of loss of flame. The programming portion of the control
provides a pre-purging period, proving of the pilot and main flame,
and a period of continued blower operation to postpurge the boiler
of all unburned fuel vapor. Other safety controls shut down the
burner under low-water conditions, excess steam pressure, or water
temperature.
Safety interlock controls include combustion and atomizing air
proving switches and, depending upon the fuel and insurance
carrier requirements, controls that prove the presence of adequate
fuel pressure, plus temperature proving controls when heated fuel
oil is used.
The sequence of burner operation from startup through shutdown is
governed by the program relay in conjunction with the operating,
limit and interlock devices. The devices are wired into the circuitry
to provide safe operation and protect against incorrect operating
techniques.
All CB-LE boilers have the burner assembly attached to the front
head. The entire head may be swung open for inspection and
maintenance.
Combustion air is provided by a centrifugal blower located in the
front head. Combustion air delivery to the burner is under the
control of the modulating motor. The motor also regulates the flow
of fuel through a linkage system connected to the gas butterfly valve
and/or oil through a cam-operated metering valve. Fuel input and
air are thus properly proportioned for most efficient combustion.
Filtered primary air for atomizing fuel oil is furnished independently
of combustion air by an air pump. The 60” CB-LE boiler uses a side-
mounted air compressor for atomizing air.
2-2 Part No. 750-184

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.
Indicator lights signaling load demand, fuel valve, low water, and
flame failure conditions are standard equipment.
In addition to the standard basic controls supplied, other devices
may be required to meet specific requirements of an insurance
carrier or local code. Refer to the Wiring Diagram (WD) prepared by
Cleaver-Brooks for your specific installation to determine the
specific controls in the burner and limit control circuits.
11
5
1,2
6
3,4
8
10
1. Forced draft fan motor 7. Control panel

2. Forced draft fan 8. Flame Scanner
3. Mod motor 9. Ignition transformer
4. Mod motor transformer 10. Ignition cable
5. Combustion air proving switch 11. Pressure gauge
6. Junction box
Figure 2-2 Controls/Components Common to All Boilers
Part No. 750-184 2-3

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.
The actual controls furnished with any given boiler will depend upon
the type of fuel for which it is equipped, and whether it is a hot
water or steam boiler. Refer to the applicable group or groups within
Chapter 2 that apply to the particular boiler.
Boilers with optional features may have control components not
listed here.
C. COMPONENTS COMMON TO ALL BOILERS

1. Forced Draft Fan Motor (Figure 2-5): Drives the forced draft fan
directly to provide combustion air. Also referred to as a blower
motor.
2. Forced Draft Fan (Figure 2-6): Provides all air, under pressure, for
combustion of pilot fuel and main fuel, and for purging.
Figure 2-3 Fan Motor
3. Modulating Motor (Figure 2-6): Operates the rotary air damper
and fuel metering valves through a cam and linkage system to
provide proper air/fuel ratios under all boiler load conditions.
4. Modulating Motor Transformer (located in the mod motor):
Reduces control circuit voltage (115 Vac) to required voltage
(24Vac) for operation of the modulating motor.
5. Forced Draft Fan Motor Starter (Figure 2-9 & 2-10): Energizes
forced draft fan (blower) motor.
6. Ignition Transformer: Provides high voltage spark for ignition of
gas pilot or light oil pilot.
7. Low Fire Switch (located in mod motor): An internal auxiliary
switch, cam actuated by the motor shaft, which must be closed
to indicate that the air damper and fuel metering valve are in the
Figure 2-4 Fan low fire position before an ignition cycle can occur.
8. Atomizing Air Proving Switch: A pressure-sensitive switch

actuated by air pressure from the Air Pump. Its contacts close to
prove presence of atomizing air. The fuel valves cannot be
energized unless this switch is satisfied.
9. Manual-Automatic Switch (Figure 2-8): When set at
“automatic,” subsequent operation is at the command of the
modulating control, which governs the position of the modulating
motor in accordance with load demand. When set at “manual,”
the modulating motor, through the manual flame control, can be
positioned at a desired burner firing rate. The primary purpose of
the manual position is for testing and setting the air/fuel ratio
through the entire firing range.
10.Manual Flame Control (Figure 2-8): A manually operated
potentiometer that permits the positioning of the modulating
Figure 2-5 Mod Motor
motor to a desired burner firing rate when the manual-automatic
switch is set on “manual“. It is used primarily for initial or
2-4 Part No. 750-184

subsequent setting of fuel input throughout the firing range. It

has no control over the firing rate when the manual-automatic
11.Burner Switch (Figure 2-8): A manually operated start-stop
switch for directly starting and stopping operation of burner.
12.Flame Detector: Monitors gas or oil pilot and energizes the
programmer flame relay in response to a flame signal. It
continues to monitor main flame (oil or gas) after expiration of
pilot providing period. A standard equipped boiler has a lead
sulfide (infrared sensitive) detector.
13.Combustion Air Proving Switch: A pressure-sensitive switch
actuated by air pressure from the forced draft fan. Its contacts
close to prove presence of combustion air. The fuel valves cannot
be energized unless this switch is satisfied. The combustion air
proving switch is provided on all gas fired or combination gas-oil
burners. An oil fired boiler does not normally have a separate
switch but utilizes the atomizing air proving switch to the same
effect, since the presence of atomizing air from the air pump,
which is belt driven from the blower motor, is evidence of blower Figure 2-6 Stack Thermometer
operation.
14.Alarm: Sounds to notify the operator of a condition requiring
attention. The alarm is available as optional equipment.
15.Stack Thermometer (Figure 2-6): Indicates temperature of
vented flue gases.
16.Diffuser (Figure 2-7): A circular plate, located at the furnace end
of the burner drawer, that imparts a rotary swirling motion to
combustion air immediately prior to its entering the flame, thus
providing a thorough and efficient mixture with the fuel.
17.Rotary Air Damper (Figure 2-7): Provides accurate control of
combustion air in proportion to fuel input for various load
demands. It consists of two concentric cylinders with openings.
The outer is stationary. The inner is rotated, under control of the
modulating motor, to vary the effective size of the openings
where they overlap.
18.Indicator Lights (Figure 2-8): Provide visual information of boiler Diffuser Rotary Air
operation as follows (indicator lights vary with controls Damper
provided):
• Flame Failure Figure 2-7 Diffuser & Damper
• Load Demand
• Fuel Valve (valve open)
• Low Water
Figure 2-8 Control Panel
Part No. 750-184 2-5

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. The
sequence includes air purge periods prior to ignition and upon
burner shutdown.
The flame detector portion of the control monitors both oil and gas
flames and provides protection in the event of loss of a flame signal.
The control recycles automatically during normal operation, or
following a power interruption. It must be manually reset following
a safety shutdown caused by a loss of flame. An internal checking
circuit, effective on every start, prevents burner operation in the
event anything causes the flame relay to hold in during this period.
D. CONTROLS FOR GAS FIRING

See Figure 2-9. Depending upon the requirements of the insurance
carrier or other governing agencies, the gas flow control system
components may vary. Refer to the Dimension Diagram (DD)
prepared by Cleaver-Brooks for your specified installation.
1. Gas Pilot Valve: A solenoid valve that opens during the ignition period
to admit fuel to the pilot. It closes after main flame is established. The
sequence of energizing and de-energizing is controlled by the
programming relay. A second gas pilot valve may be required by
insurance regulations.
2. Gas Pilot Shutoff Cock: For manually opening or closing the gas supply
to gas pilot valve.
3. Gas Pressure Gauge: Indicates gas pressure to pilot.
4. Gas Pressure Regulating Valve: Reduces incoming gas pressure to suit
the pilot.
5. Main Gas Cock: For manually opening and closing the main fuel gas
supply downstream of the main gas line pressure regulator. A second
shutoff cock, downstream of the main gas valve(s), is installed to
provide a means of shutting off the gas line whenever a test is made for
leakage across the main gas valve.
6. Butterfly Gas Valve: The pivoted disc in the valve is actuated by
connecting linkage from the gas modulating cam to regulate the rate of
gas flow to the burner.
7. Main Gas Valves: Electrically actuated shutoff valves that open
simultaneously to admit gas to the burner. The downstream valve is
equipped with a “proof of closure” switch that is connected into the pre-
ignition interlock circuit.
8. Low Gas Pressure Switch: A pressure-actuated switch that is closed
whenever main gas line pressure is above a preselected pressure.
Should the pressure drop below the setting, the switch contacts open a
circuit causing the main gas valve(s) to close, or prevent the burner
from starting. The switch is usually equipped with a device that must
be manually reset after being tripped.
9. High Gas Pressure Switch: A pressure actuated switch that is closed
whenever main gas line pressure is below a preselected pressure.
Should the pressure rise above the setting, the switch contacts will
open a circuit causing the main gas valve(s) to close, or prevent the
burner from starting. The switch is usually equipped with a device that
must be manually reset after being tripped.
2-6 Part No. 750-184

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
Low Gas Pressure Switch
Shut Off Valve
PILOT GAS TRAIN
Pilot Pressure Regulator

Gas Pilot Valve
Pilot Shut Off Cock Pressure Gauge
Figure 2-9 Gas Train
E. CONTROLS COMMON TO OIL-FIRED BOILERS

(INCLUDING COMBINATION)
See Figure 2-10. The following items are applicable to all oil fired
or gas and oil fired boilers.
1. Oil Drawer Switch: Opens the limit circuit if oil drawer burner gun
is not latched in the forward position required for burning oil.
2. Atomizing Air Proving Switch: Pressure-actuated switch whose
contacts are closed when sufficient atomizing air pressure from
Part No. 750-184 2-7

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. Oil Solenoid Valve: Opens when energized through contacts in
the programmer and allows fuel oil flow from the oil metering
valve to the burner nozzle. A light oil fired burner uses two valves
operating simultaneously.
5. Fuel Oil Controller: An assembly combining into a single unit the
gauges, regulators and valves required for regulating the flow of
fuel oil. All controllers have the following integral parts. In
addition to these, the controller used on a No. 6 oil fired burner
has additional components described in Section I.
A. Oil Metering Valve: Valve metering stem moves to increase
or decrease the orifice area to regulate the supply of fuel oil
to the burner nozzle in accordance with boiler load
variances. Stem movement is controlled by the modulating
motor through linkage and the oil metering cam.
B. Oil Modulating Cam: Assembly consisting of a quadrant, a
series of adjustable allen-head screws and a contour spring
provided for adjustment of oil input at any point in the
modulating range.
C. Oil Burner Pressure Gauge: Indicates pressure of the fuel oil
at the metering valve.
D. Oil Pressure Regulator: For adjustment of the pressure of oil
at the metering valve.
6. Oil Relief Valve: Maintains a constant oil supply pressure to the
fuel oil controller by bypassing excess fuel oil.
2-8 Part No. 750-184

1 2
7
4
1. OIL DRAWER SWITCH 5. FUEL OIL CONTROLLER

2. ATOMIZING AIR PROVING SWITCH 6. OIL RELIEF VALVE
3. ATOMIZING AIR PRESSURE GAUGE 7. TERMINAL BLOCK
4. OIL SOLENOID VALVE
Figure 2-10 Components Common to Oil Fired Boilers
Part No. 750-184 2-9

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
OIL PRESSURE REGULATOR
OIL BURNER
PRESSURE GAUGE OIL RETURN PRESSURE GAUGE
FUEL OIL THERMOMETER
OIL SUPPLY
OIL RETURN
MANUAL BY-PASS VALVE

ORIFICED VALVE
TO MAIN OIL BACK PRESSURE VALVE

SOLENOID VALVE
Figure 2-12 Oil Control Valve Assembly - Heavy Oil
2-10 Part No. 750-184

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. It is energized through programmer contacts. It
is deenergized to shut off pilot fuel flow after main flame is
ignited and established.
11.Back Pressure Orifice: A restriction located in the oil return line
immediately downstream of the fuel oil controller to create back
pressure (100 and 200 series only).`
12.Air Pump Module Assembly (Figure 2-13, 2-14): Provides the AIR INTAKE
compressed air required to atomize the fuel oil for proper CONTROL VALVE
combustion. The CB-LE air pump module is started AIR FILTER

automatically by the programmer’s sequence. It includes
components described A-H.
A. Air Pump Motor: Drives the air pump and an air cooling fan. The DRIVE BELT
motor is started and stopped simultaneously with the forced draft HOUSING
fan motor.
B. Air Pump: Provides air for atomization of the fuel oil. AIR PUMP
C. Air Filter: The filter cleans the air supply prior to entering air
pump.
D. Check Valve: Prevents lubricating oil and compressed air from
surging back through the pump and air filter when the pump
AIR-OIL
stops. RECEIVER
TANK
E CA LUBE OIL LEVEL

D B SIGHT GLASS
G
Figure 2-13 Belt Driven Air Pump

(Model CB-OS)
F
A. AIR PUMP MOTOR F. LUBE OIL LEVEL SIGHT GLASS

B. AIR PUMP G. LUBE OIL COOLING COIL
C. AIR FILTER
D. CHECK VALVE
E. AIR-OIL RECEIVER TANK
Figure 2-14 Air Pump, CB-LE
E. Air-Oil Receiver Tank: Holds a supply of oil for lubricating the air
pump. The receiver tank also separates lube oil from the
atomizing air before delivery to nozzle.
F. Lube Oil Level Sight Glass: Indicates the level of lubricating oil in
the air-oil receiver tank.
Part No. 750-184 2-11

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.
13.Low Oil Pressure Switch (Optional): Switch contacts open when
the fuel oil pressure drops below selected pressure. Switch will
interrupt the limit circuit upon loss of sufficient fuel oil pressure
for correct combustion.
14.Fuel Oil Pump: Transfers fuel oil from the storage tank and
delivers it under pressure to the burner system.
F. ADDITIONAL CONTROLS FOR HEAVY OIL

An oil heater is provided to heat heavy oil to the point where it can
be effectively atomized and burned. Most heavy oil heaters utilize
an electric heater to reduce the viscosity of the heavy oil until the
point where either steam or hot water is available. Heavy oil heaters
operating with hot water will have additional controls not shown
here.
Heater Switch (Not Shown): Manually provides power to the oil
heater system.
1. Oil Heater (Electric): Used for heating sufficient fuel oil for low-
fire flow during cold starts before steam or hot water is available
for heating. The heater must be turned off during extended boiler
lay-up, or at any time the fuel oil transfer pump is stopped.
2. Electric Oil Heater Thermostat: Senses fuel oil temperature and
energizes or deenergizes the electric oil heater to maintain
required temperature of the fuel oil.
3. Steam Oil Heater Thermostat: Senses fuel oil temperature and
controls the opening and closing of the steam heater valve to
maintain the required temperature of the fuel oil.
4. Oil Heater Shell (Steam/Hot Water): Heats fuel oil through
medium of steam or hot water. Electric heater is housed in the
steam heater, but is housed separately on a hot water heater.
Steam oil heaters on 15 psi boilers operate at boiler pressure.
Steam oil heaters furnished on high pressure boilers are to be
operated at less than 15 psi. Operation is accomplished with a
steam pressure regulator valve.
5. Oil Return To Tank: Excess oil returned to the heavy oils supply
tank.
6. Oil Inlet From Supply Tank: Heavy oil inlet from the supply tank.
7. Steam Heater Check Valve: Prevents oil contamination of the
waterside of pressure vessel should any leakage occur in the oil
heater.
8. Steam Trap: Drains condensate and prevents loss of steam from
the steam oil heater. Condensate must be piped to a safe point
of discharge.
9. Check Valve (Steam Heater Discharge): Prevents air entry during
shutdown periods when cooling action may create vacuum
within steam heater.
10.Steam Heater Pressure Regulator: Adjust to provide reduced
(usually less than 15 psi) steam pressure to the heater to
2-12 Part No. 750-184

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.
12.Steam Pressure Gauge: Indicates steam pressure entering the
heater.
13.Oil Relief Valve: Allows release of excessive pressure to the
return side of the oil line piped to the tank.
14.Low-Oil-Temperature Switch: Thermostatic switch that prevents
burner from starting, or stops burner firing if fuel oil temperature
is lower than required for oil burner operation.
15.Oil Supply Pressure Gauge: Indicates fuel oil pressure in the oil
heater and supply pressure to the fuel oil controller’s pressure
regulator.
15 14 13 12
11
10
16 9
17
18
1 2 3 4 5
6 7 8
1. OIL HEATER (ELECTRIC) 10. STEAM HEATER PRESSURE REGULATOR

2. OIL HEATER THERMOSTAT (STEAM) 11. STEAM HEATER SOLENOID VALVE
3. OIL HEATER THERMOSTAT (ELECTRIC) 12. STEAM PRESSURE GAUGE
4. OIL HEATER SHELL 13. OIL RELIEF VALVE
5. OIL RETURN TO TANK 14. LOW OIL TEMPERATURE SWITCH
6. OIL INLET FROM TANK 15. OIL SUPPLY PRESSURE GAUGE
7. CHECK VALVE 16. OIL RETURNED FROM FUEL OIL CONTROLLER
8. STEAM TRAP 17. HEATED OIL TO BURNER
9. CHECK VALVE 18. FUEL OIL STRAINER
Figure 2-15 Oil Heating Assembly (Steam)
In addition to the components of the fuel oil controller mentioned in

Section E, the following are used with a heavy oil fired burner.
A. High-Oil-Temperature Switch (Optional): Switch contacts open when
fuel oil temperature raises above a selected temperature. Switch will
interrupt the limit circuit in the event fuel oil temperature rises above
the selected point.
Part No. 750-184 2-13

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.
D. Fuel Oil Thermometer: Indicates temperature of fuel oil being
supplied to the fuel oil controller.
E. Back Pressure Valve: For adjustment of oil pressure on the
downstream side of the metering valve. Also regulates rate of return
oil flow.
F. Oil Return Pressure Gauge: Indicates oil pressure on the return side
of the fuel oil controller.
G. Manual By-Pass Valve: Provided as a time saver in establishing oil
flow. When open, it permits circulation of oil through the supply and
return lines. The valve must be closed prior to initial light off.
H. Orifice Oil Control Valve: Valve may be opened prior to start-up to aid
in establishing fuel oil flow through the controller. The valve must be
closed prior to initial light off. Its disc has an orifice to permit a
continuous circulation of hot fuel oil through the controller.
I. Air Purge Valve: Solenoid valve opens simultaneously with closing of
oil solenoid valve at burner shutdown, allowing compressed air to
purge oil from the burner nozzle and adjacent piping. The oil is
burned by the diminishing flame, which continues burning for
approximately 4 seconds after the oil solenoid valve closes.
J. Air Purge Orifice Nozzle: Limits purging air to proper quantity for
expelling unburned oil at normal delivery rate.
K. Air Purge Orifice Nozzle Filter: Filters the purging air of any particles
that might plug the air purge orifice nozzle.
L. Air Purge Check Valve: Valve check prevents fuel oil from entering the
atomizing air line.
M.Air Purge Relay: When energized, controls operation of air purge
valve.
G. CONTROLS FOR COMBINATION BURNERS ONLY

Burners equipped to burn either oil or gas include equipment for
each fuel. The selector switch engages the appropriate interlocks
and controls for gas or oil operation.
H. COMBUSTION AIR
Air for combustion of fuel (often referred to as “secondary” air) is
furnished by the forced draft fan mounted in the boiler head. In
operation, air pressure is built up in the entire head and is forced
through a diffuser plate for a thorough mixture with the fuel for
proper combustion. The supply of secondary air to the burner is
governed by automatically throttling the output of the fan by
regulating the rotary air damper. The damper provides the proper
2-14 Part No. 750-184

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. All other burners are equipped with a gas burning pilot.
In the case of a combination burner, the gas pilot is used to ignite
either the main gas flame or the oil flame. Either pilot serves the
same function. Unless exception is taken in the text, the term pilot
is used interchangeably.
At the beginning of the ignition cycle, and governed by the program
relay, the pilot solenoid valve and ignition transformer are
simultaneously energized.
The ignition transformer supplies high voltage current for the
igniting spark. A gas pilot has a single electrode and a spark arcs
between the tip of the electrode and the wall of the tube surrounding
it. A light oil pilot has two electrodes and the arc is between their
tips. The pilot solenoid valve and the transformer are deenergized
after main flame is ignited and established.
Fuel for the gas pilot is supplied from the utility’s main, or from a
tank (bottle) supply. Secondary air flows into and mixes with the
pilot gas stream to provide an adequate flame.
Insurance regulations may require two gas pilot solenoid valves with
a normally open vent valve between them. The vent valve closes
when the gas pilot valves open, and opens when the gas pilot valves
shut to vent gas, should any be present in the pilot line during the
deenergized period of the gas pilot valves.
Fuel for a light-oil pilot is provided from the line that supplies oil
under pressure for the main flame. A solenoid actuated valve
controls flow of oil to the pilot nozzle. The valve is energized
simultaneously with the ignition transformer at the beginning of the
ignition cycle and is deenergized after main flame is ignited and
established.
J. ATOMIZING AIR
Air for atomizing the fuel oil (often referred to as “primary air”) is
pumped by the air pump into the air-oil receiver tank and delivered
under pressure through a manifold block to the oil burner nozzle.
The atomizing air mixes with the fuel oil just prior to the oil leaving
the nozzle.
Atomizing air pressure is indicated by the air pressure gauge on the
burner gun.
Air pressure from the pump also forces sufficient oil from the tank
to the pump bearings to lubricate them and also to provide a seal
and lubrication for the pump vanes. As a result, the air delivered to
the tank contains some lube oil; however, most of it is recovered
Part No. 750-184 2-15

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. OIL FUEL FLOW - LIGHT OIL

The oil fuel flow system schematic is shown in Figure 2-16. Oil flow
is indicated by arrows and the pertinent controls are called out. Fuel
oil is delivered into the system by a supply pump which delivers part
of its discharge to the oil burner. Excess oil is returned to the oil
storage tank through the fuel oil relief valve and oil return line.
Normally the pump operates only while the burner is in operation,
although a positioning switch is often provided so that either
continuous or automatic pump operation can be obtained.
The oil flows through a fuel oil strainer to prevent any foreign
material from flowing through the control valves and nozzle. The
fuel oil controller contains in a single unit, a metering valve, a
regulator, and a gauge required to regulate the pressure and flow of
oil to the burner. The adjustable regulator controls the pressure. To
assist in the regulation, back pressure is created by an orifice nozzle
located in the oil return line immediately downstream of the fuel oil
controller.
The programming relay energizes or deenergizes the solenoid oil
valves to permit or cut off oil flow to the burner. Two valves,
operating simultaneously, are used. The valves are closed when
deenergized. They cannot be opened (energized) unless the
combustion air proving switch and the atomizing air proving switch
are closed. The two switches are satisfied, respectively, by sufficient
combustion air pressure from the forced draft fan and pressurized
air from the air pump.
The oil flow to the burner is controlled by the movement of the
metering stem in the oil metering valve, which varies the flow to
meet load demands. The metering valve and the air damper are
controlled simultaneously at all times by the modulating motor to
proportion combustion air and fuel for changes in load demand.
2-16 Part No. 750-184

NOZZLE AIR
AIR STRAINER PRESSURE GAUGE
MANIFOLD OIL BURNER NOZZLE
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
OIL PRESSURE
OIL BURNER REGULATOR
AIR OIL
RECEIVER TANK PRESSURE GAUGE
LUBE OIL
OIL METERING
VALVE
OIL MODULATING
CAM
OIL RETURN
BACK PRESSURE ORIFICE
OIL RELIEF
VALVE
FUEL OIL
RETURN
FUEL OIL VACUUM
STRAINER CHECK GAUGE
VALVE
OIL SUPPLY FUEL OIL
PRESSURE SUPPLY PUMP
GAUGE SHUTOFF
PRIMING
VALVE
TEE
FUEL
OIL
INLET
NOT SUPPLIED
FUEL OIL BY CLEAVER BROOKS
STRAINER
Figure 2-16 Light Oil Flow
Part No. 750-184 2-17

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. The remainder
of the fuel oil returns to the oil storage tank through a fuel oil relief
valve and oil return line.
The combination electric and steam oil preheater is controlled by
thermostats. The electric oil heater thermostat energizes the electric
heater, which is provided to supply heated oil on cold starts. The
steam heater thermostat controls operation of the steam solenoid
valve to permit a flow of steam to the heater when steam is
available.
A hot water boiler is equipped to heat the oil with hot water from
the boiler, unless other preheating equipment is utilized. The
electric heater, which is housed separately, is sized to provide
heated oil on a cold start. The hot water thermostat controls the
operation of a pump that supplies hot water to the oil heater when
hot water is available.
The heated oil flows through a fuel oil strainer to prevent any foreign
matter from entering the control valves and nozzle.
The fuel oil controller contains, in a single unit, the necessary
valves, regulators and gauges to regulate the pressure and flow of
oil to the burner.
The program relay energizes or deenergizes the solenoid oil valve to
permit or cut off oil flow to the burner. The oil solenoid is closed
when deenergized. It cannot be opened (energized) unless the
combustion air proving switch, the atomizing air proving switch,
and the low oil-temperature and any pressure switches are closed.
They are satisfied, respectively, by sufficient combustion air
pressure from the forced draft fan, pressurized air from the air pump
and sufficient oil temperature and pressure.
Oil flow to the burner is controlled by the movement of the metering
stem of the oil metering valve, which varies the flow to meet load
demands. The metering valve and the air damper are controlled
simultaneously at all times by the modulating motor to proportion
combustion air and fuel for changes in load demand.
Oil is purged from the burner gun upon each burner shutdown. The
air purge solenoid valve opens as the fuel valve closes, diverting
atomizing air through the oil line. The air assures a clean nozzle and
line for subsequent restart.
2-18 Part No. 750-184

AIR STRAINER
NOZZLE AIR
PRESSURE GAUGE
MANIFOLD OIL BURNER NOZZLE

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
OIL PRESSURE
AIR PURGE REGULATOR
AIR OIL VALVE
RECEIVER TANK FUEL OIL
THERMOMETER
AIR PURGE
CHECK VALVE
LUBE OIL OIL METERING

AIR PURGE VALVE
CHECK VALVE
OIL MODULATING LOW OIL
CAM TEMPERATURE
SWITCH
PRESSURE
RELIEF VALVE MANUAL
BY-PASS
OIL RETURN VALVE
PRESSURE
GAUGE
OIL BURNER
NOTE: DIAGRAM SHOWS COMPONENTS USED WITH PRESSURE
GAUGE
STEAM GENERATORS. REFER TO FIGURE 1-2 FOR ORIFICED
CORRESPONDING HOT WATER HEATING COMPONENTS. VALVE
OIL SUPPLY OIL RELIEF FUEL OIL

PRESSURE VALVE RETURN
GAUGE
OIL HEATER NOTE: CONDENSATE FROM STEAM

THERMOSTAT TRAP MUST BE WASTED AND PIPED
STEAM HEATER
(ELECTRIC) PRESSURE GAUGE TO A SAFE POINT OF DISCHARGE.
STEAM HEATER
SOLENOID VALVE
STEAM PRESSURE
REGULATOR
STEAM SHUTOFF
VALVE
FUEL OIL
STRAINER
OIL HEATER STEAM INLET
SHELL
CHECK VALVE
STEAM STRAINER
VACUUM GAUGE
OIL HEATER
(ELECTRIC) OIL HEATER CHECK STEAM TRAP CHECK VALVE
THERMOSTAT VALVE
(STEAM) SHUTOFF
PRIMING TEE VALVE
FUEL
OIL
INLET
* THESE ITEMS ARE USED ON HIGH FUEL OIL NOT SUPPLIED
PRESSURE GENERATORS ONLY SUPPLY PUMP FUEL OIL BY CLEAVER BROOKS
STRAINER
Figure 2-17 Heavy Oil Flow
Part No. 750-184 2-19

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.
The main gas valve is of the normally closed type, and is opened
(energized) in proper sequence by the programming relay.
The butterfly gas valve modulates the flow of gas from low through
high fire settings. The position of the butterfly valve disc is governed
by the gas modulating cam. The butterfly gas valve, and the air
control damper are controlled simultaneously by the modulating
motor to proportion combustion air and fuel for changes in load
demand.
The gas flow rate required for rated burner input depends upon the
heating value (Btu/cubic foot) of the gas supplied. The gas pressure
regulator adjusts the gas pressure (flow rate) to the entrance of the
gas train. The regulator is not always supplied with the burner, but
may be provided by others.
The main gas valves cannot be energized (opened) unless the
combustion air proving switch is closed to indicate a sufficient
supply of combustion air. The low gas pressure and high gas
pressure switches must be closed to prove sufficient, but not
excessive, gas fuel pressure.
N. MODULATING FIRING
The modulating motor, through a linkage arrangement, controls the
air damper and the butterfly gas valve (or the oil metering valve) to
maintain a constant air/fuel ratio throughout the firing range.
During burner operation, the motor is controlled by a modulating
pressure control on a steam boiler, or by a modulating temperature
control on a hot water boiler. A manually operated potentiometer is
provided to permit positioning of the motor at the desired burner
firing rate. The potentiometer is used primarily for initial or
subsequent checking and setting of fuel input. Normal operation
should be with the manual-automatic switch in the “automatic”
position and under the control of the modulating control.
The modulating motor (commonly called a damper motor) is
reversible. It has an internal limit switch that restricts shaft rotation
to 90°. During normal operation the motor will move in either
direction or stop at any position within the range.
The motor potentiometer is electrically connected to a matching
potentiometer in the modulating control. Changing steam pressure
or water temperature alters the electrical resistance of the
modulating controller potentiometer. The change in resistance
compels an integral balancing relay to start, stop, or reverse the
motor rotation. Rotation in either direction continues until the
resistance ratio of the two potentiometers is equal.
2-20 Part No. 750-184

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. A low-fire switch, integral to the
motor, is actuated by the rotation of the motor. The switch must be
closed to establish that the damper and fuel metering valves are in
the low-fire position before the programmer commences into the
ignition period. During this time, neither the manual flame control
nor the modulating control have any control over the damper motor,
regardless of their setting.
An optionally equipped boiler uses a second integral switch to
establish that the motor has driven the damper to an open position
during the pre-purge period. The second integral switch closes, as
high fire position is approached, to complete an internal circuit in
the programmer to allow continuation of the programming cycle.
Part No. 750-184 2-21

2-22 Part No. 750-184

Chapter 3
Waterside Care and Requirements
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
B. WATER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
C. WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
D. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
E. BOIL-OUT OF A NEW UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
F. WASHING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
G. BLOWDOWN STEAM BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
H. PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
I. PREPARATION FOR EXTENDED LAY-UP . . . . . . . . . . . . . . . . . . . . 3-16
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.
Feedwater equipment should be checked and ready for use. Be sure
that all valves, piping, boiler feed pumps, and receivers are installed
in accordance with prevailing codes and practices.
Water requirements for both steam and hot water boilers are
essential to boiler life and length of service. It is vital that care be
taken in placing the pressure vessel into initial service. The
waterside of new boilers and new or remodeled steam or hot water
systems may contain oil, grease or other foreign matter. A method
of boiling out the vessel to remove the accumulations is described
later in Chapter 3.
Boilers, as a part of a hot water system, require proper water
circulation. The system must be operated as intended by its
designer in order to avoid thermal shock or severe, possibly
damaging, stresses from occurring to the pressure vessel.
Note: This manual only covers boilers using water. Glycol solutions
have different operating requirements, circulation rates and
temperatures, etc.
B. WATER REQUIREMENTS
1. HOT WATER BOILER

Air Removal
The hot water outlet includes a dip tube which extends 2 to 3 inches
into the boiler. The dip tube reduces the possibility of air, which may
be trapped at the top of the shell, from entering into the system.
Oxygen or air released in the boiler will collect or be trapped at the
top of the boiler shell.
The air vent tapping on the top center line of the boiler should be
piped into the expansion or compression tank. Air trapped at the top
of the boiler will find its way out of the boiler through the tapping.
Minimum Water Temperature - The minimum recommended boiler
water temperature is 170°F. When water temperatures lower than
170°F are used, the combustion gases are reduced in temperature
to a point where water vapor condenses, causing corrosion in the
boiler and possible breeching.
Condensation is more severe on a unit that operates intermittently
and which is greatly oversized for the actual load. Condensation can
be minimized by maintaining boiler water temperatures above
170°F.
3-2 Part No. 750-184

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. (The electric preheater on the boiler must provide
additional heat to the oil if boiler water temperature is not
maintained above 200°F.)
Note: If the operating water temperature going to the system must
be lower than 170°F, the operating boiler water temperature
should be a minimum of 170°F (200 °F if used to preheat No.
6 oil) and mixing valves should be used to avoid damage to
the equipment.
Rapid Replacement of Boiler Water - The system layout and

controls should be arranged to prevent the possibility of pumping
large quantities of cold water into a hot boiler, which will cause
shock or thermal stresses. Water temperature in a boiler of 200°F
or 240°F cannot be completely replaced with 80°F water in a few
minutes time without causing thermal stress. The same fact applies
to periods of normal operation, as well as during initial start-up.
Note: The circulating pumps should be interlocked with the burner
so that the burner cannot operate unless the circulating pump
is running in order to avoid damage to the equipment.
When individual zone circul a t i n g p u m p s a r e u se d, i t i s
recommended that they be kept running-even though the heat users
do not require hot water. The relief device or by-pass valve will thus
allow continuous circulation through the boiler and can help prevent
rapid replacement of boiler water with cold zone water.
Continuous Flow Through the Boiler - The system should be piped
and the controls arranged to allow water circulation through the
boiler under all operating conditions. The operation of three-way
valves and system controls should be checked to be sure that the
boiler will not be by-passed. Constant circulation through the boiler
eliminates the possibility of stratification within the unit and results
in more even water temperatures to the system.
A rule of thumb of 3/4 to 1 gpm per boiler horsepower can be used
to determine the minimum continuous flow rate through the boiler
under all operating conditions. The operator should determine that
a flow of water exists through the boiler before initial firing or refiring
after boiler has been drained.
Water Circulation
Table 3-1 shows the maximum gpm circulation rate of boiler water
in relation to full boiler output and system temperature drop.
Multiple Boiler Installations - When multiple boilers are used, care
must be taken to ensure adequate or proportional flow through the
boilers. Proportional flow can best be accomplished by use of
balancing valves and gauges in the supply line from each boiler. If
balancing valves or orifice plates are used, a significant pressure
drop (e.g., 3-5 psi) must be taken across the balancing device to
accomplish the purpose.
Part No. 750-184 3-3

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. The net result would
be that the common header water temperature to the system would
not be up to the desired point.
Pump Location - It is recommended that the system circulating
pumps take suction from the outlet connection on the boiler, and
that they discharge to the system load. In order to put the boiler and
the expansion tank on the suction side of the pump. The suction
side is preferred because it decreases air entry into the system and
does not impose the system head on the boiler.
It is common practice to install a standby system circulating pump.
The main circulating pumps are usually located adjacent to the
boilers in the boiler room.
Pump Operation - Pumps are normally started and stopped by
manual switches. It is also desirable to interlock the pump with the
burner so that the burner cannot operate unless the circulating
pump is running.
Pressure - The design of the system and usage requirements 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 ensure that the proper relationship of pressure-
to-temperature exists within the boiler so that all of the boiler’s
internal surfaces are fully wetted at all times. For this reason, the
internal boiler pressure, as indicated on the water pressure gauge,
must be held to the level shown in Figure 3-2.
When initially firing a newly installed boiler, or when cutting an
existing boiler into an operating system, the boiler or boilers to be
cut into operation MUST be pressurized equal to the system and/or
other boilers prior to opening the header valves.
It is advisable to have a thermometer installed in the return line to
indicate return water temperature. Knowing the supply water
temperature, the boiler system differential can be established. With
knowledge of the pumping rate, the operator can easily detect any
excessive load condition and take appropriate corrective action.
! Caution
Special caution must be taken to guard against any condition, or
combination of conditions, that might lead to the transfer of cold
water to a hot boiler or hot water to a cold boiler. Rapid changes in
temperature within the boiler can cause severe damage.
3-4 Part No. 750-184

Table 3-1 Maximum Circulating Rate

BOILER BOILER OUT- SYSTEM TEMPERATURE DROP - DEGREES °F
SIZE PUT (1000)
10 20 30 40 50 60 70 80 90 100
(BHP) BTU/HR
MAXIMUM CIRCULATING RATE - GPM
15 500 100 50 33 25 20 17 14 12 11 10
20 670 134 67 45 33 27 22 19 17 15 13
30 1,005 200 100 67 50 40 33 29 25 22 20
40 1,340 268 134 89 67 54 45 38 33 30 27
50 1,675 335 168 112 84 67 56 48 42 37 33
60 2,010 402 201 134 101 80 67 58 50 45 40
70 2,345 470 235 157 118 94 78 67 59 52 47
80 2,680 536 268 179 134 107 90 77 67 60 54
100 3,350 670 335 223 168 134 112 96 84 75 67
125 4,185 836 418 279 209 168 140 120 105 93 84
150 5,025 1,005 503 335 251 201 168 144 126 112 100
200 6,695 1,340 670 447 335 268 224 192 168 149 134
250 8,370 1,675 838 558 419 335 280 240 210 186 167
300 10,045 2,010 1,005 670 503 402 335 287 251 223 201
350 11,720 2,350 1,175 784 587 470 392 336 294 261 235
400 13,400 2,680 1,340 895 670 535 447 383 335 298 268
500 16,740 3,350 1,675 1,120 838 670 558 479 419 372 335
600 20,080 4,020 2,010 1,340 1,005 805 670 575 502 448 402
700 23,430 4,690 2,345 1,565 1,175 940 785 670 585 520 470
800 26,780 5,360 2,680 1,785 1,340 1,075 895 765 670 595 535
Part No. 750-184 3-5

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. After opening the valves, momentarily energize
the feed pump motor to establish correct pump rotation. With the
correct rotation established, close the boiler feed pump entrance
switch. The pump should shut down when the water level reaches
the proper level.
Feedwater pumps must have adequate capacity to maintain
required water level under all operating conditions. Check the
feedwater pumps periodically and maintain as necessary to prevent
unexpected breakdowns.
Note: Prior to operating the pump, carefully check the alignment of
the flexible coupling, if one is used. A properly aligned
coupling will last a long time and provide trouble-free
mechanical operation.
3-6 Part No. 750-184

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. If the valves are
installed, it is illegal to operate the boiler with closed or
unsealed open valves.
! Warning
The isolation valves and the water column piping must be locked
open during operation. Failure to do so may result in a low water
condition. Failure to follow these instructions could result in serious
personal injury or death
High Water Alarm CASTING MARK

High Water Warning (Low Water Cut-Off)
Pump Off
Pump On
Low Water Warning
Figure 3-2 C-B Level Master water levels
C. WATER TREATMENT
Properly treated boiler feed water, coupled with good engineering
and operating practices, lead to maximum effectiveness and long
trouble-free life of pressure vessels, at the lowest operating cost.
Contact your local Cleaver-Brooks authorized representative for
information on how to prevent the presence of unwanted solids and
corrosive gases.
Part No. 750-184 3-7

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. Prevent intercrystalline cracking or caustic embrittlement of
boiler metal.
4. Prevent carryover and foaming.
Accomplishment of the above objectives generally requires proper
feedwater treatment before and after introduction of the water into
the boiler. The selection of pre-treatment processes depends upon
the water source, its chemical characteristics, amount of makeup
water needed, plant operating practices, etc. Treating methods
include filtering, softening, de-mineralizing, deaerating, and
preheating. After-treatment involves chemical treatment of the
boiler water.
Because of the variables involved, no single boiler compound can
be considered a “cure-all” nor is it advisable to experiment with
homemade treating methods. Sound recommendations and their
employment should be augmented by a periodic analysis of the
feedwater, boiler water, and condensate.
The internal or waterside surfaces of the pressure vessel should be
inspected with enough frequency to determine the presence of any
contamination, accumulations of foreign matter, or corrosion, and/
or pitting. If any of the conditions are detected, contact your local
Cleaver-Brooks authorized representative for advice on corrective
action.
A properly sized water meter should be installed in the raw water
make-up line in order to accurately determine the amount of raw
water admitted to the boiler (steam or hot water) and to aid in
maintaining proper waterside conditions.
D. CLEANING
1. HOT WATER AND STEAM PIPING

Steam and water piping systems connected to the boiler may
contain oil, grease, or foreign matter. The impurities must be
removed in order to prevent damage to pressure vessel heating
surfaces. On a steam system, 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.
For more information, contact your local Cleaver-Brooks authorized
representative.
On a hot water system, chemical cleaning is generally necessary
and the entire system should be drained after treatment. Consult
3-8 Part No. 750-184

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.
2. PRESSURE VESSEL
The waterside of the pressure vessel must be kept clean from
grease, sludge, and foreign material. Such deposits, if present, will
shorten the life of the pressure vessel, will interfere with efficient
operation and functioning of control of safety devices, and quite
possibly cause unnecessary and expensive re-work, repairs, and
down-time.
The installation and operating conditions that the boiler will be
subjected to should be considered and cleaning of the waterside of
the pressure vessel should be provided during the course of initial
start-up.
The pressure vessel and the steam and return lines or hot water
piping represent, in effect, a closed system. Although the steam and
return (condensate) lines or the hot water piping system may have
been previously cleaned, it is possible that:
(1) Cleaning has been inadequate.
(2) Partial or total old system is involved.
(3) Conditions may prevent adequate cleaning of piping.
The pressure vessel waterside should be inspected on a periodic
basis. An inspection will reveal true internal conditions and serve as
a check against conditions indicated by chemical analysis of the
boiler water. Inspection should be made three months after initial
starting and at regular 6-, 9-, or 12-month intervals thereafter. The
frequency of further periodic inspections will depend upon the
internal conditions found.
If any unwanted conditions are observed, contact your local
Cleaver-Brooks authorized representative for recommendations.
Any sludge, mud or sediment found will need to be flushed out. If
excessive mud of sludge is noticed during the blowdown the
scheduling or frequency of blowdown may need to be revised. The
need for periodic draining or washout will also be indicated.
Any oil or grease present on the heating surfaces should be removed
promptly by a boil-out with an alkaline detergent solution.
Note: Temperature of initial fill of water for hydrostatic tests, boil-
out, or for normal operation should be as stated in the ASME
Boiler Code.
E. BOIL-OUT OF A NEW UNIT

The internal surfaces of a newly installed boiler may have oil, grease
or other protective coatings used in manufacturing. Such coatings
must be removed because they lower the heat transfer rate and
could cause over-heating of a tube. Before boiling out procedures
Part No. 750-184 3-9

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.
Do not permit the dry material or the concentrated solution to come
in contact with skin or clothing. Failure to follow these instructions
could result in serious personal injury or death.
Your local Cleaver-Brooks authorized representative will be able to
recommend a cleaning or boil-out procedure. In the event such
ser vice is unavailable or is yet unscheduled, the following
information may be of assistance.
There are several chemicals suitable for boil-out. One combination
often used is soda ash (sodium carbonate) and caustic soda
(sodium hydroxide) at the rate of 3 to 5 pounds each per 1,000
pounds of water, along with a small amount of laundry detergent
added as a wetting agent.
The suggested general procedure for cleaning a boiler is as follows:
(1) Refer to Table 3-2 to determine water capacity. Have sufficient
cleaning material on hand to complete the job.
(2) When dissolving chemicals, the following procedure is
suggested. Warm water should be put into a suitable container.
Slowly introduce the dry chemical into the water, stirring it at all
times until the chemical is completely dissolved. Add the chemical
slowly and in small amounts to prevent excessive heat and
turbulence.
(3) An over-flow pipe should be attached to one of the top boiler
openings and routed to a safe point of discharge. A relief or safety
valve tapping is usually used.
(4) Water relief valves and steam safety valves must be removed
before adding the boil-out solution so that neither it nor the grease
which it may carry will contaminate the valves. Use care in
removing and reinstalling the valves.
Table 3-2 Water Capacity and Weights
WATER – GALLONS WATER – WEIGHT
GENERATOR
SIZES
NORMAL FLOODED NORMAL FLOODED
CB & CB-LE
125 HP 689 920 5750 7670
150 HP 869 1115 7250 9295
200 HP 1034 1335 8625 11130
(5) All valves in the piping leading to or from the system must be
closed to prevent the cleaning solution from getting into the system.
3-10 Part No. 750-184

(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.
(7) The boiler should then be fired intermittently at a low rate
sufficient to hold solution just at the boiling point. Boil the water for
at least five hours. Do not produce steam pressure.
(8) Allow a small amount of fresh water to enter the boiler to create
a slight overflow that will carry off surface impurities.
(9) Continue the boil and overflow process until the water clears.
Shut the burner down.
(10) Let the boiler cool to 120°F or less.
! Warning
Be sure to drain the hot water to a safe point of discharge to avoid
scalding.Failure to follow these instructions could result in serious
personal injury or death
(11) Remove handhole plates and wash the waterside surfaces

thoroughly using a high pressure water stream.
(12) Inspect the surfaces. If they are not clean, repeat the boil out.
(13) After closing the handholes and reinstalling the safety or relief
valves, fill the boiler and fire it until the water is heated to at least
180°F to drive off any dissolved gases, which might otherwise
corrode the metal.
The above procedure may be omitted in the case of a unit previously
used or known to be internally clean. However, consideration must
be given to the possibility of contaminating materials entering the
boiler from the system.
On a steam system, the condensate should be wasted until tests
show the elimination of undesirable impurities. During the period
that condensate is wasted, be sure make-up water is treated to
prevent an accumulation of unwanted materials or corrosion.
On a hot water system, chemical cleaning is generally necessary
and the entire system should be drained after treatment. Consult
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.
Part No. 750-184 3-11

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
of sludge, sediment, scale, etc., on the pressure vessel waterside.
If the operator is absolutely certain that the system is tight, then an
annual waterside inspection may be sufficient. However, if there is
any doubt, the pressure vessel waterside should be inspected no
later than three months after initially placing the boiler into
operation, and periodically thereafter as indicated by conditions
observed during inspections.
2. STEAM BOILER
No later than three months after initially placing the boiler into
operation and starting service, and thereafter as conditions warrant,
the pressure vessel should be drained after being properly cooled to
near ambient temperature. Handhole covers should be removed and
waterside surfaces should be inspected for corrosion, pitting, or
formation of deposits.
Flushing of Pressure Vessel Interior
Upon completion of the inspection, the pressure vessel interior
should be flushed out, as required, with a high pressure hose. If
deposits are not fully removed by flushing, a consultation may be
required with your local Cleaver-Brooks authorized representative.
In extreme cases, it may be necessary to resort to acid cleaning.
Professional advice is recommended if acid cleaning is required.
The inspections will indicate the effectiveness of the feedwater
treatment. The effectiveness of treatment, the water conditions, and
the amount of fresh water make-up required are all factors to be
considered in establishing frequency of future pressure vessel
washouts. Contact your local Cleaver-brooks authorized
representative for more information.
G. BLOWDOWN STEAM BOILER

Boiler water blowdown is the removal of some of the concentrated
water from the pressure vessel and its replacement with feedwater
so that the lowering of the concentration of solids in the boiler water
occurs.
Solids are brought in by the feedwater even though the water is
treated prior to use through external processes that are designed to
remove unwanted substances which contribute to scale and deposit
formations. However, none of the processes can remove all
3-12 Part No. 750-184

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.
Scale has a low heat transfer value and acts as an insulation barrier.
Scale retards heat transfer, which not only results in lower operating
efficiency, and consequently higher fuel consumption, but more
importantly, can cause overheating of boiler metal. Over heating of
boiler metal can result in tube failures or other pressure vessel metal
damage and lead to boiler down-time and costly repairs.
Scale is caused primarily by calcium and magnesium salts, silica
and oil. Any calcium and magnesium salts in the boiler water are
generally precipitated by the use of sodium phosphate, along with
organic materials, to maintain the precipitates or “sludge” in a fluid
form. The solids such as sodium salts and suspended dirt do not
readily form scale. But as the boiler water boils off as relatively pure
steam, the remaining water is thickened with the solids. If the
concentration is permitted to accumulate, foaming and priming will
occur and the sludge can cause harmful deposits that bring about
overheating of the metal.
The lowering or removal of the concentration requires the use of
boiler water blowdown.
1. TYPES OF BLOWDOWN
There are two principal types of blowdown: intermittent manual
blowdown, and continuous blowdown.
Intermittent Manual Blowdown
Manual or sludge blowdown is necessary for the operation of the
boiler regardless of whether or not continuous blowdown is
employed.
The blowdown tappings are located at the bottom or lowest part of
the boiler in order to lower the dissolved solids in the pressure
vessel water, and to remove a por tion of the sludge that
accumulates in the lower part of the vessel.
Equipment generally consists of a quick opening valve and a shut-
off valve. The valves and necessary piping are not normally
furnished with the boiler, but supplied by others. All piping must be
to a safe point of discharge. Piping must be properly supported and
free to expand.
Continuous Blowdown
Continuous blowdown is used in conjunction with a surface blow-
off tapping and is the continuous removal of concentrated water.
The surface blow-off opening, when furnished, is on the top center
line of the pressure vessel. It is provided with an internal collecting
pipe terminating slightly below the working water level for the
Part No. 750-184 3-13

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.
The flow control valve and piping are generally provided by others.
All piping must be to a safe point of discharge.
Frequency of Manual Blowdown
When continuous blowdown is utilized, manual blowdown is
primarily used to remove suspended solids or sludge. The
continuous blowdown removes sediment and oil from the surface of
the water along with a prescribed amount of dissolved solids.
When surface or continuous blowdown is not utilized, manual
blowdown is used to control the dissolved or suspended solids in
addition to the sludge.
In practice, the valve(s) of the bottom blowdown are opened
periodically in accordance with an operating schedule and/or
chemical control tests. From the standpoint of control, economy and
results, frequent short blows are preferred to infrequent lengthy
blows. The length and frequency of the blwdown is particularly
important when the suspended solids content of the water is high.
With the use of frequent short blows a more uniform concentration
of the pressure vessel water is maintained.
In cases where the feedwater is exceptionally pure, or where there
is a high percentage of return condensate, blowdown may be
employed less frequently since less sludge accumulates in the
pressure vessel. When dissolved and/or suspended solids approach
or exceed predetermined limits, manual blowdown to lower the
concentrations is required.
It is generally recommended that a steam boiler be blown down at
least once in every eight-hour period, but frequency may vary
depending upon water and operating conditions. The blowdown
amounts and schedule should be recommended by your local
Cleaver-Brooks authorized representative.
A hot water boiler does not normally include openings for surface
blowdown and bottom blowdown since blowdowns are seldom
practiced. The need remains to be alert to system water losses and
corresponding amount of raw water make-up. A water meter is
recommended for water make-up lines.
Manual Blowdown Procedure
Blowdown is most effective at a point in time when the generation
of steam is at the lowest rate and feedwater input is also low, thus
providing a minimum dilution of the boiler water with low
concentration feedwater.
3-14 Part No. 750-184

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. Valves will vary depending upon pressure involved and
make or manufacturer. If seatless valves are installed, follow the
manufacturer’s recommendations.
If a quick opening valve and globe type of slow opening valve are in
combination, the former is normally opened first and closed last
with blow down accomplished with the globe or slow opening valve.
When opening the second or downstream valve, crack it slightly to
allow the lines to warm, then continue opening slowly.
! Caution
Do not pump the lever action valve open and closed, as water
hammer is apt to break the valve bodies or pipe fittings. Failure to
follow these instructions could cause damage to the equipment.
The length of each blow should be determined by actual water
analysis. Lowering the water in the gauge glass approximately 1/2”
is often acceptable as a guide to adequate blow. However, lowering
the water 1/2” should not be interpreted as a rule since water
analysis procedures should prevail. If the glass cannot be viewed by
the party operating the valve, another operator should watch the
glass and direct the valve operator.
Close the downstream (slow opening) valve first and as fast as
possible. Then close the valve next to the boiler. Slightly crack the
downstream valve and then close it tightly.
Under no circumstances should a blow-off valve be left open and
the operator should never leave until the blowdown operation is
completed and the valves are closed.
H. PERIODIC INSPECTION
Insurance regulations or local laws will require a periodic inspection
of the pressure vessel by an authorized inspector. Sufficient notice
is generally given to permit removal of the boiler from service and
preparation for inspection.
! Warning
To avoid the hazard of electrical shock, use a low voltage flashlight
during an internal inspection. Preferably, inspectors should work in
pairs. Failure to follow these instructions could result in serious
When shutting down the boiler, the load should be reduced
gradually and the pressure vessel cooled at a rate that avoids
damaging temperature differential that can cause harmful stresses.
Vessels should not normally be drained until all pressure is relieved
Part No. 750-184 3-15

- 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. Some heat, however, may be desirable to dry out
the interior of the boiler.
If the internal inspection is being made at the request of an
authorized inspector, it is well to ask the inspector observe the
conditions prior to cleaning or flushing of waterside surfaces.
Be certain that a supply of manhole and handhole gaskets is
available, along with any other gaskets or items needed to place the
unit back into operation after inspection.
Have available information on the boiler design, dimensions,
generating capacity, operating pressure or temperature, time in
service, defects found previously, and any repairs or modifications.
Also have available for reference records of previous inspections.
Be prepared to perform any testing required by the inspector
including a hydrostatic test.
After proper cooling and draining of the vessel, flush out the
waterside with a high pressure water hose. Remove any scale or
deposits from the waterside surfaces and check for internal or
external corrosion and leakage.
The fireside surface should also be thoroughly cleaned so that metal
surfaces, welds, joints, tube ends, fittings and any previous repairs
can be readily checked.
Be sure that steam valves, and valves to expansion tank (hot water),
feedwater valves, blow-off valves, all fuel valves, valves to
expansion tank, and electrical switches are shut off prior to opening
handholes, manhole and front or rear doors. Adequately vent the
pressure vessel prior to entry.
Clean out the low-water cutoff piping, the water level controls and
cross-connecting pipes. Replace the water gauge glass and clean
out the water cocks. Also check and clean the drain and the
blowdown valves and piping.
Check all water and steam piping and valves for leaks, wear,
corrosion, and other damage. Replace or repair as required.
I. PREPARATION FOR EXTENDED LAY-UP

Many boilers used for heating or seasonal loads or for stand-by
service may have extended periods of non-use. Special attention
must be given to idle boilers so that neither waterside nor fireside
surfaces are allowed to deteriorate from corrosion.
Too many conditions exist to lay down definite rules. There are two
methods of storage: wet or dry. Your local Cleaver-Brooks authorized
representative can recommend the better method depending upon
circumstances in the particular installation.
3-16 Part No. 750-184

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.
Although pollution control regulations may continue to limit the
permissible sulphur content of fuel oils, care must be taken to avoid
corrosion problems that sulphur can cause, especially in a boiler
that is seasonally shut town. Dormant periods, and even frequent
shutdowns, expose the fireside surfaces to condensation below the
dew point during cooling. Moisture and any sulphur residue can
form an acid solution. Under certain conditions, and especially in
areas with high humidity, the corrosive effect of the acid will be
serious enough to eat through or severely damage boiler tubes or
other metal heating surfaces during the time that a boiler is out of
service.
The condition does not generally occur during normal firing
operation, because the high temperature of operation vaporizes any
condensation. However, proper boiler operation must be
maintained, especially with a hot water boiler, to prevent the flue
gases from falling below the dew point.
At the start of lay-up, thoroughly clean the fireside by removing any
soot or other products of combustion from the tubes, tube sheets
and other fireside surfaces. Brushing will generally suffice. Sweep
away or vacuum any accumulation. The fireside surfaces may be
flushed with water. However, all moisture must be eliminated after
flushing and the surface dried by blowing air or applying some form
of heat. It is good practice to protect the cleaned surfaces by coating
them with an anti-corrosive material to prevent rust.
To prevent condensation from forming in the control cabinet, keep
the control circuit energized. For extended lay-up periods, especially
where high humidity or large swings in ambient temperature occur,
the program relay should be removed and stored in a dr y
atmosphere.
Dry storage is generally employed when the boiler will be out of
ser vice for a significant period of time, or where freezing
temperatures may exist. In the dry storage method the boiler must
be thoroughly dried because any moisture would cause corrosion.
Both fireside and waterside surfaces must be cleaned of all scale,
deposits, soot, etc. Steps must be taken to eliminate moisture by
placing moisture-absorbing materials such as quick lime (at 2
pounds for 3 cubic feet of volume) or silica gel (at 5 pounds for 30
cubic feet of volume) on trays inside the vessel. Fireside surfaces
may be coated with an anti-corrosive material, or grease or tar
paint. Refractories should be brushed clean and wash-coated. All
openings to the pressure vessel, such as manhole and handholes,
should be shut tightly. Feedwater and steam valves should be
closed. Damper and vents should be closed to prevent air from
reaching fireside surfaces. Periodic inspection should be made and
absorption materials renewed.
Part No. 750-184 3-17

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. Variables preclude definite
recommendations. However, it is suggested that the pressure vessel
be drained, thoroughly cleaned internally, and re-filled to
overflowing with treated water. If deaerated water is not available,
the unit should be fired to boil the water for a short period of time.
Additional chemicals may be suggested by your local Cleaver-
Brooks authorized representative to minimize corrosion. Internal
water pressure should be maintained at greater than atmospheric
pressure. Nitrogen is often used to pressurize the vessel. Fireside
surfaces must be thoroughly cleaned and refractory should be
wash-coated.
3-18 Part No. 750-184

Chapter 4
Sequence of Operation
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
B. CIRCUIT AND INTERLOCK CONTROLS . . . . . . . . . . . . . . . . . . . . . 4-2
C. SEQUENCE OF OPERATION - OIL OR GAS . . . . . . . . . . . . . . . . . . . 4-4
D. FLAME LOSS SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
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.
Notice
Note: The make or model of the program relay provided will
vary depending upon job specifications. The following
sequence applies regardless of the make or model. Please
refer to the Wiring Diagram (WD) prepared by Cleaver-
Brooks for your specific installation.
Abbreviations for the various electrical components are listed in Figure 4-1.
The sequences outlined in Chapter 4 employ specific nomenclature to aid in
applying the text to the wiring diagram.
The burner and control system are in starting condition when the following
conditions exist:
• Boiler water is up to the correct level, closing the low-water cutoff switch.
• The low-water light (panel) is off.
• The operating limit pressure control (steam boiler) or the operating limit
temperature control (hot water boiler) and high limit pressure or
temperature control are below their cutoff setting.
• All applicable limits are correct for burner operation.
• The load demand light glows.
All entrance switches are closed and power is present at the line terminals
of:
• Blower motor starter
• Air compressor motor starter (if provided)
• Oil heater relay (if provided)
• Oil pump motor starter (if provided).
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 program relay. Chapters 6 and 7 contain operating
instructions and specific information on setting and adjusting the controls.
B. CIRCUIT AND INTERLOCK CONTROLS

The burner control circuit is a two-wire system designed for 115 Vac, 60 Hz,
single-phase power.
The electrical portion of the boiler is made up of individual circuits with
controls that are wired in a manner designed to provide a safe workable
system. The program relay provides connection points for the
interconnection of the various circuits.
The controls used vary depending upon the fuel oil or gas and the specific
requirement of applicable regulatory bodies. Refer to the boiler wiring
4-2 Part No. 750-184

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
• High limit control (HLC) - pressure or temperature
• Low-water cutoff (LWCO)
• Gas-oil selector switch (GOS) - (Combination burner only)
• Oil drawer switch (ODS)-Oil burner
• Low oil temperature switch (LOTS) - (Nos. 4, 5 and 6 oil only)
• Low gas pressures switch (LGPS)
• High gas pressure switch (HGPS)
• LE Proximity switch interlock
• Fuel valve interlock circuit
• Main gas valve auxiliary switch (MGVAS)
• Oil valve auxiliary switch (OVAS)
Blower Motor Starter Circuit

• Blower motor starter (BMS)
• Air compressor motor starter (ACMS) (if provided)
• Air purge valve (APV) (Nos. 5 or 6 oil only)
Running lnterlock Circuit

• Blower motor starter interlock (BMSI)
• Combustion air proving switch (CAPS)
• Atomizing air proving switch (AAPS) (if provided)
Low Fire Proving Circuit

• Low fire switch (LFS)
Pilot Ignition Circuit

• Gas pilot valve (GPV)
• Ignition transformer (IT)
• Gas pilot vent valve (GPVV) (if provided)
Flame Detector Circuit

• Flame detector (FD)
• Main fuel valve circuit
Part No. 750-184 4-3

• 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)
• Manual-automatic switch (MAS)
• 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.
High Fire Proving Circuit

• High fire switch (HFS)
Running Interlock and Limit Circuit

• Low oil pressure switch (LOPS)
• High oil pressure switch (HOPS)
• High oil temperature switch (HOTS)
• Auxiliary low-water cutoff (ALWCO)
C. SEQUENCE OF OPERATION - OIL OR GAS

On a combination fuel unit, the gas/oil switch must be set for the proper fuel.
The following sequence occurs with power present at the program relay (PR)
input terminals and with all other operating conditions satisfied.
Pre-Purge Cycle - When the burner switch (BS) is turned “on,” and controls
wired in the “limit” and “fuel valve interlock” circuits are closed and no flame
signal is present, the “blower motor start circuit” is powered energizing the
blower motor starter (BMS). The load demand light (LDL) turns on. When
firing oil, the air compressor motor starter (ACMS) (if provided) is also
powered. Air purge valve (APV) (Nos. 5 and 6 oil only) remains deenergized.
At the same time, the program relay signals the modulating damper motor
(MDM) to open the air damper. The damper begins to open and drives to its
full open or high fire position. Opening the damper motor allows a flow of
purging air through the boiler prior to the ignition cycle.
On certain boilers the circuitry will include a high fire switch (HFS). The
purpose of the switch is to prove that the modulating damper motor (MDM)
has driven the damper to the open position during the pre-purge cycle. In
this instance, the “high fire proving circuit” is utilized.
The controls wired into the “running interlock circuit” must be closed within
10 seconds after the start sequence. In the event any of the controls are not
4-4 Part No. 750-184

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.
To assure that the system is in low fire position prior to ignition, the low fire
switch (LFS) must be closed to complete the “low fire proving circuit.” The
sequence will stop and hold until the modulating damper motor (MDM) has
returned to the low fire position and the contacts of the low fire switch (LFS)
are closed. Once the low fire switch is closed, the sequence is allowed to
continue.
Notice
Note: The ignition trial cannot be started if flame or a flame
simulating condition is sensed during the pre-purge period.
A safety shutdown will occur if flame is sensed at this time.
Ignition Cycle - The ignition transformer (IT) and gas pilot valve (GPV) are
energized from the appropriate pilot ignition terminal.
Notice
Note: An oil-fired burner may be equipped with an oil pilot
rather than a gas pilot. The ignition sequence of both is
identical.
The pilot flame must be established and proven by the flame detector (FD)
within a 10 second period in order for the ignition cycle to continue. If for
any reason this does not happen, the system will shut down and safety
lockout will occur.
Notice
Note: Depending upon the requirements of the regulatory
body, insurer or fuel being burned, either the 10 or 15
second pilot ignition terminal may be used. Both provide the
same function but differ in time interval allowed for proving
main flame ignition. Refer to the boiler wiring diagram.
With a proven pilot, the main fuel valve(s) (OV or MGV) is energized and the
main fuel valve light (FVL) in the panel is lighted. The main flame is ignited
and the trial period for proving the main flame begins. It lasts 10 seconds
for light oil and natural gas, and 15 seconds for heavy oil. At the end of the
proving period, if the flame detector still detects main flame, the ignition
transformer and pilot valve are deenergized and pilot flame is extinguished.
Notice
Note: If the main flame does not light, or stay lit, the fuel
valve will close. The safety switch will trip to lock out the
control. Refer to flame loss sequence (section D) for
description of action.
! Warning
The cause for loss of flame or any other unusual condition should be
investigated and corrected before attempting to restart. Failure to
Part No. 750-184 4-5

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). This
allows operation in ranges above low fire.
With the manual-automatic switch (MAS) set at automatic, subsequent
modulated firing will be at the command of the modulating control (MC),
which governs the position of the modulating damper motor (MDM). The air
damper and fuel valves are actuated by the motor through a linkage and cam
assembly to provide modulated firing rates.
Notice
Note: Normal operation of the burner should be with the
switch in the manual-automatic position and under the
direction of the modulating control. The manual position is
provided for initial 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. Excess air flow subjects the
pressure vessel metal and refractory to undesirable
conditions. The effectiveness of nozzle purging is lost on a
No. 6 oil burner.
The burner starting cycle is now complete. The (LDL) and (FVL) lights on the
panel remain lit. Demand firing continues as required by load conditions.
Burner Shudown-Post Purge - The burner will fire until steam pressure or
water temperature in excess of demand is generated. With modulated firing,
the modulating damper motor (MDM) should return to the low fire position
before the 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. The blower motor continues to run to force
air through the boiler for the post purge period.
On a No. 6 oil burner, the air purge valve (APV) is powered from the blower
motor start circuit via the contacts of the air purge relay (APR) to provide an
air purge of the oil nozzle. The damper motor returns to the low fire position
if it is not already in that position.
The blower motor start circuit is deenergized at the end of the post purge
cycle and the shutdown cycle is complete.
The program relay is now ready for subsequent recycling, and when steam
pressure or water temperature drops to close the contacts of the operating
control, the burner again goes through its normal starting and operating
cycle.
D. FLAME LOSS SEQUENCE

The program relay will recycle automatically each time the operating control
closes, or after a power failure. It will lockout following a safety shutdown
4-6 Part No. 750-184

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. The control will lock out upon any abnormal
condition affecting air supervisory controls wired in the running interlock
circuit.
! Warning
The lockout switch must be manually reset following a safety
shutdown. The cause for loss of flame or any unusual condition
should be investigated and corrected before attempting to restart.
Failure to follow these instructions could result in serious personal
injury or death.
1. No pilot flame
The pilot flame must be ignited and proven within a 10-second period after
the ignition cycle begins. If not proven within this period, the main fuel valve
circuit will not be powered and the fuel valve(s) will not be energized. The
ignition circuit is immediately deenergized and the pilot valve closes, the
reset switch lights and lockout occurs immediately.
The blower motor will continue to operate. The flame failure light and the
alarm bell (optional) are energized 10 seconds later.
The blower motor will be deenergized. The lockout switch must be manually
reset before operation can be resumed (refer to the previous caution).
2. Pilot but no main flame
When the pilot flame is proven, the main fuel valve circuit is energized.
Depending upon the length of the trial-for-ignition period, the pilot flame will
be extinguished 10 or 15 seconds later. The flame detecting circuit will
respond to deenergize the main fuel valve circuit within 2 to 4 seconds to
stop the flow of fuel. The reset switch lights and lockout occurs immediately.
The blower motor will continue to operate.
The flame failure light and alarm bell (optional) are energized 10 seconds
later.
reset before operation can be resumed (refer to the previous caution).
3. Loss of flame
If a flame outage occurs during normal operation and/or the flame is no
longer sensed by the detector, the flame relay will trip within 2 to 4 seconds
to deenergize the fuel valve circuit and shut off the fuel flow. The reset switch
lights and lockout occurs immediately. The blower motor continues
operation. The flame failure light and alarm bell (optional) are energized 10
seconds later.
reset before operation can be resumed. (Refer to the previous caution.)
If the burner will not start, or upon a safety lockout, the trouble shooting
section in the operating manual and the technical bulletin should be referred
to for assistance in pinpointing problems that may not be readily apparent.
Part No. 750-184 4-7

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.
Knowledge of the system and its controls will make troubleshooting much
easier. Costly down time or delays can be prevented by systematic checks of
the actual operation against the normal sequence to determine the stage at
which performance deviates from normal. Following a routine may possibly
eliminate overlooking an obvious condition, often one that is relatively
simple to correct.
Remember, a safety device, for the most part, is doing its job when it shuts
down or refuses to operate. Never attempt to circumvent any of the safety
features.
Preventive maintenance and scheduled inspection of all components should
be followed. Periodic checking of the relay is recommended to see that a
safety lockout will occur under conditions of failure to ignite either pilot or
main flame, or from loss of flame.
4-8 Part No. 750-184

Table 4-1 Electrical Nomenclature MNEMONIC DESCRIPTION

BMSI Blower Motor Starter Interlock
MNEMONIC DESCRIPTION BMSS Boiler Master Selector Switch
A BS Burner Switch
A Amber (Color Of Pilot Light) BSS Boiler Selector Switch
AAFL Atomizing Air Failure Light BWPM Booster Water Pump Motor
AAFR Atomizing Air Failure Relay BWT Booster Water Thermostat
AAPL Atomizing Air Proven Light C
AAPS Atomizing Air Proving Switch CAFL Combustion Air Failure Light
AAPS-B Atomizing Air Proving Switch- Burner CAFR Combustion Air Failure Relay
AAPS-C Atomizing Air Proving Switch- Compressor CAP Capacitor
AASS Atomizing Air Selector Switch CAPS Combustion Air Proving Switch
AB Alarm Bell CCCB Control Circuit - Circuit Breaker
ACCR Air Compressor Control Relay CCF Control Circuit Fuse
ACM Air Compressor Motor CCRS Control Circuit Reset Switch
ACMCB Air Compressor Motor Circuit Breaker CCT Control Circuit Transformer
ACMF Air Compressor Motor Fuses CIPL Changeover In Progress Light
ACMS Air Compressor Motor Starter CL Canopy Light
ACMSI Air Compressor Motor Starter Interlock CLS Canopy Light Switch
AH Alarm Horn COPS Changeover Pressure Switch
ALFR Assured Low Fire Relay COR Changeover Relay
ALWCO Auxiliary Low Water Cutoff COTD Changeover Time Delay
AM Ammeter CPOL Control Power on Light
AMS Atomizing Media Switch CR Control Relay
AOV Auxiliary Oil Valve CSSS Control System Selector Switch
APR Air Purge Relay CWPM Circulating Water Pump Motor
APV Air Purge Valve CWPMCB Circulating Water Pump Motor Circuit Breaker
AR Alarm Relay CWPMF Circulating Water Pump Motor Fuses
AS Auxiliary Switch (Suffix) CWPMS Circulating Water Pump Motor Starter
ASR Alarm Silencing Relay CWPMSI Circulating Water Pump Motor Starter Interlock
ASS Alarm Silencing Switch CWPR Circulating Water Pump Relay
ASV Atomizing Steam Valve CWPS Circulating Water Pump Switch
AT Annunciator Transformer CWSV Cooling Water Solenoid Valve
AWCBDS Auxiliary Water Column Blowdown Switch D
B D Denotes Digester Gas Equipment (Prefix)
B Blue (Color of Pilot Light) DCVM Direct Current Voltmeter
BC Bias Control DG Draft Gauge
BDCS Breeching Damper Closed Switch DGHPV Digester Gas Housing Purge Valve
BDOS Breeching Damper Open Switch DHWC Deaerator High Water Control
BDRS Blowdown/Reset Switch DHWL Deaerator High Water Light
BFPL Boiler Feed Pump Light DHWR Deaerator High Water Relay
BFPM Boiler Feed Pump Motor DISC Disconnect (Entrance Switch)
BFPMCB Boiler Feed Pump Motor Circuit Breaker DLWC Deaerator Low Water Control
BFPMF Boiler Feed Pump Motor Fuses DLWL Deaerator Low Water Light
BFPMS Boiler Feed Pump Motor Starter DLWR Deaerator Low Water Relay
BFPS Boiler Feed Pump Switch DM Damper Motor
BFTS Back Flow Temperature Switch DMT Damper Motor Transformer
BHS Boiler - Header Switch DNS Day-Night Switch
BIOL Boiler in Operation Light DODE Delay On Deenergization (Timer)
BIOR Boiler In Operation Relay DOE Delay On Energization (Timer)
BM Blower Motor DPS Damper Positioning Switch
BMCB Blower Motor Circuit Breaker DS Door Switch
BMCR Blower Motor Control Relay E
BMF Blower Motor Fuses EDS Emergency Door Switch
BMPR Blower Motor Power Relay ESS Emergency Stop Switch
BMPS Blower Motor Purge Switch ETM Elapsed Time Meter
BMR Blower Motor Relay F
BMS Blower Motor Starter FADM Fresh Air Damper Motor
Part No. 750-184 4-9

MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION

FADR Fresh Air Damper Relay HGPS High Gas Pressure Switch
FD Flame Detector HHFL Header High Fire Light
FDJB Flame Detector Junction Box H/LWA High Low Water Alarm
FDPS Flow Differential Pressure Switch HLC High Limit Control
FFA Flame Failure Alarm HLFC High-Low Fire Control
FFL Flame Failure Light HLPC High Limit Pressure Control
FFR Flame Failure Relay HLTC High Limit Temperature Control
FGR Flue Gas Recirculation HMC Header Modulating Control
FGRCDTD Flue Gas Recirculation Cool Down Time Delay HOPL High Oil Pressure Light
FGRCPS Flue Gas Recirculation Cam Position Switch HOPR High Oil Pressure Relay
FGRFM Flue Gas Recirculation Fan Motor HOPS High Oil Pressure Switch
FGRFMS Flue Gas Recirculation Fan Motor Starter HOLC Header Operating Limit Control
FGRFMSI Flue Gas Recirculation Fan Motor Starter Interlock HOTL High Oil Temperature Light
FGRMVLS Flue Gas Recirculation Manual Valve Limit Switch HOTR High Oil Temperature Relay
FGRTD Flue Gas Recirculation Time Delay HOTS High Oil Temperature Switch
FORS First Out Reset Switch HPCO High Pressure Cutoff
FPM Feed Pump Motor HSPC High Steam Pressure Control
FPMS Feed Pump Motor Starter HSPL High Steam Pressure Light
FPR Feed Pump Relay HSPR High Steam Pressure Relay
FPS Feed Pump Switch HSTC High Stack Temperature Control
FRI Firing Rate Interface HSTL High Stack Temperature Light
FRP Firing Rate Potentiometer (O2 Trim) HSTS High Stack Temperature Switch
FS Flow Switch HWAR High Water Alarm Relay
FSS Fuel Selector Switch HWC High Water Control
FSSM Flame Signal Strength Meter HWCO High Water Cutoff
FVEL Fuel Valve Energized Light HWL High Water Light
FVL Fuel Valve Light I
FVR Fuel Valve Relay (I.C.) Instantaneously Closed
FWC Feed Water Control (I.O.) Instantaneously Open
FWVT Feed Water Valve Transformer IL Ignition Light
G INT Interval (Timer)
G Green (Color Of Pilot Light) IR Ignition Relay
GGL Gauge Glass Light IT Ignition Transformer
GOL Gas Operation Light J
GOR Gas-Oil Relay JPP Jackshaft Position Potentiometer
GOS Gas-Oil Switch L
GOR Gas-Oil Relay LAMPS Low Atomizing Media Pressure Switch
GPS Gas Pressure Sensor LASPS Low Atomizing Steam Pressure Switch
GPV Gas Pilot Valve LDL Load Demand Light
GPVV Gas Pilot Vent Valve LDPS Low Differential Pressure Switch
GR Gas Relay LDS Low Draft Switch
GSSV Gas Sensor Solenoid Valve LFAV Low Fire Air Valve
GVEL Gas Valve Energized Light LFGV Low Fire Gas Valve
GVTS Gas Valve Test Switch LFHTD Low Fire Hold Time Delay
H LFL Low Fire Light
HATC High Ambient Temperature Control LFOV Low Fire Oil Valve
HBWTC High Boiler Water Temperature Control LFPS Low Fire Pressure Switch
HBWTL High Boiler Water Temperature Light LFR Low Fire Relay
HFAV High Fire Air Valve LFS Low Fire Switch
HFGV High Fire Gas Valve LFS-A Low Fire Switch - Air
HFL High Fire Light LFS-F Low Fire Switch - Fuel
HFOV High Fire Oil Valve LFS-G Low Fire Switch - Gas
HFPS High Furnace Pressure Switch LFS-O Low Fire Switch - Oil
HFS High Fire Switch LFTC Low Fire Temperature Control
HFS-A High Fire Switch - Air LGPL Low Gas Pressure Light
HGPL High Gas Pressure Light LGPR Low Gas Pressure Relay
HGPR High Gas Pressure Relay LGPS Low Gas Pressure Switch
4-10 Part No. 750-184


LIAPS Low Instrument Air Pressure Switch (N.C.) Normally Closed
LLPC Low Limit Pressure Control (N.O.) Normally Open
LLPR Low Limit Pressure Relay NFL No Flow Light
LLR Lead Lag Relay NFR No Flow Relay
LLTC Low Limit Temperature Control NGHPV Natural Gas Housing Purge Valve
LLTR Low Limit Temperature Relay O
LOPL Low Oil Pressure Light ODA Outlet Damper Actuator
LOPR Low Oil Pressure Relay ODM Outlet Damper Motor
LOPS Low Oil Pressure Switch ODMAS Outlet Damper Motor Auxiliary Switch
LOTL Low Oil Temperature Light ODMT Outlet Damper Motor Transformer
LOTR Low Oil Temperature Relay ODS Oil Drawer Switch
LOTS Low Oil Temperature Switch OH Oil Heater
LPAPS Low Plant Air Pressure Switch OHCB Oil Heater Circuit Breaker
LPCO Low Pressure Cutoff OHF Oil Heater Fuses
LPS Low Pressure Switch OHR Oil Heater Relay
LSPAR Low Steam Pressure Alarm Relay OHS Oil Heater Switch
LSPC Low Steam Pressure Control OHT Oil Heater Thermostat
LSPL Low Steam Pressure Light OLC Operating Limit Control
LSPR Low Steam Pressure Relay OLPC Operating Limit Pressure Control
LSPS Low Steam Pressure Switch OL’S Thermal Overloads
LTS Lamp Test Switch OLTC Operating Limit Temperature Control
LWA Low Water Alarm OMPM Oil Metering Pump Motor
LWAR Low Water Alarm Relay OMPMF Oil Metering Pump Motor Fuse
LWCO Low Water Cutoff OOL Oil Operation Light
LWFL Low Water Flow Light OPM Oil Pump Motor
LWL Low Water Light OPMCB Oil Pump Motor Circuit Breaker
LWR Low Water Relay OPMF Oil Pump Motor Fuses
LWRR Low Water Reset Relay OPMS Oil Pump Motor Starter
M OPPM Oil Purge Pump Motor
MA Milli-amp OPR OIl Purge Relay
MAS Manual - Automatic Switch OPRL Oil Pump Running Light
MAM Micrometer OPRS Oil Pressure Sensor
MC Modulating Control OPS Oil Pump Switch
MCS Manual Control Switch OPSPM Oil Pump Supply Pump Motor
MDM Modulating Damper Motor OPV Oil Purge Valve
MDMAS Modulating Damper Motor Auxiliary Switch OR Oil Relay
MFC Manual Flame Control (Potentiometer) ORV Oil Return Valve
MFGRTS Minimum Flue Gas Recirculation Temperature Switch OSOV Oil Shutoff Valve
MFVL Main Fuel Valve Light OSPS O2 Set Point Switch
MFWV Motorized Feed Water Valve OSS Oil Selector Switch
MGV Main Gas Valve OT Outdoor Thermostat
MGVAS Main Gas Valve Auxiliary Switch OTS Oil Temperature Sensor
MGVEL Main Gas Valve Energized Light OV Oil Valve
MGVV Main Gas Vent Valve OVAS Oil Valve Auxiliary Switch
MLC Modulating Level Control OVEL Oil Valve Energized Light
(MOM) Momentary P
MOV Main Oil Valve P Denotes Propane Gas Equipment (Prefix)
MOVAS Main Oil Valve Auxiliary Switch PAASV Plant Air Atomizing Solenoid Valve
MOVEL Main Oil Valve Energized Light PAPS Purge Air Proving Switch
MPC Modulating Pressure Control PC Pump Control
MPCB Main Power Circuit Breaker PCL Purge Complete Light
MPP Manual Positioning Potentiometer PCR Pump Control Relay
(MR) Manual Reset PFCC Power Factor Correction Capacitor
MTC Modulating Temperature Control PFFL Pilot Flame Failure Light
MVA Make-Up Valve Actuator PFFR Pilot Flame Failure Relay
N PFPS Positive Furnace Pressure Switch
N Denotes Natural Gas Equipment (Prefix) PHGPS Pilot High Gas Pressure Switch
Part No. 750-184 4-11


PIPL Purge in Progress Light STLWC Surge Tank Low Water Control
PIS Pilot Ignition Switch STLWL Surge Tank Low Water Light
PLC Programmable Logic Controller STLWR Surge Tank Low Water Relay
PLGPS Pilot Low Gas Pressure Switch T
POL Power On Light (T.C.) Timed Closed
POV Pilot Oil Valve (T.O.) Timed Open
PPL Pre-Purging Light TB Terminal Block
PPR Post Purge Relay T/C Thermocouple
PPTD Post Purge Time Delay TC Time Clock
PR Program Relay TCR Time Clock Relay
PRL Purge Ready Light TD Time Delay
PRPTD Pre-Purge Time Delay TDAS Time Delay Auxiliary Switch
PR Program Relay TFWR Transistorized Feedwater Relay
PRPTD Per-Purge Time Delay TPL Transfer Pump Light
PS Power Supply TPM Transfer Pump Motor
PSF Power Supply Fuse TPMCB Transfer Pump Motor Circuit Breaker
PSS Pump Selector Switch TPMF Transfer Pump Motor Fuses
PSV Purge Solenoid Valve TPMS Transfer Pump Motor Starter
PT Purge Timer TPS Transfer Pump Switch
PTS Pump Transfer Switch U
PUCR Purge Complete Relay UVFD Ultra-Violet Flame Detector
PUR Purge Relay V
R V Voltmeter
R Red (Color of Pilot Light) VDR Voltage Differential Relay
RAR Remote Alarm Relay W
RATD Remote Alarm Time Delay W White (Color of Pilot Light)
RES Resistor WC Water Column
RML Run Mode Light WCBDS Water Column Blow Down Switch
RMR Release To Modulate Relay WF Water Feeder
RS Range Switch WFNL Water Flow Normal Light
RSR Remote Start Relay WLC Water Level Control
RTD Resistance Temperature Detector WO Denotes Waste Oil Equipment (Prefix)
S WTS Water Temperature Sensor
SBFPL Stand By Feed Pump Light Y
SBFPM Stand By Feed Pump Motor Y Yellow (Color of Pilot Light)
SBFPMCB Stand By Feed Pump Motor Circuit Breaker
SBFPMF Stand By Feed Pump Motor Fuses
SBFPMS Stand By Feed Pump Motor Starter
SBOV Surface Blow Off Valve
SBPS Sootblower Pressure Switch
SBR Sootblower Relay
SC Scanner
SCTS Supervisory Cock Test Switch
SDL Steam Demand Light
SHT Steam Heater Thermostat
SHV Steam Heater Valve
SLCL Safety Limits Complete Light
SPIR System Pump Interlock Relay
SPS Steam Pressure Sensor
SS Selector Switch
SSC Sequencing Step Controller
SSL Safety Shutdown Light
SSR Solid State Relay
SSV SpanSolenoid Relay
STHWC Surge Tank High Water Control
STHWL Surge Tank High Water Light
STHWR Surge Tank High Water Relay
4-12 Part No. 750-184

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. GAS PILOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
D. ATOMIZING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
E. FIRING PREPARATIONS FOR NO. 2 OIL (SERIES 100-200) . . . . . . 5-5
F. FIRING PREPARATION FOR NO. 6 OIL (SERIES 400-600) . . . . . . . . 5-7
G. FIRING PREPARATIONS FOR GAS (SERIES 200-400-700) . . . . . . . 5-9
H. IFGR SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
I. START-UP, OPERATING AND SHUTDOWN - ALL FUELS . . . . . . . . . 5-11
J. CONTROL OPERATIONAL TEST AND CHECKS . . . . . . . . . . . . . . . 5-16
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
are made.
The operator should be familiar with the burner, boiler, and all
controls and components. To quickly locate and identify the various
controls and components mentioned in the following paragraphs,
refer to the illustrations and the contents of Chapters 1, 2 and 3.
Instructions for adjusting major components are given in Chapter 6;
this should be reviewed prior to firing. The wiring diagram should
also have been studied, along with the firing sequence outlined in
Chapter 4.
! Warning
Be sure the starting instructions be read completely until they are
thoroughly understood, before attempting to operate the boiler,
rather than performing each operation as it is read for the first time.
injury or death.
Verify supply of fuel and proper voltage. Check for blown fuses, open
circuit breakers, dropped out overloads, etc. Check reset of all
starters and controls having manual reset features. Check the
lockout switch on the programmer and reset if necessary.
The boiler should be filled with water to the proper operating level
using water of ambient temperature. Be sure that treated feedwater
is available and used. In heating applications, the entire system
should be filled and vented. Refer to Chapter 3 for water
requirements. On a steam boiler, open the test valve to vent air
displaced during filling. Leave the test valve open until the escape
of steam is noted after the burner is operating.
! Warning
Prior to firing a boiler, be sure that discharge piping from safety
valves or relief valves, and discharge piping from all blowdown and
drain valves, is piped to a SAFE point of discharge, so that discharge
of hot water or steam cannot possibly cause injury. Failure to follow
these instructions could result in serious personal injury or death.
Check all linkage for full and free movement of the damper and
metering valves and cams. The check can be done by loosening the
linkage at the damper motor connecting arm and manipulating the
linkage by hand.
Check for rotation of all motors by momentarily closing the motor
starter or relay. The blower impeller rotation is counter-clockwise
5-2 Part No. 750-184

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).
Before operating the boiler feed pump or oil supply pump, be sure
all valves in the line are open or properly positioned.
FAN MOTOR ROTATION COUNTERCLOCKWISE
For safety reasons, perform a final pre-startup inspection, especially
checking for any loose or incomplete piping or wiring or any other
situations that might present a hazard.
Note: The pressure vessel support legs are welded to mounting skids in
front and secured by bolts at the rear of the pressure vessel. The
bolts are tightened for shipment. When the boiler is installed, and
prior to initial firing, the bolts securing the rear legs to the skid must
be loosened to allow for expansion and contraction caused by
differences in temperature between pressure vessel and skids and
to avoid damage to the equipment. Figure 5-1 Fan Motor CB-LE
B. CONTROL SETTINGS - STEAM AND HOT WATER

See Chapter 6 for adjustment instructions for the following controls.
Inspect the Operating Limit Control for proper setting.
1. The operating limit pressure control of a steam boiler should be
set slightly above the highest desired steam pressure, but at
least 10% lower than the setting of the safety valve.
2. The operating limit temperature control on a hot water boiler
should be set slightly above the highest desired water tempera- AIR COMPRESSOR ROTATION
ture and within the limits of the pressure vessel. CLOCKWISE FROM DRIVE END
Figure 5-2 Air Compressor CB-LE

Inspect the High Limit Control for proper setting. (CB Option)
1. On a high pressure steam boiler, the high limit pressure control
should be set approximately 10 psig above the operating limit
pressure control setting, if feasible, or midway between the oper-
ating limit pressure and the safety valve setting. The setting on a
low pressure steam boiler may be 2 or 3 psig above the operat-
ing limit setting, but must not exceed the safety valve setting.
2. On a hot water boiler, the high limit temperature control should
be 5-10°F above the operating limit temperature control setting
but within the limits of the design pressure of the pressure ves-
sel.
Inspect the Modulating Control for proper setting. The control must
be set and adjusted so that the modulating motor returns to low fire
position before the operating limit control opens. It is further
desirable to have its low point setting somewhat below the cut-in Figure 5-3 Fan Motor and Air
setting of the limit control so that the burner operates in low fire Pump, Model CB (clockwise
position for a brief period on each start rather than immediately rotation)
driving to a high fire position.
Part No. 750-184 5-3

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.
Inspect the Low-water Cutoff and Pump Control as well as the
Auxiliary Low-water Cutoff (if equipped with this optional device).
Check for freedom of float movement. Float movement can be
verified by observing the level of water in the gauge glass when the
water supply has been cut off either by the stopping of the feed
pump or by the closing of a valve, and the restarting of the pump or
opening of the valve when water is drained from the pressure vessel.
The importance of proper functioning of low-water controls cannot
be over-emphasized. Be sure that the control and the piping is level.
The settings of controls relating to fuel, either oil or gas, are covered
in subsequent sections.
In the event the boiler is equipped with optional control devices not
listed here, be certain to ascertain that their settings are correct. If
additional information is required, see your local Cleaver-Brooks
authorized representative or contact Cleaver-Brooks.
On initial start-up or whenever the boiler is placed into operation
from a “cold” start, the Manual-automatic Selector Switch should
be set at “manual” and the Manual Flame Control set at “close.”
After the boiler is in operation and thoroughly warmed, the selector
switch should be turned to “automatic,” so that the burner firing
rate may be controlled by the Modulating Control in accordance
with load demands.
Close all power entrance switches (supplied by others).
C. GAS PILOT
The gas pilot should be checked for satisfactory performance prior
to initial firing. Follow the pilot flame adjustment instructions given
in Chapter 6.
On initial starting attempts, several efforts might be required to fully
bleed the pilot line. While checking pilot adjustment, observe
whether the pilot flame is extinguished promptly when the burner
switch is opened. A lingering flame indicates a leaking gas pilot
valve, which is a condition requiring correction before proceeding.
D. ATOMIZING AIR
The supply and pressure of the atomizing air on an oil-fired burner
should be checked. Before starting, inspect the oil pump lube oil
level. Add oil if necessary to bring the level to the mid-point or
slightly higher of the sight glass. Use SAE 20 detergent oil of a grade
mentioned in Chapter 8 and fill in accordance with instructions
given there.
5-4 Part No. 750-184

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. If the burner is a combination
fuel burner, be sure that the gas/oil selector switch is set to “oil.”
Turn the Burner Switch on. The burner will cycle to the low fire pre-
purge position and stop there.
Observe the reading on the air pressure gauge. With no oil flow, the
pressure should be a minimum of 7 psi.
If there is no pressure, determine the cause and correct it before
proceeding. Check for obstructions in the air inlet line, incorrect
rotation, or a loose oil nozzle or other leaks. If the pressure is much
higher without any oil flow, check for obstruction in the discharge
line or at the oil nozzle. If there is no obstruction, restrict the air flow
by adjusting the air intake valve screw.
The air pressure will increase when an oil flow exists. At low firing
rate, the air pressure may rise to 12 psi or more.
Note: The air pressure should not exceed 35 psi at high fire. Greater
air pressure causes excessive wear of the air pump, increases
lube oil usage, and can overload the motor, thus causing
damage to the equipment.
Note: Abnormally high pressure indicated on the nozzle air pressure

gauge is an indication that the burner nozzle has become
clogged. In the event of clogging, check the nozzle and clean
as necessary.
After air flow has been verified, turn the burner switch off and return
the run/test switch to the run position.
E. FIRING PREPARATIONS FOR NO. 2 OIL (SERIES

100-200)
Prior to initial firing, oil flow and pressure should be established and
verified. Atomizing air pressure should also be established as
outlined in Section D.
See section H for IFGR setting procedures.
If the burner is a combination fuel model, be certain that the Main
Gas Shutoff Cock is closed and set the Gas/oil Selector Switch to
“oil.” Insert the burner drawer gun into its most forward position
and latch it in place.
Oil Flow - Open all valves in the oil suction and oil return lines.
If the oil supply tank is located above the level of the pump and flow
to the pump is by gravity, then it will usually be necessary to vent
the suction line to allow oil to fill the line. Venting the suction line
can generally be accomplished by cracking a union fitting, or by
opening the cap of the oil strainer using care to prevent spillage of
oil. Tighten the fitting or the cap as soon as oil flow appears.
Part No. 750-184 5-5

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. Non-lubricating fluids such as kerosene should
not be used for priming.
Prior to priming the suction line and the initial start, check to make
certain that all plugs, connections, etc., have been securely
tightened to prevent leaks.
If the fuel oil supply originates from a pressurized loop, it is
assumed that the pressure of the loop will be at a minimum of 75
psi. Under these conditions, the relief valve at the terminal block
should be adjusted to the point where it becomes inoperative (or
removed and openings plugged). To render inoperative, turn the
adjusting screw in as far as possible.
A standard equipped boiler has a selector switch incorporated in the
oil pump motor starter. Momentarily energize the starter to check for
proper pump rotation. With the rotation verified, operate the pump
to determine that oil circulation exists. Observe the regulated oil
pressure gauge for indication that flow is established. If no pressure
shows on the gauge after a few moments, stop the oil pump and re-
prime. If the supply tank is lower than the pump, it is possible that
the initial priming of the suction line, followed by operation of the
pump, will not establish oil flow. This might be caused by
obstruction in the suction line, excessive lift, inadequate priming,
suction line leaks, etc. If oil flow is not readily established, avoid
prolonged operation of the pump to minimize risk of damage to
internal parts of the pump. If oil flow is not established after a
second or third priming attempt, a full investigation is required to
determine the cause.
A vacuum (or a compound pressure-vacuum) gauge should be
installed at the suction port of the pump and its reading observed
and recorded for future guidance. If a vacuum condition exists, the
reading will reveal the tightness of the system. It is advisable to
maintain the vacuum reading at less than 10" Hg. A vacuum in
excess of 10" Hg. may allow oil to vaporize, causing cavitation, loss
of prime, and unstable firing condition.
Oil Pressure - Oil supply pressure is regulated by adjusting the
pressure relief valve at the oil terminal block (Figure 2-16). A
pressure gauge should be installed in the terminal block and the
relief valve adjusted to obtain a minimum reading of 75 psi when
the burner is firing at maximum rate.
When oil is supplied from a pressurized loop to a multiple boiler
installation, the relief valve in the loop should be properly adjusted
to provide this reading. In this circumstance, the relief valve at the
terminal block should be adjusted to the point when it will be
inoperative (or removed and openings plugged). To render
inoperative, turn the adjusting screw in as far as possible.
Adjustment may also be required to the regulator on the fuel oil
controller (Figure 2-17). The pressure regulating valve is equipped
with tubing that directs and adds atomizing air pressure to the
5-6 Part No. 750-184

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.
The pressure gauge will indicate a higher reading when the flame is
present and will increase as the firing rate increases. After the
burner is firing and when the air pump is running, final adjustment
can be made at the fuel oil controller.
Final regulation of oil flow to the nozzle can be done later, if
necessary, by adjusting the metering cam screws as outlined in
Chapter 6.
Starting - When all the conditions covered above and in Sections A,
B, C and D are assured, the burner is ready for firing.
F. FIRING PREPARATION FOR NO. 6 OIL (SERIES 400-

600)
Prior to initial firing, oil flow, pressure and temperature should be
established and verified. Atomizing air pressure should also be
established as outlined in Section D. Prior to firing, attach
combustion analysis instruments and monitor consistently
throughout the startup sequence. Refer to the adjustment
procedures in Chapter 6.
If the boiler is a combination fuel model, be certain that the main
gas shutoff cock is closed and set the gas/oil selector switch to “oil.”
Insert the burner drawer gun into its most forward position and latch
it in place.
Oil Flow - Open all valves in the oil suction and oil return lines.
Open the By-pass Valve on the fuel oil controller until oil flow is
established. Normally, the Orifice Valve is left in a closed position.
However, on cold starts, it may be opened for brief periods to aid in
establishing oil flow. The by-pass and orifice valves must be
returned to their closed positions as soon as oil flow is established
as indicated by a reading on the oil supply pressure gauge. Do not
attempt to set pressures while valves are open.
Momentarily energize the fuel oil pump starter to check for proper
pump rotation. With the rotation verified, prime the suction line
strainer with oil and turn the fuel oil pump switch to the "ON"
position. Check the oil supply pressure gauge for indication that oil
flow is established. If no pressure shows on the gauge after a few
moments, stop the oil pump and re-prime. Heavy oil in the storage
tank must be at a temperature to provide oil viscosity to permit flow
through the oil pump and suction line. If oil flow is not established
after several attempts, the conditions preventing oil flow must be
determined and corrected to avoid damage to the pump’s internal
mechanism.
A vacuum gauge should be installed in the oil suction line and its
reading observed and recorded for future guidance.
Oil Pressure - Oil pressure is regulated at several points. The first is
at the relief valve at the oil heater. The relief valve should be set so
Part No. 750-184 5-7

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. Since the air pump is not
running at this time, only tentative adjustments can be made.
Without the air supply, adjust the fuel oil pressure regulator so that
the burner oil gauge registers approximately 35 psi. Adjust the back
pressure relief valve so that its gauge reads about 10 psi less than
the burner gauge.
The pressure gauges will indicate higher readings when a flame is
present. The pressure will increase as the firing rate increases. The
pressure reading on the two gauges on the controller will, despite
the fluctuation, retain a nearly constant difference of 10 psi.
Final regulation of oil flow to the nozzle can be done, if necessary,
by adjusting the metering cam screws as outlined in Chapter 6.
Suggested oil pressures at high fire operation:
Oil Supply at the Fuel Oil Controller 75 psi
Regulated Oil Pressure Gauge 30-45 psi
! Caution
Before turning on the electric oil heater switch, be certain that the
heater shell is filled with fuel oil and the flow is established. Failure
to follow these instructions could result in equipment damage.
Oil Temperature - After determining that the heater shell is filled
and that fuel oil circulation exists, turn the oil heater switch to “on.”
Adjust the electric oil heater thermostat to maintain oil temperature
at approximately 200°F.
The electric heater on burners equipped for No. 6 fuel oil is sized
so that it is capable of supplying heated oil at a rate no greater than
that required for low fire operation and is primarily supplied for
convenience on cold starts. Heating coils utilizing either steam or
hot water are supplied to provide sufficient heat so that higher rates
of firing can be accomplished once steam pressure or hot water is
available. In normal operation, the thermostat governing the electric
heating element is kept at a lower setting than the thermostat
governing admission of steam to the heater, or of hot water
circulation, so that heating is not performed electrically except when
steam or hot water is not available.
Set the steam thermostat or the hot water thermostat to maintain
an oil temperature of 220-230°F. The electric heater will be turned
off automatically as soon as steam or hot water provides heat.
Note: The temperatures listed are tentative. The composition of the
fuel oil in a given grade can vary, necessitating a higher or
lower preheating temperature. The viscosity of the oil at the
nozzle should be less than 300 SSU and preferably less than
5-8 Part No. 750-184

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. Be certain that hot oil is
moving through the controller. The orifice gate valve must also be
closed. If the temperature drops, open the orifice gate valve until a
rise is noted, then close it.
Once the correct setting of the heater thermostats has been
established, set the low oil temperature switch at the point
approximately 30°F lower than the normal burning temperature. If
the system is equipped with a high oil temperature switch, it should
be set to open at 20 -30°F higher than normal burning temperature.
Note: The maximum oil temperature allowed in the system is
250°F.
Starting - When all the conditions covered above and in Sections A,
B, C and D are assured, the burner is ready for firing.
G. FIRING PREPARATIONS FOR GAS (SERIES 200-

400-700)
• Prior to initial starting, check the linkage attached to the gas
butterfly valve to assure that movement is free from binding.
• Verify the presence and availability of gas. On a new installation,
representatives of the gas utility should be present when gas first
flows into the system to supervise purging of the new gas line,
unless they have already done so.
• Determine that the pilot is operating properly, as outlined in
Section C, Chapter 5.
• Determine that sufficient pressure exists at the entrance to the
gas train by installing a test gauge downstream of the regulator.
• The gas pressure regulator must be adjusted to the proper
pressure level. Since the regulator is generally supplied by others,
adjustment should proceed according to instructions supplied by
its manufacturer.
It is necessary for the operator to know the burner requirements in
gas quantity and pressure. The information can generally be found
on the Dimension Diagram (DD) supplied by Cleaver-Brooks for the
specific installation. Should the information not be readily available,
consult the Cleaver-Brooks Service Department giving the boiler
serial number. Chapter 6 contains additional information along with
standard gas flow and pressure requirements.
• If the burner is a combination fuel model, set the gas/oil switch
to “gas.” Withdraw the oil burner gun and latch it in its rearward
position.
• On initial start-up, it is recommended that the main gas shutoff
cock remains closed until the programmer has cycled through
prepurge and pilot sequences. When the fuel light on the control
panel comes on, observe the action of the motorized gas valve
stem to determine that it opens when energized. As soon as it is
confirmed, turn the burner switch “OFF” and let programmer
finish its cycle. Check that the gas valve has closed. Again, turn
Part No. 750-184 5-9

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” and allow the programmer
to recycle normally for a new lighting trial. Several efforts may be
necessary to “bleed” air from the line.
! Warning
Do not repeat unsuccessful lighting attempts without re-checking the
burner and pilot adjustments. Failure to follow these instructions
could result in serious personal injury or death
Note: The burner and control system is designed to provide a
“prepurge” period of fan operation prior to establishing
ignition spark and pilot flame. Do not attempt to alter the
system or to take any action that might circumvent the
feature.
Once the main flame is established, turn the Burner Switch to the
"OFF" position and observe that the flame is extinguished promptly.
The flame may continue to burn for a second or two after normal
shutdown due to the gas remaining downstream from the fuel valve.
If the flame continues to burn for a longer period or during blower
motor spindown, it could indicate a main gas valve leak.
Immediately turn the Burner Switch off and close the main gas
cock. Investigate and correct the cause of the valve leakage before
relighting the burner. The main gas valve should provide a tight
seal, provided nothing prevents tight closure. Foreign material
may be present in either the new or renovated gas lines unless
adequate care is taken in cleaning and purging.
When the conditions covered in Section G and in Sections A, B and
C are assured, the burner is ready for firing.
H. IFGR SETUP
Note: Initial IFGR linkage settings and adjustments must be
established by a Cleaver-Brooks authorized representative.
Set up of the LE Option requires simultaneous consideration
of air-to-fuel ratios and NOx levels. This can only be
accomplished with proper combustion emissions monitoring
equipment with NOx, O2, CO, and smoke spot measuring
capability.
It is recommended that the final “installed” settings be recorded for
future reference; see Figures 5-5 and 5-6. The settings should be
marked on the linkage as well.
Normally, once the system has been set and adjusted, the settings
should not be changed unless conditions (including boiler settings)
change. In that case, it will be necessary to contact your local
Cleaver-Brooks authorized representative for assistance.
After the IFGR system is initially set up, it will start up with the
boiler as an integrated boiler system. After shut down periods in
which maintenance and /or adjustments have been performed on
5-10 Part No. 750-184

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.
4. Check fan impeller and motor rotation. Correct rotation is
counter-clockwise when viewed from the front of the boiler.
5. Verify that all the IFGR components are set to the settings
recorded on the Start Up report or as noted by the Cleaver-
Brooks authorized representative during original set up. Be sure
that all linkages are secure.
6. Start and warm the boiler as described in this Operation and
Maintenance manual.
7. Adjust the boiler components as described in this Operation and
Maintenance manual to achieve proper boiler operation.
Refer to Chapter 8 for instructions on cassette removal and
installation.
I. START-UP, OPERATING AND SHUTDOWN - ALL

FUELS
Depending upon the fuel being burned, the applicable previous
Note: On an initial starting
sections in Chapter 5 should be reviewed for preliminar y
attempt, several efforts
instructions.
might be required to
When firing with oil, be certain that the Burner Gun is in its most accomplish “bleeding” of
forward position and latched in place. When firing with gas, the fuel lines, main or pilot. If
burner gun should be properly withdrawn and latched in place. The ignition does not then
fuel selector switch should be, accordingly, set to either oil or gas. o c c u r, d o n o t r e p e a t
unsuccessful attempts
Set the Manual-Automatic Switch to “manual” and turn the manual
without rechecking the
flame control to “close.”
burner and pilot
Turn burner switch to “ON.” The load demand light should glow. adjustment.
The low-water level light should remain out, indicating a safe water
level in the boiler. The programmer is now sequencing. See Chapter
4 for sequence details.
Part No. 750-184 5-11

BOILER HP PPM NOX "A" "B" "C" "D" "E" "F" "G" "H" "J" "K"
60 10° 3/8" 3-1/8" #2 #2 11° 79° #8 40° 20°

30 10° 13/16" 3-1/8" #2 #2 11° 79° #8 40° 20°
125
25 10° 1" 5-3/4" #2 #5 11° 79° #8 30° 23°
20 10° 1-1/4" 6-1/2" #2 #5 7° 83° #8 25° 24°
60 10° 3/8" 3-1/8" #2 #2 11° 79° #8 40° 20°
30 10° 13/16" 3-1/8" #2 #2 11° 79° #8 40° 20°
150
25 10° 1" 5-3/4" #2 #5 8° 82° #8 37° 23°
20 10° 1-1/4" 6-3/8" #2 #5 10° 80° #8 33° 24°
60 10° 3/8" 3-1/8" #2 #2 11° 79° #8 40° 20°
30 10° 13/16" 3-1/8" #2 #2 11° 79° #8 40° 20°
200
25 10° 1" 2" #2 #5 0° 90° #8 46° 16°
20 NOT OFFERED
JACKSHAFT LINKAGE ROD
JACKSHAFT LINKAGE ROD POSITION LABEL QUICK DISCONNECT LINKAGE
GAS JACKSHAFT DRIVE ARM OIL JACKSHAFT DRIVE ARM

PROXIMITY SWITCH AND DRIVE ARM
(COMBINATION GAS & OIL SYSTEMS ONLY)
2”
2-3/4”
JACKSHAFT LINKAGE ROD
GAS JACKSHAFT DRIVE ARM

THE IFGR SYSTEM CAN BE EQUIPPED WITH
40∞ EITHER A SINGLE OR DUAL LINKAGE ARM,
OIL JACKSHAFT DRIVE ARM DEPENDING ON THE NUMBER OF FUELS USED
20∞ AND THE NOX LEVELS DESIRED. ALL SINGLE-
FUELED BOILERS HAVE A SINGLE DRIVE ARM.
DUAL-FUELED BOILERS MAY OR MAY NOT
HAVE A DUAL ARM, DEPENDING ON THE
OPTION PURCHASED.
Figure 5-4 Jackshaft Linkage Settings
5-12 Part No. 750-184

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
HOLE POSITION INTERNAL ARM
HOLE #5
(SLOW-OPENING DAMPER) HOLE # 8
(FAST OPENING DAMPER)
90∞
NOTE: RECORD “INSTALLED”
VALUES ON THIS ILLUSTRATION (SETTINGS HAVE TO BE
FOR FUTURE REFERENCE. VERIFIED AND RECORDED
AT THE TIME OF START UP)
A.______ EXTERNAL ARM HOLE POSITION

B.______ DEGREES
Figure 5-5 Overtravel Linkage Settings
“B”
“D”
LINKAGE CONNECTION POINT
HOLE #1
HOLE #2
NOTE: RECORD “INSTALLED” “C”
VALUES ON THIS ILLUSTRATION
FOR FUTURE REFERENCE.
A.______ FLANGE COLLAR SETTING FLANGE COLLAR
B.______ DAMPER POSITION AT LOW-FIRE

C.______ DAMPER LINKAGE ARM ANGLE (DEGREES)
D.______ HOLE POSITION NUMBER
“A”
DAMPER SHOWN IN THE LOW-FIRE POSITION
Figure 5-6
Part No. 750-184 5-13

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.
! Warning
Do not re-light the pilot or attempt to start the main burner, either
oil or gas, if the combustion chamber is hot and/or if gas or oil vapor
combustion gases are present in the furnace or flue passages.
injury or death
! Warning
The burner and control system is designed to provide a “pre-purge”
period of fan operation prior to establishing ignition spark and pilot
flame. Do not attempt to alter the system or take any action that
might circumvent the “pre-purge” feature. Failure to follow these
instructions could result in serious personal injury or death
After main flame ignition, the burner should be set on manual

control at its low fire setting (that is, with manual flame control at
“close”) until the boiler is properly warmed. Close the steam header.
In the case of a steam boiler, CLOSE THE TEST VALVE when steam
begins to appear.
A hot water boiler must have a continuous flow of system water
through the vessel during the warm-up period. The entire water
content of the system and boiler must be warmed prior to increasing
fuel input.
If the flame at low fire provides insufficient heat to reach normal
operating pressure or temperature after 30 minutes, gradually
increase the firing rate by turning the Manual Flame Control in one
point increments to no higher than the third cam screw. 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. At this point a combustion analysis should be made,
with instruments, and fuel flow regulated as required. Refer to the
adjustment procedures in Chapter 6. After making the high-fire
adjustment, manually decrease the firing rate, stopping at each cam
screw to analyze combustion gases, and adjust as required.
To properly perform the testing and adjusting, it is necessary that
the burner be allowed to fire at a maximum rate long enough to
achieve desired results.
Operating - Normal operation of the burner should be with the
switch in the automatic position and under the direction of the
modulating control. The manual position is provided for initial
5-14 Part No. 750-184

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. The
cycling of hot flame to cool air subjects the pressure vessel metal
and refractory to undesirable conditions.
With the switch set at “auto,” the burner will operate on a
modulating basis according to the load demand.
The burner will continue to operate with modulated firing until the
operating limit pressure or temperature is reached, unless:
1. The burner is manually turned “off.”
2. A low-water condition is detected by low-water level control.
3. The electrical or fuel supply is interrupted.
4. The combustion air pressure or atomizing air pressure drops
below minimum level.
Note: There can be other reasons for shutdown such as motor

overload, flame outages, tripped circuit breakers, blown
fuses, or through other interlock devices in the circuitry.
When the burner is shut down normally, by either the Operating

Limit Control or by manually switching the burner off, the load
demand light no longer glows.
Shutdown through conditions causing safety or interlock controls to
open will actuate the Flame Failure Light (and alarm if so equipped)
and the Load Demand Light will remain lit. The cause of this type
of shutdown will have to be located, investigated, and corrected
before operation can be resumed. Refer to the “trouble-shooting”
section in Chapter 7.
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. The
timer begins operation and the blower motor continues running to
force air through the furnace in the post-purge period.
At the end of the programmed post-purge period, the blower motor
is turned off. The air pump motor of an oil-fired burner is also turned
off. The timer has returned to its original starting position and stops.
The unit is ready to re-start.
! Warning
It is advisable to check for tight shut-off of fuel valves. Despite
precautions and strainers, foreign material in either new or
renovated fuel lines may lodge under a valve seat and prevent tight
closure. The situation is especially true in new installations.
Promptly correct any conditions causing leakage. Failure to follow
these instructions could result in serious personal injury or death.
Part No. 750-184 5-15

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.
The operating limit control may be checked by allowing steam
pressure or water temperature to increase until the burner shuts
down. Depending upon the load, it may be necessary to manually
increase the firing rate to raise steam pressure to the burner shut off
point. If the load is heavy, the header valve can be closed or
throttled until the pressure increases. Observe the steam gauge to
check the cut off pressure as the operating limit control shuts the
burner down. Slowly open the header valve to release steam
pressure and check the cut-in setting as the burner restarts. Check
the modulating control for the desired operating pressure range. See
Chapter 6 for instructions on the adjustment of controls.
The water temperature on a hot water boiler that may be operating
at less than full load may be raised by manually increasing the firing
rate until the burner shuts down through the action of the operating
limit control. Observe the thermometer to verify the desired settings
at the point of cut-out and again when the burner restarts. Return
the manual automatic switch to “automatic” and check the
modulating control for the desired temperature range. See Chapter
6 for instructions on the adjustment of the controls.
Check the proper operation and setting of the low-water cutoff (and
pump operating control, if used).
Proper operation of the flame failure device should be checked at
startup and at least once a week thereafter. Refer to 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.
Check for tight shut-off of all fuel valves. Despite precautions and
strainers, foreign material may lodge under a valve seat and prevent
tight closure. Promptly correct any conditions that cause leakage.
5-16 Part No. 750-184

Chapter 6
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
B. LINKAGE - MODULATING MOTOR AND AIR DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
C. MODULATING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
D. MODULATING MOTOR SWITCHES - LOW FIRE AND HIGH FIRE . . . . . . . . . . . . . . . . . . . . . . . . 6-4
E. BURNER OPERATING CONTROLS - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
F. MODULATING PRESSURE CONTROL (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
G. OPERATING LIMIT PRESSURE CONTROL (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
H. HIGH LIMIT PRESSURE CONTROL (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
I. MODULATING TEMPERATURE CONTROL (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
J. OPERATING LIMIT TEMPERATURE CONTROL (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
K. HIGH LIMIT TEMPERATURE CONTROL (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
L. LOW WATER CUTOFF DEVICES (Steam and Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
M. COMBUSTION AIR PROVING SWITCH (CAPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
N. ATOMIZING AIR PROVING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
O. GAS PILOT FLAME ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
P. GAS PRESSURE AND FLOW INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Q. GAS FUEL COMBUSTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
R. LOW-GAS-PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
S. HIGH-GAS-PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
T. FUEL OIL PRESSURE AND TEMPERATURE - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
U. FUEL OIL COMBUSTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
V. BURNER DRAWER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
W. OIL DRAWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
X. LOW-OIL-TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Y. HIGH-OIL-TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Z. LOW OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
AA. ELECTRIC OIL HEATER THERMOSTAT (400 and 600 Series - Steam) . . . . . . . . . . . . . . . . . . . 6-26
BB. STEAM OIL HEATER THERMOSTAT (No. 6 Oil) (400 and 600 Series - Steam) . . . . . . . . . . . . . 6-27
CC. HOT WATER OIL HEATER THERMOSTAT (400 and 600 Series) . . . . . . . . . . . . . . . . . . . . . . . 6-27
DD. STEAM HEATER PRESSURE REGULATOR (400 and 600 Series - Steam) . . . . . . . . . . . . . . . . 6-27
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. However, variable conditions such as
burning characteristics of the fuel and operating load conditions will
require further adjustment. Contact your local qualified Cleaver-
Brooks Service representative after installation to assure correct
start-up and maximum operating efficiency and economy.
A combustion efficiency analysis made during the initial start-up
will help to determine what additional adjustments are required in
a particular installation.
Prior to placing the boiler into service, a complete inspection should
be made of all controls, connecting piping, wiring, and all fastenings
such as nuts, bolts and setscrews to be sure that no damage has
occurred, or that adjustments have not changed during shipment
and installation.
The adjustment procedures in Chapter 6 apply to standard
components furnished on steam or hot water boilers fired with gas
and/or the various grades of oil.
B. LINKAGE - MODULATING MOTOR AND AIR

DAMPER
The linkage consists of various arms, connecting rods, and swivel
ball joints that transmit motion from the modulating motor to the
metering cam(s), to the rotary air damper, and to the gas butterfly
valve, and the IFGR system used on the CB-LE.
When properly adjusted, a coordinated movement of the damper
and metering cams within the limits of the modulating motor travel
is attained to provide proper fuel-air ratios through the firing range
and NOx emission levels.
In linkage adjustments there are several important factors that must
serve as guides.
1. The modulating motor must be able to complete its full travel
range.
! Caution
Do not restrict the full travel of the modulating motor. Failure to
follow these instructions could result in equipment damage.
2. Initial adjustment should be made with the motor in full closed
position, that is with the shaft on the power end of the motor in
its most counterclockwise position.
6-2 Part No. 750-184

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.
4. Over-travel linkage, where used, should not be required in order
to extend its spring to the fullest stretch.
With the modulating motor in the low fire position, the arm on its
shaft should be at an angle of 45° below the horizontal. The driven
arm on the jack shaft should also be 45° below horizontal. Secure
both arms and fit the connecting linkage rod in place between them.
Refer to Figure 6-1.
Position the oil and/or gas modulating cams on the jackshaft so that
the cam follower assembly is between the first and second cam
adjusting screws (under the first adjusting screw for High Turndown
Part No. 750-184 6-3

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. The screw is provided so that it is possible to tell, even
ROTARY AIR with the burner is in place, whether the damper rotor is in fully
DAMPER ARM
ROTARY AIR opened or closed position. Rotating the damper clockwise to the
STOP SCREW DAMPER
s t o p s c r e w o p e n s t h e d a m p e r. R o t a t i n g t h e d a m p e r
counterclockwise to the stop screw closes the damper. Normally,
the rate of flow of air through the damper with the rotor in low fire
position is about one-third of maximum for a standard burner.
The amount of angular movement controlling the rate of air flow is
determined by the location of the ends of the rotary air damper rod
DIFFUSER PLATE DAMPER ARM in both the jack shaft arm and the air damper arm.When the air
damper is in low fire position, the jackshaft arm should be at 45°
Figure 6-2 and the rotar y air damper arm should be at an angle of
approximately 60° below the horizontal (Figure 6-1). This will
ensure that the angular movement of the damper starts slowly,
increasing in rate as the high fire position is approached.
Prior to initially firing a boiler it is advisable to check for free
movement of the linkage. The damper motor must be allowed to
complete its full stroke and the damper must move freely from low
to high fire position. Adjustment of linkage connected to a gas
butterfly valve is described in Section Q of Chapter 6.
C. MODULATING MOTOR
The modulating motor has a 90° shaft rotation. The motor
manufacturer also provides a 160° stroke model for other
applications. If a replacement is obtained from someone other than
a Cleaver-Brooks Service or Parts representative, it may have an
incorrect stroke. To prevent damage, determine the 90° stroke
1
prior to installing a replacement.
2
The stroke may be determined by powering the motor and
1. ADJUST THE LINKAGE TOWARD connecting terminals R-B to actually determine the stroke as motor
THE DRIVE SHAFT FOR LESS
MOVEMENT. drives to an open position.
2. ADJUST AWAY FROM THE DRIVE
SHAFT FOR MORE LINKAGE
MOVEMENT. D. MODULATING MOTOR SWITCHES - LOW FIRE AND
Figure 6-3
HIGH FIRE
The modulating motor contains either one or two internal switches
depending upon application. The microswitches are actuated by
adjustable cams attached to the motor shaft.
Note: If the boiler is equipped with the CB-Hawk ICS, there are
no end switches. Do not attempt to adjust the
Modulating Motor if the unit is equipped with the CB-
Hawk ICS
Factory replacement motors have the cams preset. The low fire start
switch is set to make the red and yellow leads at approximately 8°
on motor closing. The high fire purge air proving switch (located in
6-4 Part No. 750-184

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.
E. BURNER OPERATING CONTROLS - GENERAL

Note: Adjustments to the boiler operating controls should be
made by an authorized Cleaver-Brooks Representative.
Refe r to t h e ap p r o p r i at e b oi l e r O p e ra t i o n a n d
Maintenance manual for specific information on boiler
startup and operation.
The standard boiler operating control package consists of three
separate controls, the High Limit Control, Operating Limit Control
and the Modulating control.
The High Limit Control senses the hot water temperature or steam
pressure. It is used as a safety limit to turn the burner off in the
event the operating limit control fails. The high limit control should
be set sufficiently above the operating limit control to avoid
nuisance shutdowns.
The Operating Limit Control senses temperature or pressure and
automatically turns the burner on to initiate the start up sequence
when required and turns the burner off to initiate the shutdown Figure 6-4 Steam Operating Controls
sequence when the demand is satisfied. The control must be set to
initiate startup only at the low fire position.
The Modulating Control senses changes in the hot water
temperature or steam pressure and signals the modulating motor to
control the flow of fuel and air to the burner. With either steam or
hot water boilers, the modulating control must be set to ensure the
burner is at its minimum low fire position before the operating limit
control either starts or stops the burner.
When adjusting or setting controls, first be sure all control devices
are securely mounted and level. With the temperature sensing
control, make sure the sensing bulb is properly bottomed in its well
and is secured against movement. Be sure the connecting tubing is
not kinked.
The dial settings are generally accurate, although it is not unusual
to have a slight variation between a scale setting and an actual
pressure gauge or thermometer reading. Always adjust control
setting to agree with pressure gauge or thermometer readings.
Accurate instrument readings are required. When necessary use
auxiliary test equipment to set controls.
Burner controls correctly set to match load demands will provide Figure 6-5 Hot Water Controls
operational advantages and achieve the following desirable
objectives:
• The burner will be operating in low fire position prior to shut
down.
• The burner will operate at low fire for a brief period on each start
during normal operation.
Part No. 750-184 6-5

• 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” whenever the pressure or temperature is less
than point B and “off” whenever pressure or temperature is greater
than point A. The distance between points A and B represents the
“on-off” differential of the Operating Limit Control.
In normal operation, the burner will shut down whenever the
pressure or temperature rises above setting A. At that point the
switch in the Operating Limit Control will open. As the pressure or
temperature drops back to B, the Operating Limit Control closes
and the burner will restart. The Modulating Control will signal the
modulating motor to be in a low fire position. If the load demands
exceed the low fire input potential, the Modulating Control will
increase the firing rate proportionately as pressure or temperature
falls toward point D. The modulating motor will stop at any
intermediate point between C and D whenever the fuel input
balances the load requirement.
100% D
Modulation Control Response

Increasing
Firing Rate Operating Limit Control

Response High Limit Control
Safety Shutdown
C
B A
Minimum Input
(Low Fire) Falling Temp.
or Pressure
Modulated Firing “ON - OFF”

Range Differential
Rising Temp.
or Pressure
Burner Off
(Burner ON) (Burner OFF) (Burner OFF)
0%
Boiler Temp.or Press Increasing
Figure 6-6 Firing Graph
6-6 Part No. 750-184

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.
The firing graph (Figure 6-6) shows that point B and point C do not
coincide. Extreme load conditions could require the points be
closely matched.
When set as shown, with a time lag between B and C, the burner
will be in a low fire position upon a restart and will fire at that rate
for a short period of time before falling pressure or temperature
requires an increase in the firing rate.
Note: On-Off cycling in excess of 8 cycles per hour will
shorten the life of the combustion air motor and cause
excessive wear on switch gear and pilot electrodes.
If points B and C overlap when restart occurs, the burner would
drive to a higher firing position immediately after the main flame
was proven.
Note: It is not recommended that the boiler controls be set so
as to overlap the modulating control range and
operating control range.
When firing a cold boiler, it is recommended that the burner be kept
at low fire, under manual flame control, until normal operating
pressure or temperature is reached. If the burner is not under
manual control on a cold start, it will immediately move toward high
fire as soon as the program control releases the circuit that holds
the burner in low fire. The modulating control will be calling for high
fire and the burner will move to that position as rapidly as the
damper motor can complete its travel.
Note: Rapid heat input can subject the pressure vessel metal
and refractory to undesirable conditions.
Do not operate the boiler at a temperature in excess of 90% of the
safety valve relief setting. The closer the operating pressure is to
the safety valve relief pressure, the greater the possibility of valve
leakage. Continued leakage, however slight, will cause erosion and
necessitate early safety valve replacement. The control settings on
a hot water boiler must be within the temperature limits of the
boiler.
Ideally, the boiler operating controls should be set under actual load
conditions. Especially under new construction conditions, the boiler
is initially started and set to operate under less than full load
requirements. As soon as possible thereafter, the controls should be
reset to provide maximum utilization of the modulating firing
system. To accomplish maximum utilization, and assuming that air/
fuel combustion ratios have been set, make the required
adjustments to the controls to bring the boiler pressure or
temperature up to meet the load requirements.
Part No. 750-184 6-7

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.
When the Modulating Control is set and the burner is in full high
fire, the scale setting of the Modulating Pressure Control on a steam
boiler will indicate the low point of the modulating range. The scale
setting of the Modulating Temperature Control on a hot water boiler
will have a reading that indicates the midpoint of the modulating
range.
The Operating Limit control should now be adjusted and the
differential established. In an installation that does not require a
very close control of steam pressure or water temperature the
adjustable differential (Figure 6-6 A to B) should be set as wide as
conditions permit, since a wide setting will provide less frequent
burner cycling.
The High Limit Control provides a safety factor to shut the burner
off in the event the Operating Limit Control should fail. The setting
of the control should be sufficiently above the Operating Limit
Control to avoid nuisance shutdowns. The setting must be within
the limits of the safety valve settings and should not exceed 90% of
the valve setting. The control requires manual resetting after it shuts
off the burner.
In the setting of the controls, consideration must be given to the
time required for a burner restart. Each start, requires a prepurge
period, plus the fixed time required for proving the pilot and main
flame. In addition, approximately one-half minute is required for the
damper motor to travel from low to high fire. The time lag may allow
pressure or temperature to drop below desirable limits.
F. MODULATING PRESSURE CONTROL (STEAM)

Turn the adjusting screw until the indicator is opposite the low point
of the desired modulating range. Modulated firing will range
between the low point and a higher point equal to the modulating
range of the particular control. In 0-15 psi controls the range is 1/
2 lb; in 5-150 psi controls the range is 5 lbs; in 10-300 psi controls
the range is 12 lbs.
! Caution
To prevent burner shutdown at other than low-fire setting, adjust the
modulating pressure control to modulate to low fire BEFORE the
operating limit pressure control shuts off the burner. Failure to
follow these instructions could result in damage to the equipment.
G. OPERATING LIMIT PRESSURE CONTROL (STEAM)

Set the “cut-out” (burner-off) pressure on the main scale using the
large adjusting screw. Set the differential on the short scale by
turning the small adjusting screw until the indicator points to the
desired difference between cut-out and cut-in pressures. The “cut-
6-8 Part No. 750-184

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. The control will break a circuit when pressure
reaches this point. The setting should be sufficiently above the
operating limit pressure control to avoid shutdowns, and preferably
not exceed 90% of safety valve setting. The control requires
manual resetting after tripping on a pressure increase. To reset,
allow pressure to return to normal and then press the reset button.
I. MODULATING TEMPERATURE CONTROL (HOT

WATER)
Turn the knob on the front of the case until the pointer indicates the
desired setpoint temperature. The desired set point is the center
point of a proportional range. The control has a 3 to 30° differential
and may be adjusted to vary the temperature range within which
modulating action is desired. With the cover off, turn the adjustment
wheel until pointer indicates desired range.
! Caution
To prevent burner shutdown at other than low-fire setting adjust
modulating temperature control to modulate low fire BEFORE
operating limit temperature control shuts off burner. Failure to
follow these instructions could result in damage to the equipment.
J. OPERATING LIMIT TEMPERATURE CONTROL (HOT

WATER)
Set “cut-out” (burner off) temperature on the scale by inserting a
screwdriver through the cover opening to engage the slotted head
adjusting screw. The “cut-in” (burner on) temperature is the cut-out
temperature MINUS the differential. The differential is adjusted
from 5 to 30° F.
K. HIGH LIMIT TEMPERATURE CONTROL (HOT

WATER)
Set the “cut-out” (burner off) temperature on scale using the
adjusting screw. The control will break the circuit and lock out on a
rise in water temperature above the setting. The setting should be
sufficiently above the operating limit temperature to avoid
unnecessary shutdowns. On a 30 psig hot water boiler, the setting
is not to exceed 240° F. The control requires manual resetting after
tripping on a temperature increase. To reset, allow the water
temperature to drop below the cut-out setting less differential, and
then press the manual reset button.
Part No. 750-184 6-9

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.
M. COMBUSTION AIR PROVING SWITCH (CAPS)

Air pressure against the diaphragm actuates the switch which,
when made, completes a circuit to prove the presence of
combustion air. The pressure of the combustion air is at its
minimum value when the damper is full open. The Combustion Air
Proving Switch should be adjusted with the damper fully open. It
should be set slightly below the minimum pressure, but not too
close to that point to cause nuisance shutdowns.
The run/test switch on the program relay should be set to TEST. Turn
the burner switch on. The blower will start (provided that all limit
circuits are completed) and the programmer will remain in the low-
fire (damper closed) portion of the prepurge.
Note: On an oil fired boiler, the atomizing air proving switch
(AAPS) must also be closed.
Note: On a combination fuel fired burner, the fuel selector
switch could be set at “gas” to eliminate the atomizing
air proving switch from the circuitry.
To have the modulating damper motor drive to high fire (damper
open), remove the cover from the motor and remove the wire from
terminal W.
Slowly turn down the Combustion Air Proving Switch, adjusting,
screw until it breaks the circuit. Here the programmer will lock out
and must be manually reset before it can be restarted. Add a half
turn or so to the adjusting screw to remake its circuit.
Recycle the program relay to be sure that normal operation is
obtained. Replace the wire on terminal W and reinstall the cover.
Return the test switch to the RUN position.
N. ATOMIZING AIR PROVING SWITCH

The air pressure against the diaphragm actuates the switch which,
when closed, completes a circuit to prove the presence of atomizing
air. The pressure of the atomizing air is at its minimum value when
there is no fuel present at the nozzle. Adjustment of the switch
should be done while the unit is running but not firing. The control
should be set slightly below the minimum pressure, but not too
close to that point to cause nuisance shutdowns.
The control adjustment may be made during the prepurge period of
operation by stopping the programmer during the prepurge period
through the use of the TEST switch. Refer to the control instruction
bulletin for details.
6-10 Part No. 750-184

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.
The adjustment of the air switch may be made either during the
damper closed or damper open position of prepurge. It is also
possible to make the adjustment with the relay stopped in the
damper open position in a similar manner to the adjustment of the
Combustion Air Proving Switch described in Section M.
After making the adjustment, recycle the control to be sure that
normal operation is obtained. The TEST switch must be set to RUN
position.
O. GAS PILOT FLAME ADJUSTMENT

The size of the gas pilot flame is regulated by adjusting the gas flow
through the Pilot Gas Regulator and the Pilot Adjusting Cock on the
front of the burner. The flame must be sufficient to ignite the main
flame and to be seen by the flame detector. But an extremely large
flame is not required. An overly rich flame can cause sooting or
carbon buildup on the flame detector. Too small a flame can cause
ignition problems.
Although it is possible to visibly adjust the size of the pilot flame, it
is preferable to obtain a microamp or voltage reading of the flame
signal.
The correct voltage or microamp readings can be found in the
information supplied with the flame safeguard system.
The program relay used may be of the type that provides message
information that includes a constant flame signal of dc voltage. In
this case a separate dc voltmeter is not required.
To Measure and Adjust Pilot:
1. When making a pilot adjustment, turn the Manual-Automatic
Switch to “manual” and the Manual Flame Control to “close.”
Open both the Pilot Cutoff Cock and the Pilot Adjusting Cock.
The Main Gas Cock should remain closed.
The regulator in the pilot line, if provided, is to reduce the gas
pressure to suit the pilot's requirement of between 5 to 10" WC.
Regulator adjustment is not critical; however, with a lower pressure
the final adjustment of the pilot flame with adjusting cock is less
sensitive.
2. Connect the micro-ammeter as outlined earlier.
3. Turn the burner switch on. Let the burner go through the normal
prepurge cycle. When the ignition trial period is signaled, set the
test switch to the TEST position to stop the sequence.
4. If the pilot flame is not established within 10 seconds, turn off
the burner switch. Repeat the lighting attempt.
Note: On an initial starting attempt, portions of the fuel lines
may be empty and require “bleeding” time. It is better to
accomplish this with repeated short lighting trial
Part No. 750-184 6-11

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. The pilot flame can then be observed through this open-
ing.
! Warning
Wear a protective shield or suitable glasses and keep eyes sufficiently
away from the sight tube opening to avoid serious personal injury or
death. Never remove the flame detector while the main burner is
firing. Failure to follow these instructions could result in serious
! Warning
When checking the pilot flame, be aware the electrode is energized.
injury.
6. To make the final adjustment, slowly close the Gas Pilot Adjust-
ing Cock until the flame can no longer be seen through the sight
tube. Then slowly open the cock until a flame providing full sight
tube coverage is observed.
The adjustment must be accomplished within the time limit of the
safety switch or approximately 30 seconds after the detector is
removed. If the control shuts down, manually reset it. Replace the
detector and repeat the process from step 5.
7. When a suitable flame as indicated in paragraph 6 is obtained,
replace the detector. Observe the reading on the micro-ammeter.
The reading should be between 2-1/4 and 5 microamps when
using a lead sulfide detector and a standard amplifier. See the
flame signal table in the manufacturer's bulletin for values of
other combinations.
The flame signal indicated on the annunciator type relay should not
be less than 10 Vdc, and may be as high as 20 Vdc or greater.
The reading must be steady. If the reading fluctuates, recheck the
adjustment. Be sure that the flame detector is properly seated and
that the lens is clean.
8. Return the test switch to the RUN position.
9. If main flame has not been previously established, proceed to do
so in accordance with instructions elsewhere in the manual.
10. The reading of the main flame signal should also be checked.
Observe the flame signal for pilot alone, pilot and main burner
flame together and the main burner flame at high, low, and
intermediate firing rate positions. Readings should be steady and
in the range indicated in paragraph 7. If there are any devia-
6-12 Part No. 750-184

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.
Once the optimum pressure has been established, it should be
recorded and periodic checks made to verify that the regulator is
holding the pressure at this level. Occasional modification in fuel
composition or pressure by the supplier may, at times, require
readjustment to return the burner to peak efficiency.
Pressure
The gas supplied must provide not only the quantity of gas
demanded by the unit, but must also be at a pressure high enough
to overcome the pressure loss due to the frictional resistance
imposed by the burner system and the control valves.
The pressure required at the entrance to the burner gas train for
rated boiler output is termed “net regulated pressure.” The gas
pressure regulator must be adjusted to achieve the pressure to
assure full input.
The pressure requirement varies with boiler size, altitude, and type
of gas train. See Tables 6-1 to 6-3.
The pressures listed are based on 1000 Btu/cu-ft natural gas at
elevations up to 700 feet above sea level. For installation at higher
altitudes, multiply the selected pressure by the proper factor from
Table 6-5.
Gas Flow
The volume of gas flow is measured in terms of cubic feet and is
determined by a meter reading. The gas flow rate required for
maximum boiler output depends on the heating value (Btu/cu-ft) of
the gas supplied and boiler efficiency. The supplying utility can
provide precise information on fuel heating value.
INPUT = OUTPUT x 100%

EFFICIENCY
GAS FLOW = INPUT
GAS BTU’s/Ft3
= OUTPUT x 100
EFFICIENCY x GAS BTU’s/Ft3
Part No. 750-184 6-13

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
125 1.5 0.8 - 3.0 1.5 0.7 - 3.0 1.5 0.7 - 3.0
150 1.5 1.0 -3.0 1.5 0.9 - 3.0 1.5 0.9 - 3.0
1.5 1.5 - 4.0 1.5 1.5 - 4.0

200 NA NA 2** 1.0 - 1.5 2** 1.0 - 1.5
*Table is based on Siemens gas train, which includes a regulating actuator.
**Oversize gas train
Table 6-2 Gas pressure requirements, NTI gas trains, CB-LE 125-200 HP
CBLE 15 PPM CBLE 9 PPM
Gas Train Pressure Range Gas Train Pressure Range
Boiler HP Size, in PSI Size, in PSI
125 1.5 3.3 - 6.0 1.5 3.3 - 6.0
150 1.5 3.9 - 6.0 1.5 4.1 - 6.0
200 1.5 4.5 - 7.0 1.5 4.5 - 7.0
Table 6-3 Gas pressure requirements, standard and oversize gas

trains, CB Ohio Special 100-225 HP
Boiler HP Gas Train Size (In.) Min. Pressure Max. Pressure PSI
100 1.5 14” WC 2
2 9” WC 1
125 1.5 19” WC 2
2 13” WC 1
150 1.5 25” WC 3
2 17” WC 2
175 1.5 35” WC 3
2 21” WC 2
200 1.5 45” WC 3
2 30” WC 2
2.5 24” WC 1.5
225 1.5 56” WC 3
2 37” WC 2.5
2.5 31” WC 2
Table is based on Siemens gas train, which includes a regulating STANDARD

actuator. OVERSIZE
UNDERSIZE
6-14 Part No. 750-184

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 1.05
2000 1.07 2 1.11
2500 1.09 3 1.18
3000 1.11 4 1.25
4000 1.16 5 1.32
6 1.39
5000 1.21
7 1.45
6000 1.25
8 1.53
7000 1.30
9 1.59
8000 1.35
10 1.66
9000 1.40
11 1.72
12 1.81
Pressure Correction 13 1.86
The flow rate outlined in Section P is based on a “base” pressure, 14 1.93

which is usually atmospheric or 14.7 psia.
15 2.00
Meters generally measure gas in cubic feet at “line” or supply

pressure. To convert the volume obtained from a meter reading into Table 6-6 Max. gas
cubic feet at base pressure, it is necessary to multiply the meter consumption (natural gas)
index reading by the correction factor obtained from Table 6-4.
CB-LE
Conversely: HP FT3/HR
125 5103
To determine what the meter index reading should be in order to
150 6124
provide the volume of gas required for input, divide the desired flow
200 8165
rate by the proper pressure correction factor. This answer indicates
the number of cubic feet at line pressure which must pass through
the meter to deliver the equivalent number of cubic feet at base CB OHIO SPECIAL
pressure. HP FT3/HR
125S 5230
As an example: 150S 6280
Assume that a 200 horsepower boiler is installed at 2,000 feet 175S 7350
above sea level; is equipped with a standard gas train and a high 200S 8370
turndown burner; and that 1,000 Btu natural gas is available with 225S 9415
an incoming gas pressure of 3 psig. The pressure and flow
requirements can be determined as follows:
Part No. 750-184 6-15

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. Multiplying
the results in a calculated net regulated gas requirement of
approximately 16.6" WC. This is the initial pressure to which the
regulator should be adjusted. Slight additional adjustment can be
made later, if necessary, to obtain the gas input needed for burner
rating.
Flow
Since the gas flow rate is based on standard conditions of flow,
correction must be made for the supply pressure through the meter
of 3 psig. Determine the flow rate by dividing the Btu content of the
gas into the burner input and “correct” this answer by applying the
correction factor for 3 psig (Table 6-4).
Btu/hr Input = CFH (Cubic feet/hour)
Btu/cu-ft
OR
8,369,000 = 8,369 CFH (At 14.7 Ib-atmospheric base 1,000 pressure)
THEN
8,369 = 7,092 CFH
1.18
This is the CFH (at line pressure) that must pass through the meter
so that the equivalent full input requirement of 25,100 CFH (at
base pressure) will be delivered.
Checking Gas Flow
Your gas supplier can generally furnish a gas meter flow chart from
which gas flow can be determined. After a short observation period,
the information aids in adjusting the regulator to increase or
decrease flow as required to obtain rated output.
Final adjustment of the gas fuel is carried out by means of the
adjusting screws in the gas modulating cam, while performing a
combustion efficiency analysis. See Section Q for details.
Note: The information given in this section is for all practical
purposes sufficient to set and adjust controls for gas
input. Your gas supplier can, if necessary, furnish exact
correction factors that take into consideration Btu
content, exact base pressure, specific gravity,
temperature, etc., of the gas used.
Q. GAS FUEL COMBUSTION ADJUSTMENT

After operating for a sufficient period of time to assure a warm
boiler, adjustments should be made to obtain efficient combustion.
6-16 Part No. 750-184

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 O2
present in the flue gas. O2 readings determine the total amount or
excess air in the combustion process, above the point of
stoichiometric combustion or perfect combustion. Stoichiometric
combustion is a term used to describe a condition when there is the
exact amount, molecule for molecule, of air for the fuel attempting
to be burned. This can be accomplished under laborator y
conditions, however it’s not practical to attempt to meet this
condition in a boiler. Stoichiometric combustion however, is the
reference point used when setting fuel/air ratios in a boiler.
There must always be excess air in the combustion process to
account for changes in boiler room temperature and atmospheric
conditions, and to ensure the combustion is on the proper side of
the combustion curve.
Proper setting of the air/fuel ratios at all rates of firing must be
established by the use of a combustion or flue gas analyzer. The
appearance or color of the gas flame is not an indication of its
efficiency, because an efficient gas flame will vary from transparent
blue to translucent yellow.
Most flue gas analyzers in use today measure the content, by
percentage of oxygen (O 2) and carbon monoxide (CO) either by
percent or parts per million (ppm). Carbon dioxide (CO 2) is not
normally measured with todays flue gas analyzers, but may be
displayed via a calculation.
The O2 levels through the entire firing range of the burner, low fire
to high fire should be tested. The burner manufacture s
recommendations on turndown should also be followed and the
turndown range of the burner should not be exceeded.
Part No. 750-184 6-17

12 FIRST VISIBLE TRACE OF STACK HAZE
11
PER CENT CO2 IN FLUE GAS

10
9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6
PER CENT O2 IN FLUE GAS PER CENT CO
60 50 40 30 20 15 10 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. Failure to follow these
instructions could result in damage to the equipment.
It is important to understand what the readings shown on an
instrument refer to when setting combustion in a boiler. To assist
with this understanding Figure 6-7 shows the relationship between
O2 levels (excess air) and the products of combustion for a typical
flue gas analysis (natural gas).
One of the products of combustion is CO2 (Carbon Dioxide). This is
shown in percentage.
Another product of combustion is CO (carbon monoxide) and is
shown in both percentage and parts per million (ppm). The
maximum CO level standardly allowed is less than 400 ppm.
However, this may change subject to local regulations.
The percent O 2 recorded on an instrument equates to percent
excess air, i.e. 3% O2 is approximately 15% excess air and 4% O2
6-18 Part No. 750-184

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 O2 readings of between 3% to 4%
be attained with less than 400 ppm CO, at high fire.
Using information from Section P of Chapter 6, determine the
standard conditions of gas pressure and flow for the size boiler and
the gas train on it. Calculate the actual pressure and flow through
the use of correction factors that compensate for incoming gas
pressure and altitude.
Basically, gas adjustments are made with a gas pressure regulator,
which controls the pressure, and with the butterfly gas valve (Figure
6-8) which directly controls the rate of flow.
In initially setting the linkage, back off the low fire stop screw on the
butterfly valve so that the valve is closed. Then run the screw out to
touch the arm, and give it two complete turns. Adjust the
connecting rod so that the override tension is released and so that TO FOLLOWER OF
GAS MODULATING CAM
the arm is now just touching the stop screw. Tighten the locknuts
on all ball joints.
The low fire setting should be regarded as tentative until the proper
HIGH
gas pressure for high fire operation is established. FIRE
To reach the high fire rate, turn the manual flame control switch BUTTERFLY GAS
VALVE ROD
toward “OPEN” in minor increments while monitoring combustion
for overly rich or lean conditions. LOW
OVERRIDE FIRE
SPRINGS BUTTERFLY GAS
Set and lock the high fire stop screw so that it is just touching the VALVE ARM
valve arm.
Determine the actual gas flow from a meter reading. (See section P
of Chapter 6.) With the butterfly valve open and with regulated gas
pressure set at the calculated pressure, the actual flow rate should
be close to the required input. If corrections are necessary, increase
or decrease the gas pressure by adjusting the gas pressure regulator, LOW FIRE HIGH FIRE
STOP SCREW STOP SCREW
following the manufacturer's directions for regulator adjustment.
When proper gas flow is obtained, take a flue gas reading. The O2
should be between 3% and 4% at high fire. Figure 6-8 Butterfly gas valve
If the fuel input is correct, but the O2 values do not fall within this
range, the air damper travel may need to be adjusted. Adjustment
of the air damper linkage is described in Section B of Chapter 6.
With the high-fire air/fuel ratio established, the gas pressure
regulator needs no further adjusting.
After being certain that the air control damper and its linkage are
correctly adjusted to provide the proper amount of combustion air,
and after adjusting the gas pressure regulator, final adjustment can
be made, if necessary, to the gas modulating cam to obtain a
constant air/fuel ratio throughout 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.
Part No. 750-184 6-19

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
decrease it. Flow rate is highest when the cam follower assembly is
closest to jackshaft.
Through the manual flame control switch, position the cam so that
the adjusting screw adjacent to the end or high fire screw contacts
the cam follower. Perform a combustion analysis at this point. If an
adjustment is necessary, turn the adjustment screw accordingly to
increase or decrease fuel flow. Take a combustion reading to verify
input. Repeat as necessary until the desired flow is obtained.
Repeat the process, stopping at each adjusting screw, until the low
fire adjusting screw is reached.
Note: Do not use any lubricant on the adjusting setscrews.
The set screws have a nylon locking insert intended to
provide locking torque and resistance to loosening and
a lubricant could damage equipment.
Standard Burner Low Fire Adjustment
The fuel input should be adjusted using the low fire cam screw, to
approximately 25% of that at high fire (Table 6-6). At low fire the
O2 flue gas reading should be between 6-7%.
It may be necessary to readjust the setting of the low fire stop screw
to obtain the proper air/fuel ratio at the low fire rate. To ensure that
the low fire position of the gas butterfly valve is always the same,
allow one turn of the stop screw for overtravel.
If the air damper needs to be adjusted in order to provide the correct
low fire air/fuel ratio, combustion must be rechecked at higher firing
rates and adjusted as required.
If all cam screws are properly adjusted, none will deviate from the
general overall contour of the cam face.
R. LOW-GAS-PRESSURE SWITCH
Adjust the scale setting to slightly below the normal burning
pressure. The control circuit will be broken when pressure falls
below this point. Since gas line distribution pressure may decrease
under some conditions, shutdowns may result if the setting is too
close to normal. However, regulations require that the setting may
not be less than 50% of the rated pressure downstream of the
regulator.
Manual resetting is necessary after a pressure drop. Press the reset
lever after pressure is restored. Be sure that the mercury switch
equipped control is level.
6-20 Part No. 750-184

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.
Manual resetting is necessary after a pressure rise. Press the reset
lever after pressure falls. Be sure that the mercury switch equipped
control is level.
T. FUEL OIL PRESSURE AND TEMPERATURE -

GENERAL
Variations in burning characteristics of the fuel oil may occasionally
require adjustments to assure highest combustion efficiency. The
handling and burning characteristics may vary from one delivery of
oil to another. Therefore, it is recommended that the oil system be
inspected from time to time to verify that pressures and viscosity are
at the proper operating levels.
Because of variation in oils, including chemical content, source,
blends, and viscosity characteristics, the temperatures and
pressures listed here will vary and thus may be regarded as
tentative and to be changed to provide best firing conditions. Figure
6-9 is an oil viscosity-temperature chart. It may be used as a guide,
although your oil supplier will be able to give you more exact
information based on an analysis of the oil.
Part No. 750-184 6-21

20000
10000
MAXIMUM LIMIT FOR PUMPING
4000
3000
2000
1500
1000
750
500
350
MAXIMUM LIMIT FOR ATOMIZATION
N
Viscosity - Saybolt Universal Seconds
O
200
.6
150
N
O
RECOMMENDED LIMIT FOR ATOMIZATION
100
.5
80
70
N
O
60 .4
50
45
N
40
O
.2
35
33
0 20 40 60 80 100 122 140 160 180 200 220 240 260 280 300
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.
Note: To prevent oil heater coking, the fuel oil pump must be
in operation during all times that an oil heater is in
service. During any time that the oil pump is not
operating, the oil heating system must be electrically
shut down by manually turning the oil heater switch to
the “off” position.
When the boiler is shut down, or switched over to gas firing, the
pump must operate for a sufficient period of time to cool the oil
heater. Similarly, if an electric, steam, or hot water oil heater is
removed for servicing, the temperature of the heater should be
reduced by circulating oil until it has cooled.
U. FUEL OIL COMBUSTION ADJUSTMENT

After operating for a sufficient period of time to assure a warm
boiler, adjustments should be made to obtain efficient combustion.
6-22 Part No. 750-184

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 O2
present in the flue gas. O2 readings determine the total amount or
excess air in the combustion process, above the point of
stoichiometric combustion or perfect combustion. Stoichiometric
combustion however, is the reference point used when setting fuel/
air ratios in a boiler.
There must always be excess air in the combustion process to
account for changes in boiler room conditions and to ensure the
combustion is on the proper side of the combustion curve.
Proper setting of the air/fuel ratios at all rates of firing must be
established by the use of a combustion gas analyzer. Efficient
combustion cannot be solely judged by flame condition or color,
although they may be used in making approximate settings.
Combustion settings should be done so that there is a bright sharp
flame with no visible haze.
Most flue gas analyzers in use today measure the content, by
percentage, of oxygen (O 2 ) and in some cases, smoke. Carbon
dioxide (CO2) is not normally measured with modern gas analyzers,
but may be displayed as a calculation.
The O2 levels through the entire firing range of the burner, low fire
to high fire should be tested. The burner manufacture s
recommendations on turndown should also be followed and the
turndown range of the burner should not be exceeded.
It is required to set the burner to operate with a reasonable amount
of excess air to compensate for minor variations in the pressure,
temperature, or burning properties of oil. Fifteen to 20% excess air
is considered reasonable. This would result in an O 2 reading of 3%
to 4%, at high fire.
Final adjustment to fuel input must be made to produce a minimum
of smoke. A maximum smoke spot density of a No. 2 for light oil, or
a No. 4 for heavy oil is acceptable, as measured in conformance to
ASTMD 2156-63T.
Through the use of the manual flame control, slowly bring the unit
to high fire by stages while monitoring combustion for overly rich or
lean conditions. At the high fire position, the air damper should be
fully opened and the air and oil pressure readings should be within
acceptable levels.
Take a flue gas analysis reading. If necessary, adjust the fuel oil
controller to increase or decrease oil pressure. Adjustments to the
pressure should be done before attempting to adjust the screws in
the metering cam. Ideally, the cam profile spring should be as close
to the cam casting as practical. It is more desirable to lower the oil
pressure to reduce flow, if necessary, than to extend the adjusting
screws to an extreme position in an effort to cut back flow.
After being certain that the air control damper and its linkage are
operating properly, final adjustment can be made, if necessary, to
Part No. 750-184 6-23

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.
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 fuel at that setting. The adjustment is made to
the metering cam by means of adjusting screws, which are turned
out (counterclockwise from hex-socket end) to increase the flow of
fuel and in (clockwise from hex-socket end) to decrease it. Flow rate
is highest when the cam follower assembly is closest to the
jackshaft.
If oil pressure, primary air pressure, and linkages are properly
adjusted, the metering cam should require minimal adjustment.
Using the flame control switch, position the cam so that the
adjusting screw adjacent to the end, high-fire screw, contacts the
cam follower. Make a combustion analysis at this point.
If an adjustment is necessar y, turn the adjustment screw
accordingly to increase or decrease fuel flow. Take a combustion
reading to verify input. Repeat as necessary until the desired flow is
obtained. Continue this pressure, stopping at each adjusting screw,
until the low fire position is reached.
Note: Do not use any lubricant on the adjusting setscrews.
These have a nylon locking insert intended to provide
locking torque and resistance to loosening and a
lubricant could damage the equipment.
Standard Burner Low Fire Adjustment (Heavy Oil)
The fuel input should be adjusted with the low fire cam screw, to
approximately 25% of that at high fire. At low fire the O2 flue gas
reading should be between 7- 8%.
V. BURNER DRAWER ADJUSTMENT

There are relatively few adjustments that can be made to the
burner; however, a check should be made to assure that all
components are properly located, and that all holding screws are
properly tightened. The diffuser location on gas fired boilers is quite
important. There should be 1/4” distance between the edges of the
diffuser fins and gas outlet tubes (spuds). The setting of an oil fired
burner is less exacting; the diffuser should be located with the skirt
approximately 1-1/8” from the end of the burner tube.
When the proper diffuser location is ascertained, the setting of the
nozzle in relation to the diffuser should be checked. This generally
is set at time of manufacture and seldom needs altering. It is most
important that oil spray does not impinge upon the diffuser. The
distance that the nozzle is behind the diffuser has some latitude,
and individual installations may require a slight deviation. Refer to
Figure 6-10 for initial setup dimensions.
6-24 Part No. 750-184

BURNER
BACKPLATE
ASSEMBLY
OIL NOZZLE BODY SPIDER
FRONT EDGE OF
NOZZLE ROTARY BURNER GUN DIFFUSER SKIRT
AIR DAMPER
PRESSURE STABILIZER DIFFUSER
GAUGE
NEOPRENE
“O” RING SEAL
OIL RING
INLET OIL NOZZLE
7/16"
ATOMIZING
AIR
1/4” 3/ ”
INLET 16 MAX.
IGNITION 3/32” MIN.
ELECTRODE IGNITION
GAS PILOT PIPEELECTRODE
BURNER DRAWER ELECTRODE
TUBE HOLDER
GAS PILOT
ADJUSTING
COCK
IGNITION
ELECTRODE GAS AND AIR
GLAND MIXTURE TO PILOT
GAS PILOT
ADJUSTING
COCK
AIR GAS PILOT ASPIRATOR
GAS
GAS SECONDARY PLUG

RETAINING
SCREW
ACCESS PLUG
Figure 6-10 Burner Drawer with Gas Pilot

Check the setting of the ignition electrode(s) for proper gap and
position. See Figure 6-10 for the gas pilot electrode and Figure 6-
11 for the light oil pilot. Be sure that the porcelain insulator is not
cracked and that ignition cable connections are tight.
The oil nozzle tip should be seated tightly in the body with the
swirler and the seating spring in place. See Section G in Chapter 8
for additional nozzle tip information. 3/16” 3/16”
Check to see that the flame detector sight tube and the gas pilot
tube extend through their respective openings in the diffuser face. 1/4”
W. OIL DRAWER SWITCH

The integral contacts of the control are closed by proper positioning Figure 6-11 Electrode spacing - oil
and latching of the oil drawer in its forward position (Figure 6-17). pilot
Adjustment of the switch must be such that its contacts open if the
oil drawer is not properly positioned for oil firing. The switch is
Part No. 750-184 6-25

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.
To adjust the control, insert a screwdriver into the center slot in the
control cover and turn the dial until the fixed (center) pointer is
approximately 30°F lower than the oil heater thermostat setting.
Turn the differential adjusting screw (located above dial) until the
movable indicator is approximately 5° F above the setting on the
main scale.
On a hot water boiler, the low-oil-temperature switch is an integral
part of the electric oil heater. The switch is non-adjustable and is
factory set at approximately 40° F below the maximum operating
temperature of the heater.
Y. HIGH-OIL-TEMPERATURE SWITCH
The H.O.T.S. prevents the burner from starting, or stops its
operation, if the temperature of the oil exceeds the normal operating
temperature.
To adjust, turn the dial until the pointer is approximately 25° F
above the normal operating temperature. The controls generally
have a set differential and will close 5° F below the setpoint.
Z. LOW OIL PRESSURE SWITCH

The L.O.P.S. prevents burner ignition, or stops its operation, when
the oil pressure is below the set point. Adjust the control by turning
the screw on top of control case to an indicated pressure 10 psi
below the established primary oil pressure setting indicated on the
oil supply pressure gauge. The switch will remain in a closed
position as long as the oil pressure exceeds this setting. The control
normally used automatically resets when pressure is restored after
a drop.
AA. ELECTRIC OIL HEATER THERMOSTAT (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.
The final setting of this thermostat should be at a temperature
approximately 15° F lower than the steam heater thermostat. This
eliminates the electric heater operation when the steam heater is
functioning. The electric heater is sized to provide sufficient heated
oil for low-fire operation on cold starts before steam is available.
6-26 Part No. 750-184

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.
The final setting of the thermostat should provide oil at a sufficient
temperature for efficient combustion based on flue gas analysis.
There is no need to heat the oil in excess of the temperature.
CC. HOT WATER OIL HEATER THERMOSTAT (400 AND

600 SERIES)
To adjust the thermostat, insert a screwdriver into the center slot in
the control cover and turn the dial until the pointer is at the desired
temperature level. The control generally has a set differential, and
will close 5°F below the setpoint.
The thermostat contacts close to energize the booster water pump,
which pumps water from the boiler through the heater. On cold
starts, it is normal practice to manually close the valve in the pump
discharge line until the boiler water temperature exceeds the
temperature of fuel oil entering the heater.
The electric oil heater on a hot water boiler burning No. 6 oil and
equipped with a hot water oil heater has a built-in adjustable
thermostat. The maximum temperature setting is stamped on its
dial. The desired temperature can be obtained by turning the
adjusting screw. The thermostat should be set at a temperature
approximately 15 degrees lower than the hot water heater
thermostat. Such a temperature prevents the electric heater from
operation when the water heater is functioning. The electric heater
is sized to provide sufficient heated oil for low-fire operation on cold
starts before hot water is available.
DD. STEAM HEATER PRESSURE REGULATOR (400

AND 600 SERIES - STEAM)
The regulator is provided on a boiler designed to operate at
pressures above 15 psi and reduces boiler steam pressure to the
level necessary for proper operation of the steam oil heater. The
pressure should be reduced to a point that permits sufficient
temperature to heat the oil, while allowing as continuous a steam
flow as possible. Pressure that is too high will result in frequent
cycling of the steam solenoid valve.
It is best to adjust the regulator under typical flow conditions. To do
so, it is suggested that the globe valve in the steam supply line be
closed so that there is no pressure on the regulator. Turn out the
adjusting screw fully to relieve compression on the regulator spring,
thus closing the regulator. With steam at normal pressure, open the
globe valve and then set the secondary pressure by turning the
adjusting screw or handle until the downstream gauge shows the
desired pressure.
Part No. 750-184 6-27

6-28 Part No. 750-184

Chapter 7 - Troubleshooting
Chapter 7
Troubleshooting
If the burner will not start or operate properly, the

trouble shooting chapter should be referred to for
! Warning assistance in pinpointing problems that may not be
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
and who have read and understand the contents indicates the failure condition. Refer to the control
o f t h i s m a n u a l . Fa i l u r e t o f o l l o w t h e s e bulletin for specifics and suggested remedies.
instructions could result in serious personal
injury or death Familiarity with the programmer and other controls
in the system may be obtained by studying the
contents of this manual. Knowledge of the system
and its controls will make trouble shooting much
easier. Costly down-time or delays can be prevented
! Warning by systematic checks of actual operation against the
Disconnect and lock out the main power supply normal sequence to determine the stage at which
in order to avoid the hazard of electrical performance deviates from normal. Following a
shock.Failure to follow these instructions could routine may possibly eliminate overlooking an
result in serious personal injury or death obvious condition, often one that is relatively simple
to correct.
Note: If your boiler is equipped with a CB- If an obvious condition is not apparent, check the
HAWK ICS boiler control system, refer to continuity of the circuits with a voltmeter or test
Manual No. 750-229 for specific lamp. Each circuit can be checked and the fault
in fo rm ati on rega rd in g pro ced ures isolated and corrected. Most circuitry checking can
described in this section be done between appropriate terminals on the
Chapter 7 assumes that the unit has been properly terminal boards in the control cabinet or the
installed and adjusted, and that it has been running entrance box. Refer to the schematic wiring
for some time. It is further assumed that the diagram for terminal identification.
operator has become thoroughly familiar with both
burner and manual by this time. The points under
each heading are set down briefly as possible
causes, suggestions or clues to simplify locating the
source of trouble. Methods of correcting the trouble,
once it has been identified, may be found elsewhere
in this manual.
Part No. 750-184 7-1

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. Limit circuit not completed—no voltage at end of limit circuit program relay
terminal.
A. Pressure or temperature is above setting of operation control. (Load demand
light will not glow.)
B. Water below required level.
1). Low-water light (and alarm horn) should indicate this condition.
2). Check manual reset button, if provided, on low-water control.
C. Fuel pressure must be within settings of low pressure and high pressure
switches.
D. Oil fired unit - burner gun must be in full forward position to close oil drawer
switch.
E. Heavy oil fired unit - oil temperature below minimum settings.
4. Fuel valve interlock circuit not completed.

A. Fuel valve auxiliary switch not enclosed.
NO IGNITION 1. Lack of spark.

A. Electrode grounded or porcelain cracked.
B. Improper electrode setting.
C. Loose terminal on ignition cable; cable shorted.
D. Inoperative ignition transformer.
E. Insufficient or no voltage at pilot ignition circuit terminal.
2. Spark but no flame.

A. Lack of fuel - no gas pressure, closed valve, empty tank, broken line, etc.
B. Inoperative pilot solenoid.
C. Insufficient or no voltage at pilot ignition circuit terminal.
D. Too much air.
3. Low fire switch open in low fire proving circuit.

A. Damper motor not closed, slipped cam, defective switch.
B. Damper jammed or linkage binding.
7-2 Part No. 750-184

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. Insufficient pilot flame.

MAIN FLAME
2. Gas Fired Unit.
A. Manual gas cock closed.
B. Main gas valve inoperative.
C. Gas pressure regulator inoperative.
3. Oil fired unit.

A. Oil supply cut off by obstruction, closed valve, or loss of suction.
B. Supply pump inoperative.
C. No fuel.
D. Main oil valve inoperative.
E. Check oil nozzle, gun and lines.
4. Flame detector defective, sight tube obstructed or lens dirty.
5. Insufficient or no voltage at main fuel valve circuit terminal.
BURNER STAYS IN LOW 1. Pressure or temperature above modulating control setting.

FIRE
2. Manual-automatic switch in wrong position.
3. Inoperative modulating motor (see Section F).
4. Defective modulating control.
5. Binding or loose linkage, cams, setscrews, etc.
SHUTDOWN OCCURS 1. Loss or stoppage of fuel supply.

DURING FIRING
2. Defective fuel valve; loose electrical connection.
3. Flame detector weak or defective.
4. Lens dirty or sight tube obstructed.
5. If the programmer lockout switch has not tripped, check the limit circuit for an
opened safety control.
Part No. 750-184 7-3

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.
SHUTDOWN OCCURS 7. Improper air/fuel ratio (lean fire).

DURING FIRING
A. Slipping linkage.
B. Damper stuck open.
C. Fluctuating fuel supply.
1). Temporary obstruction in fuel line.
2). Temporary drop in gas pressure.
3). Orifice gate valve accidentally opened (heavy oil).
8. Interlock device inoperative or defective.
MODULATING MOTOR 1. Manual-automatic switch in wrong position.

DOES NOT OPERATE
2. Linkage loose or jammed.
3. Motor does not drive to open or close during pre-purge or close on burner
shutdown.
A. Motor defective.
B. Loose electrical connection.
C. Damper motor transformer defective.
4. Motor does not operate on demand.

A. Manual/automatic switch in wrong position.
B. Modulating control improperly set or inoperative.
C. Motor defective.
D. Loose electrical connection.
E. Damper motor transformer defective.
7-4 Part No. 750-184

Chapter 8
Inspection and Maintenance
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
B. FIRESIDE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
C. WATER LEVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
D. WATER GAUGE GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
E. ELECTRICAL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
F. FLAME SAFETY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
G. OIL BURNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
H. GAS BURNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
I. MOTORIZED GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
J. SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
K. AIR CONTROL DAMPER, LINKAGE & CAM SPRING . . . . . . . . . . . 8-11
L. FORCED DRAFT FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
M. CB-LE FAN/MOTOR CASSETTE REMOVAL . . . . . . . . . . . . . . . . . 8-13
N. CB-LE INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . 8-13
O. CB-LE AIRBOX GASKET INSTALLATION . . . . . . . . . . . . . . . . . . . 8-14
P. CB-LE FAN/MOTOR CASSETTE INSTALLATION . . . . . . . . . . . . . . . 8-15
Q. SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
R. FUEL OIL METERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
S. AIR PUMP AND LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . 8-17
T. HEAD INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . 8-21
U. REFRACTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
V. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
W. OIL HEATERS - ELECTRIC, STEAM, HOT WATER . . . . . . . . . . . . . 8-28
X. COMBUSTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Y. AIR PUMP BELT (CB-OS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
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.
A. GENERAL
A well-planned maintenance program will help avoid unnecessary down-
time or costly repairs, promote safety, and aid boiler inspectors. An
inspection schedule with a listing of procedures should be established. It is
recommended that a boiler room log or record be maintained. Recording of
daily, weekly, monthly, and yearly maintenance activities provides a valuable
guide and aids in obtaining economical and lengthy service from Cleaver-
Brooks equipment. It is important to realize that the frequency of inspection
will depend on variable conditions such as load, fuel, system requirements,
boiler environment (indoor/outdoor), etc.
Good housekeeping helps maintain a professional appearing boiler room.
Only trained and authorized personnel should be permitted to operate,
adjust, or repair the boiler and its related equipment. The boiler room should
be kept free of all material and equipment not necessary to the operation of
the boiler or heating system.
Even though the boiler has electrical and mechanical devices that make it
automatic or semi-automatic in operation, the devices require systematic
and periodic maintenance. Any automatic feature does not relieve the
operator from responsibility, but rather frees the operator from certain
repetitive chores providing time to devote to upkeep and maintenance.
Alertness in recognizing an unusual noise, improper gauge reading, leaks,
etc., can make the operator aware of a developing malfunction and permit
prompt corrective action that may prevent extensive repairs or unexpected
downtime. Any leaks - fuel, water, steam, exhaust gas - should be repaired
promptly and under conditions that observe necessary safety precautions.
Preventive maintenance measures, such as regularly checking the tightness
of connections, locknuts, setscrews, packing glands, etc., should be
included in regular maintenance activities.
Periodic Inspection
Insurance regulations and local laws require periodic inspection of the
pressure vessel by an authorized inspector. Section H of Chapter 3 contains
information relative to the inspection.
Inspections are usually, though not necessarily, scheduled for periods of
normal boiler down time, such as an off season. This major inspection can
often be used to accomplish maintenance, replacement, or repairs that
cannot easily be done at other times. Inspection also serves as a good basis
for establishing a schedule for annual, monthly, or other periodic
maintenance programs.
While the inspection pertains primarily to the waterside and fireside surfaces
of the pressure vessel, it provides the operator an excellent opportunity for
8-2 Part No. 750-184

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.
Replacement spare parts, if not on hand, should be ordered sufficiently prior
to shutdown.
Notice
Note: Cleaver-Brooks genuine parts should be used to
ensure proper operation. Contact your local Cleaver-Brooks
representative for parts information and ordering.
Cleaver-Brooks boilers are designed, engineered, and built to provide long
life and excellent service. Good operating practices and conscientious
maintenance and care will assure efficiency and economy from their
operation, and will contribute to many years of performance.
A total protection plan includes a Planned Maintenance Program that covers
many of the items included in this chapter.
For information regarding a total protection plan, contact your local Cleaver-
B. 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 that will deteriorate fireside
metal.
Clean-out should be performed at regular and frequent intervals, depending
upon load, type, and quality of fuel, internal boiler temperature, and
combustion efficiency. A stack temperature thermometer can be used as a
guide to clean-out intervals since an accumulation of soot deposits will raise
the flue gas temperature.
Tube cleaning is accomplished by opening the front and rear doors. Tubes
may be brushed from either end. All loose soot and accumulations should Note: (CB-OS only) When cleaning
be removed. Any soot, or other deposits, should be removed from the dimple tubes use 814-00036
flue brush.
furnace and tube sheets.
Refer to Section U of Chapter 8 for instructions on properly closing rear
heads.
The flue gas outlet and stack should be inspected annually and cleaned as
necessary. Commercial firms are available to perform the work. The stack
should be inspected for damage and repaired as required.
The fireside should be thoroughly cleaned prior to any extended lay-up of the
boiler. Depending upon circumstances, a protective coating may be required.
See Section I in Chapter 3.
Part No. 750-184 8-3

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.
Always be sure of the boiler water level. On steam boilers, the water column
should be blown down daily. Check samples of boiler water and condensate
in accordance with procedures recommended by your local Cleaver-Brooks
authorized representative. Refer to Sections G and H in Chapter 3 for
blowdown instructions and internal inspection procedures.
Since low water cutoff devices are generally set by the original manufacturer,
no attempt should be made to adjust these controls to alter the point of low
water cutoff or point of pump cut-in or cut-out. If a low water device should
become erratic in operation, or if its setting changes from previously
established levels, contact your local Cleaver-Brooks authorized
representative.
Steam Boiler
The CB Level Master (CB-LE high pressure steam boilers) facilitates
preventive maintenance by providing a daily reminder to the operator that a
water column blowdown is required. A switch on the Level Master control
panel (optional external switch) allows blowdown to be performed while the
boiler is running. Upon completion of the procedure, the Level Master will
indicate a successful blowdown and will time-stamp the event and record it
in controller memory.
The Level Master also has provisions to test the Auxiliary Low Water Cutoff
(ALWCO). To perform the test, open the bottom blowdown valves with the
boiler running. When the water level reaches the ALWCO setpoint, the Level
Master will shut down the boiler. Restore water level and reset the Level
Master controller to continue operation.
For complete information on the Level Master see CB manual #750-233.
CB-LE low pressure steam and CB-OS boilers utilize a snap switch type low
water cutoff. In addition to a normal blowdown routine, the head assembly
should be removed and waterside components inspected annually. Ensure
that the float chamber and equalizing piping are free of sediment and debris.
Hot Water Boiler

It is impractical to blow down the low water cutoff devices on a hot water
boiler since the entire water content of the system would become involved.
Many hot water systems are fully closed and any loss of water will require
make-up and additional feedwater treatment that might not otherwise be
necessary. Since the boiler and system arrangement usually make it
impractical to perform daily and monthly maintenance of the low water
cutoff devices, it is essential to verify proper operation. Remove the
operating mechanism from the bowl annually or more frequently, if possible,
to check and clean float ball, internal moving parts, and the bowl housing.
Also check the cross-connecting piping to be certain that it is clean and free
of obstruction.
8-4 Part No. 750-184

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.
Close the valves when replacing the glass. Slip a packing nut, a 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. Slide the packing nuts onto each valve and
tighten.
! Warning
Do not attempt to change the gauge glass while the boiler is
in service. Failure to follow these instructions could result
in serious personal injury or death.
Check try-cocks and gauge cocks for freedom of operation and clean as
required. It is imperative that the gauge cocks are mounted in exact
alignment. If they are not, the glass will be strained and may fail
prematurely.
E. ELECTRICAL CONTROLS
The operating controls should be inspected monthly. Examine tightness of
electrical connections and keep the controls clean. Remove any dust that
accumulates in the interior of the control using a low pressure air. Take care
not to damage the mechanism.
Examine any mercury tube switches for damage or cracks. Dark scum over
the normally bright surface of the mercury, may lead to erratic switching
action. Be certain that controls are correctly leveled. The piping leading to
the pressure control actuators should be cleaned, if necessary. Covers should
be left on controls at all times.
Dust and dirt can cause excessive wear and overheating of motor starter and
relay contacts. Use a burnishing tool or a hard surface paper to clean and
polish contacts. Starter contacts are plated with silver and are not harmed
by discoloration and slight pitting. Replacement of the contacts is necessary
only if the silver has worn thin.
! Caution
Do not use files or abrasive materials such as sandpaper on
the contact points. Failure to follow these instructions could
result in equipment damage.
Thermal relay units (overloads) are of the melting-alloy type and, when
tripped, the alloy must be given time to re-solidify before relay can be reset.
If the overloads trip out repeatedly when the motor current is normal, replace
them with new overloads. If the condition continues after replacement, it will
be necessary to determine the cause of excessive current draw at the
overloads.
Power supply to the boiler must be protected with dual element fuses
(fusetrons) or circuit breakers. Similar fuses should be used in branch
circuits. Standard one-shot fuses are not recommended. See next page for
fuse sizes.
Part No. 750-184 8-5

8-6 Part No. 750-184

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. Also check to see that the amplifier and
the program module are tightly inserted.
The relay's self-diagnostic ability includes advising when it or its plug-in
modules are at fault and require replacement.
Your spare control should be stored in a dry atmosphere and wrapped in
plastic. During an extended shutdown (e.g., seasonal), the active control
should be removed and stored. Moisture can cause problems with control
operation.
It is recommended that service be rotated between the active and a spare
control to assure a working replacement is available.
! Warning
When replacing a control, be sure to lock out the main
power supply switch since the control is “hot” even though
the burner switch is off. Failure to follow these instructions
could result in serious personal injury or death.
Be sure the connecting contacts on the control and its base are not bent out
of position.
The flame detector lens should be cleaned as often as operating conditions
demand. Use a soft cloth moistened with detergent to clean the lens.
A safety check procedure should be established to test the complete
safeguard system at least once a month, or more often. Tests should verify
safety shutdown and a safety lockout upon failure to ignite the pilot, upon
failure to ignite the main flame, and upon loss of flame. Each of the
conditions should be checked on a scheduled basis.
The following tests should be used to test the complete safeguard system. If
the sequence of events is not as described, then a problem may exist.
Contact your local Cleaver-Brooks authorized representative for assistance.
Checking Pilot Flame Failure

Close the gas pilot shutoff cock. Also shut off the main fuel supply. Turn the
burner switch “on.”
The pilot ignition circuit will be energized at the end of the pre-purge period.
There should be an ignition spark, but no flame. Since there is no flame to
be detected, the program relay will signal the condition. The ignition circuit
will deenergize and the control will lock out on a safety shutdown. The flame
failure light (and optional alarm) will be activated. The blower motor will run
through the post-purge and stop.
Turn the burner switch off. Reset the safety switch. Reopen the gas pilot
shutoff cock and re-establish main fuel supply.
Checking Failure to Light Main Flame

Leave the gas pilot shutoff cock open. Shut off the main burner fuel supply.
Turn the burner switch on. The pilot will light upon completion of the pre-
Part No. 750-184 8-7

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. The blower motor will run
Turn the burner switch off. Reset the safety switch. Re-establish main fuel
supply.
Checking Loss of Flame

With the burner in normal operation, shut off the main burner fuel supply to
extinguish main flame.
The fuel valve(s) will be deenergized and the relay will signal the condition
within 4 seconds. The control will then lock out on a safety shutdown. The
flame failure light (and optional alarm) will be activated. The blower motor
will run through the post-purge and stop.
Turn the burner switch off. Reset the safety switch. Re-establish main fuel
supply.
G. OIL BURNER MAINTENANCE

The burner should be inspected for evidence of damage due to improperly
adjusted combustion. Any soot buildup on the diffuser or the oil nozzle
should be removed. The setting of the oil nozzle in relation to the diffuser
and other components is important for proper firing and should be checked.
Oil Strainers
Oil strainers should be cleaned frequently to maintain a free and full flow of
fuel.
Light Oil Strainers

The fuel oil strainer screen must be removed and cleaned at regular
intervals. It is advisable to remove the screen each month and clean
thoroughly by immersing it in solvent and blowing it dry with compressed
air. To remove, loosen the cover cap screw, being careful not to lose the
copper gasket. If necessary, tap the strainer cover gently to loosen. Check
the cover gasket for damage and replace if necessary. Slip pliers into the
cross on the top of the strainer and twist counter-clockwise to remove the
basket. Reassemble in reverse order.
Heavy Oil Strainers

Keep the cartridge of the oil strainer clear by regularly giving the exterior
handle one complete turn in either direction. Do this often until experience
indicates cleaning frequency necessary to maintain optimum conditions of
flow. If the handle turns hard, rotate the handle back and forward until it can
be turned through a complete revolution. Do not force it with a wrench or
other tool.
Drain the sump as often as experience indicates the necessity. Remove the
sump, or the head and cartridge assembly, for thorough cleaning and
inspection at frequent intervals. Exercise care not to damage the cartridge
8-8 Part No. 750-184

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. A routine check and any necessary cleaning should be made
during off periods or when the burner is firing on gas.
If at any time the burner flame appears “stringy” or “lazy,” it is possible that
the nozzle tip or swirler has become partially clogged or worn. Any blockage
within the tip will cause the air pressure gauge to increase above its normal
value.
Disassemble with the power off by unlatching and withdrawing the burner
gun. Insert the nozzle body into the hanger vice and use the spanner wrench
to remove the tip. Remove the swirler and seating spring being careful not
to drop or damage any parts.
Perform any necessary cleaning with a suitable solvent. Use a soft fiber
brush or pointed piece of soft wood for cleaning. Do not use wire or a sharp
metallic object, which could scratch or deform the orifices as well as the
precision ground surfaces of the swirler and tip. Inspect for scratches or
signs of wear or erosion, which may make the nozzle unfit for further use.
Take the necessary precautions in working with solvents.
The tip and swirler are a matched set, which are precision lapped at the time
of assembly. The close fit of the lapped surfaces must be maintained in order
to provide optimum performance. Additional lapping may be required to
provide better atomization for more efficient combustion. Do not interchange
parts if a spare is kept. In reassembling, be certain that the seating spring is
in place and that it is holding the swirler tightly against the tip. The swirler
is stationary and does not rotate, but rather imparts a swirling motion to the
oil.
See that the plugged hole is at the bottom of the nozzle body when the gun
is installed.
Cleaning Air Purge Nozzle (No. 6 Oil) and Back Pressure

Orifice Nozzle (No. 2 Oil)
The air purge nozzle and its strainer should be inspected periodically and
cleaned. The nozzle consists of a tip and internal core. Clean all internal
surfaces of the tip and the slotted parts of the core using a wood splinter to
avoid damage from scratching. Replace the core, setting it tightly but not
excessively.
Clean the strainer screen carefully to remove any foreign matter. Use suitable
solvents in cleaning. Extremely hot water at high velocity is also helpful in
cleaning. Replace strainer by screwing it into the nozzle body only finger
tight. Do not use an orifice of a size other than originally installed.
Ignition System
For best results, maintain the proper gap and dimensions of the ignition
electrode(s).
Inspect the electrode tip for signs of pitting or combustion deposits and dress
as required with a fine file. Inspect the porcelain insulator (s) for any cracks
Part No. 750-184 8-9

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. Ammonia will aid in removing carbon or soot.
Check ignition cables for cracks in the insulation. Also see that all
connections between the transformer and the electrodes are tight.
H. GAS BURNER MAINTENANCE

The gas burner components should be inspected for evidence of damage due
to improperly adjusted combustion. Combustion adjustments should be
checked monthly. See Section Q in Chapter 6.
Check periodically for a proper seal between the end of the burner housing
and boiler refractory. Any deterioration of the seal should be corrected, as an
improper or poor seal allows air leaks, which can cause overheating or
burning of the burner housing.
Whenever the burner is removed, the diffuser, gas housing and gas spuds
(HTB model only) should be checked for any deterioration. Verify that the
diffuser skirt conforms to the bore of the burner housing so as to minimize
the amount of combustion air which bypasses the diffuser. If the burner is a
high turndown burner (HTB) model, check to see that the diffuser is properly
located in reference to the gas spuds. There should be 1/4” between the
edge of the diffuser fins and the gas spuds when the burner is installed.
Check to see that the diffuser fins do not interfere with the gas ports or gas
spuds in the burner housing. See Section V in Chapter 6 for more
information.
Check the electrode setting for any cracks that might be present on the
porcelain insulator. Replace the electrode if cracking is evident, since
cracking can cause grounding of the ignition voltage. Inspect the tip of the
electrode for signs of pitting, combustion deposits and wear, and dress as
required with a fine file.
Periodically remove the access plug from the gas pilot aspirator and clean
out any accumulated lint or other foreign material.
Check the ignition cables for cracks in the insulation. Verify that all
connections between the transformer and the electrode are tight.
I. MOTORIZED GAS VALVE

The motorized gas valve (Hydramotor) operating mechanism is completely
immersed in oil and little maintenance is required because of the sealed
design. However, proper operation should be checked on a routine periodic
basis.
Keep outer parts of the valve clean, especially the stem between the operator
and the valve. A nicked, scored or otherwise damaged valve stem can cause
leakage. Do not remove dust covers if installed.
The packing gland is of the O-ring type. If oil is noticed around the operator
base or if leakage occurs, repair by replacing any leaking O-rings and refilling
the actuator with oil.
If the actuator is sluggish or fails to operate, even after the oil level is
checked, replace the entire operator portion.
8-10 Part No. 750-184

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.
A low hum or buzzing will normally be audible when the coil is energized. If
the valve develops a loud buzzing or chattering noise, check for proper
voltage and clean the plunger assembly and interior plunger tube thoroughly.
Do not use any oil. Be sure that the plunger tube and solenoid are tight when
reassembled. Take care not to nick, dent, or damage the plunger tube.
Coils may be replaced without removing the valve from the line.
! Warning
Be sure to turn off power to the valve in order to avoid
electrical shock. Failure to follow these instructions could
result in serious personal injury or death.
Check coil position and make sure that any insulating washers or retaining
springs are reinstalled in proper order.
K. AIR CONTROL DAMPER, LINKAGE AND CAM

SPRING
The burner air control damper should be checked for free movement as a
part of the monthly inspection. With the burner off and the jackshaft damper
control rod disconnected, the air control damper should rotate freely through
its entire range of movement. Any resistance to movement or excessive play
in the support bearing should be investigated and corrected before the
burner is put back in operation.
The overall tightness of the linkage assembly should be checked monthly. If
necessary, tighten the setscrews and the connections at the uniballs. Check
the uniballs for wear and replace if necessary.
The linkage assembly should be tight but should not bind. If the linkage
assembly is binding, determine the cause of the binding and correct as
necessary.
Linkage rod end attachment points should be marked on the variable
displacement linkage arms as an aid in subsequent reassembly.
Inspection of the air damper and linkage bearings should be performed on a
more frequent basis if the boiler is operating in a dirty environment.
The fuel cam profile spring should be inspected monthly for wear, scoring or
distortion. If any of the questionable conditions are found, the spring must
be replaced immediately to avoid the possibility of breakage in service. Use
care to avoid damaging the cam or spring during installation.
Lubricate occasionally with a non-gumming, dripless, high-temperature
lubricant such as graphite or a silicone derivative.
! Caution
Combustion should be checked and readjusted as required
whenever the burner is removed or any control linkage is
Part No. 750-184 8-11

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. Bolt the motor securely to the head.
2. Slide the fan onto the shaft, but do not tighten the setscrews.
3. Turn the spacers on the studs until they contact the headplate.
4. Place external tooth lockwashers next to the spacers and install the fan
housing on the studs. Hold the fan housing in place with nuts and
lockwashers. Finger tighten the nuts.
5. Slide the impeller outward until its vanes contact the fan housing. The
housing must be parallel to the impeller. Adjust the spacers as necessary
to align the housing with the impeller.
6. Slide the impeller toward the motor. Use a feeler gauge to obtain .030-
.050” clearance between the impeller and the housing.
7. Secure the key and then tighten the impeller hub setscrews. Using a
selected vane, rotate the impeller while checking to see that the clearance
between the impeller and the housing remains constant and within the
specified 0.030-0.050" clearance.
8. Install the air duct assembly through the head opening. Tighten the
screws securing the air duct to the fan housing only enough to create a
seal between the neoprene gasket and the housing.
9. After connecting the motor leads, verify that the impeller rotation is
counter-clockwise when viewed from the motor end.
Notice
Note: If the boiler is installed in a dusty location, check the
vanes occasionally for deposits of dust or dirt. These
buildups can cause a decrease in air capacity, or lead to an
unbalanced condition or cause damage to the equipment.
Do not hand operate the valve with less than 75% of the stamped set
pressure exerted on the underside of the disc. When hand operating, be sure
to hold the valve in an open position long enough to purge accumulated
foreign material from the seat area and then allow the valve to snap shut.
Frequent usage of the safety valve will cause the seat and disc to become
wire drawn or steam cut. This will cause the valve to leak and necessitate
down time of the boiler for valve repair or replacement. Repair of a valve
must be done only by the manufacturer or his authorized representative.
Avoid having the operating pressure too near the safety valve set pressure.
A 10% differential is recommended. An even greater differential is desirable
and will assure better seat tightness and valve longevity.
8-12 Part No. 750-184

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
removing the fan/motor cassette. Failure to follow these
instructions can result in electrical shock and serious
1. Disconnect and lock out electric power to the boiler.
! Caution
Chains or other devices used to attach a lifting device to the
fan/motor cassette must be arranged so the cassette does
not rotate or tilt when removed from the front head. Failure
to follow these instructions could result in damage to the
equipment.
2. Remove the fan/motor cassette fastening nuts.
! Caution
Be sure that the fan motor wiring and conduit are not
stretched during the fan/motor cassette removal. Failure to
follow these instructions can result in damage to the equip-
ment.
3. Swing the fan/motor cassette to the side and secure it to the boiler using
high strength cord. Do not over extend the motor wires.
N. CB-LE INSPECTION AND ADJUSTMENT

NOx levels should be checked periodically to ensure compliance with all
local and federal regulations, as well as to ensure that the boiler is operating
at maximum efficiency. Linkages should be inspected and free movement
(no binding) of the IFGR damper confirmed.
Increasing or decreasing NOx levels could indicate incorrect damper
positioning, loose linkages, an improper air-to-fuel ratio, or stack draft
changes. If adjustment is required, or if problems persist, contact your local
Cleaver-Brooks authorized representative for further assistance.
As ash and products of combustion pass through the IFGR damper, there
will be some accumulation on the damper, windbox, and other parts of the
IFGR system and burner.
To ensure proper operation of the IFGR system and burner, inspection and
cleaning should be performed at regular intervals depending on the load,
type of fuel, and combustion temperatures.
Part No. 750-184 8-13

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.
2. The clearance between the impeller and backplate should be checked,
and adjusted, if required. Impeller clearances must be as shown in Table
8-1.
3. The impeller clearance is checked by inserting a long feeler gauge of the
proper thickness between the impeller and the impeller housing. Impeller
clearances should be checked at the highest fin on the impeller (that fin
which is closest to the impeller housing), and must be checked at each
point where the housing is attached to the motor backplate.
4. If the impeller clearance is not correct at all points, make adjustments as
follows:
A. Loosen the retaining nuts on both sides of the impeller housing.
B. Adjust the retainers for the correct impeller clearance at two housing
attachment points 180× apart.
C. Adjust the retainers for correct clearance at the housing attachment
points 90× from those initially adjusted.
D. Adjust for correct impeller clearance at the remaining attachment
points.
5. Check and replace any gaskets that have been damaged. Gaskets that
have been in use for one year or more should be replaced. In particular,
inspect the airbox gasket for damage. If it needs to be replaced, refer to
Section O for installation instructions.
Table 1: Impeller Clearances
STANDARD 30 PPM
20 PPM
60 PPM 25 PPM
.040 ±.010 0.050 +.010/– .060 +.005/–.000

.005
O. CB-LE AIRBOX GASKET INSTALLATION

If the fan/motor cassette is opened for any reason after the unit has been in
operation for one year, the airbox gasket should be replaced.
! Caution
When replacing the airbox gasket, use only Cleaver-Brooks
components. Failure to use components designed for this
application can result in improper combustion. Failure to
follow these instructions can result in equipment damage
1. Attach the airbox gasket to the inlet box with high-temperature silicone
adhesive/sealant, using two beads of silicone about 1/4” in from each
side of the gasket (gasket surface is 2" wide).
8-14 Part No. 750-184

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. CB-LE FAN/MOTOR CASSETTE INSTALLATION

The fan/motor cassette can be closed as follows:
1. Check that all adjustment screws are tight, and check the linkage and
IFGR damper for free movement before closing the unit.
2. Position the cassette into the front door.
3. Slide the cassette into position until it begins to contact the backplate
gasket, then measure the clearance between the cassette flange and the
front door mounting face. There must be clearance of at least 1/4” to
provide adequate gasket compression when the cassette is mounted
tightly to the door.
4. Secure the cassette with the fastening nuts.
! Warning
Do not remove the davit arm assembly from the motor/fan
cassette without first verifying that the cassette is securely
bolted to the boiler. Failure to follow these instructions can
result in serious personal injury or death.
5. After the cassette has been secured to the front head, reconnect the davit
to the front door by screwing in the retaining bolt at the top centerline.
Check occasionally that the fan is securely tightened to the motor shaft.
Check the clearance between the fan vanes and housing as outlined above.
Notice
Note: If the boiler is installed in a dusty location, check the
vanes occasionally for deposits of dust or dirt. These
buildups can cause a decrease in air capacity, or lead to an
unbalanced condition or cause damage to the equipment
Q. SAFETY VALVES
The safety valve is a very 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 the 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
in accordance with sections VI and VII of the ASME Boiler and Pressure
Vessel Code.
Avoid excessive operation of the safety valve; even one opening can provide
a means of leakage. Safety valves should be operated only often enough to
assure that they are in good working order. When a pop test is required, raise
the operating pressure to the set pressure of the safety valve, allowing it to
open and reseat as it would in normal service.
Part No. 750-184 8-15

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. Failure to follow these instructions
can cause damage to the equipment.
If replacement of the metering valve packing is necessary, procure kit P/N
880-370 and install in accordance with the following procedure.
1. Shut off the oil flow. Be sure no pressure shows on the gauge.
2. Match-mark the cam hub and drive shaft. Match marking will enable
replacement of the cam in its original position and result in a minimum
of cam adjustment when the burner is refired.
3. Clamp or hold the metering stem in the down position.
4. Loosen the setscrews in the cam hub and rotate, or move the cam to a
position where it does not interfere with stem removal.
5. Withdraw the metering valve stem and spring. Do not drop or mishandle.
Check for nicks or scratches. Check that the pin holding the metering
portion is not protruding. Back off the packing gland.
6. Remove the capscrews holding the jack shaft support bracket so that the
bracket can be moved. It may also be necessary to loosen the supporting
bracket on the far end of the shaft.
7. Remove the existing packing and guides. Do not reuse the packing and
guides.
8. Lightly coat the stem with the lubricant provided with the packing kit.
Place the new packing, O-rings and guides onto the stem. The beveled
face of the guides and the teflon rings must face upward, with the
exception of the upper brass guide which is faced down. Be sure that the
O-rings are properly located.
9. Using the stem as a guide, insert the assembled packing into the cavity,
then withdraw the stem.
10.In the event the packing is too high, remove one teflon packing from each
side of the middle brass guide as needed.
Under no circumstances eliminate the two teflon packings on only one side
of the brass guide.
11.Replace the gasket, put the support in place, and secure all fastenings.
12.Replace the metering stem and spring. Lightly lubricate the stem to
facilitate insertion and easy movement. Use care when inserting so that
the orifice and the stem are not damaged.
13.Snug the packing gland, but only sufficiently to place slight tension on
the packing. The stem must move freely from the force of the spring.
14.Work the stem up and down several times to ensure that it moves freely.
8-16 Part No. 750-184

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.
17.Tighten the packing gland after a period of operation, if necessary, to
maintain proper tension on the packing. Do not overtighten.
If there are indications that the oil metering valve has become clogged at its
orifice, it will be necessary to disassemble the control to remove the
obstruction. Clean the slotted stem of the oil metering valve with suitable
solvent and blow-dry with an air line. Follow the procedure outlined above
when removing or reinstalling the metering valve stem. Also check all fuel
line strainers.
Should a pressure adjusting or relief valve become clogged, disassemble by
releasing the locknut and backing off the screw to relieve tension on
diaphragm. Remove the valve cover and the diaphragm to expose any dirt
or foreign material which may have entered the valves. Clean out carefully
and reassemble. It is recommended that the diaphragms be replaced
annually.
S. AIR PUMP AND LUBRICATING SYSTEM
Air Pump
The air pump itself requires little maintenance. However, the life of the pump
is dependent upon a sufficient supply of clean cool lubricating oil. The oil
level in the air-oil tank must be observed closely. Lack of oil will damage the
pump making replacement necessary. Disassembly or field repairs to the
pump are not recommended.
Lubricating Oil
Lubricating oil must be visible in the gauge glass at all times. There is no
specific level required as long as oil is visible. Do not operate if oil is not
visible.
Oil with proper viscosity must be used. SAE 20 detergent is recommended,
although SAE 10 detergent is also permissible.
When adding oil:
Remove the cover from the fill pipe and add oil through the conical strainer
in the pipe with the unit running.
! Caution
Oil must NEVER be added unless the pump is in operation
and the strainer screen is in place. Failure to follow these in-
structions can cause damage to the equipment.
The oil and its container should be clean. Although there is a strainer in the
lube oil line, its purpose is to remove any unwanted materials rather than to
act as a filter for unclean oil.
Part No. 750-184 8-17

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. It is
possible to visually verify oil flow during operation by removing the filler cap
and checking the flow. If necessary, the strainer may be cleaned during
operation.
In the event it is necessary to clean the strainer during operation, clean it
and replace immediately. It can be cleaned by immersing in solvent and
blowing it dry with compressed air. Do not operate without the strainer any
longer than necessary, and never add new oil unless it is in place. A spare
strainer basket can be obtained, if desired, and used on a rotating basis
while the other is serviced.
Air Cleaner
Never operate the air pump without the air cleaner in place. The cleaner
itself must be periodically checked and its element flushed and cleaned
semi-annually.
Air-Oil Tank
Pads of steel wool are used in the air to oil tank as a filtering medium to
separate the lube oil from the compressed air. The pads play a very
important role and should be replaced semi-annually. It is also important
that a proper grade of steel wool be used. Only No. 3 coarse grade American
steel wool or equal (CB919-124) should be used. Three pads are required.
When replacing the wool, insert two pads into the cylinder. Alternate the
grain of the pads. Install the spacer with its stub end toward the opening and
fit one pad over the stub. Be careful not to overly compress the wool and be
sure that it is fluffed out to fill all available space. Improper packing can
cause high oil consumption. After the last pad is in place, slip the retainer
screen onto the cylinder. Be sure to fit an O-ring gasket under the cover so
that a tight seal is obtained.
Follow previous instructions for oil replacement.
Lube Oil Cooling Coil

The fins on the tubing must be kept clean and free of any dust or dirt that
would resist air flow and cause overheating. Use an air hose to blow away
debris. Internal cleaning of the tubes is seldom required if a good quality
lube oil is used.
Flexible Coupling Alignment

Alignment of the pump and motor through the flexible coupling is extremely
important for trouble-free operation. Check the coupling alignment semi-
annually and replace the coupling insert as required. Keep the coupling
guard in place.
The most commonly used tools for checking alignment are a small
straightedge and a thickness gauge.
8-18 Part No. 750-184

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. The
check should be done on the top of the coupling and at 90 degrees. A useful
hint is to hold a flashlight behind the straightedge so that any gap can readily
be seen.
Shim stock of appropriate thickness and area is then used under either the
feet of the pump or the motor to establish parallel alignment. A tolerance of
.008" is a permissible limit.
After parallel alignment is established, check for angular alignment, which
is done by checking the gap between coupling halves. The coupling should
have a minimum gap of 1/16" and a maximum of 3/32".
Set the spacing between the halves at one point by using a thickness gauge
and then rotate the coupling slowly to be sure that clearance at that point
remains the same through 360 degrees of rotation. Adjust to obtain proper
gap by loosening the hold-down bolts and shifting either the pump or the
motor as required. Generally, a slight tapping on either the front or rear legs
is all that is needed to obtain lateral adjustment. Rear legs may require
shimming for vertical correction.
Tighten the hold-down bolts after adjustments are made and recheck
alignment.
Calipers can also be used to check angular alignment. Measure the overall
distance of the outer ends of the coupling halves at 90° intervals. Shift the
pump or motor, as required, so that the ends of the coupling are the same
distance apart at all points. The coupling will then have proper angular
alignment.
Remember that alignment in one direction may alter alignment in another.
Recheck both angular and parallel alignment procedures after making any
alteration.
A properly aligned coupling will last longer and will provide trouble-free
mechanical operation.
Air Compressor Replacement

Use the following procedures in replacing the pump on a CB-LE. Be sure to
tag the motor leads if disconnected to simplify reconnection.
Dismantling
1. Lift out the two front cylinder pins that hold the screen, and remove the
screen.
2. Disconnect the flared nut on tubing “A” (behind screen) and lift tubing “A”
high enough to prevent drainage of lubricating oil from the tank.
3. Disconnect the flared nut at the orifice fitting.
4. Remove the two sheet metal screws that hold the cylinder in place. One
screw is located at the top rear of cylinder, the other is at the bottom front.
Part No. 750-184 8-19

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. Remove the coupling guard by pushing in on both sides until it clears the
clamp.
9. Loosen the clamp at the rear of the tank and remove the tank with copper
tubing “A” attached.
10.Leave the rear pump bracket (coupling end) in place to aid in
realignment of the replacement pump. Do this by removing the two
capscrews that extend through the bracket into the pump housing.
Temporarily leave the front bracket attached to the pump.
11.Remove screws holding the front bracket to the base and lift off the pump
with its attachments. Note the location of the pipe fittings and brackets
prior to removing for installation on the replacement pump. If piping is
dismantled, be sure that the check valve is reinstalled so that the gate
swings towards the pump.
Reassembly
Reassembly in reverse order of disassembly. With the rear pump bracket left
in place, realignment and spacing between the pump shaft and the motor
shaft is greatly simplified.
There should be approximately 7/8” space between the two shafts. Place
the coupling insert between the coupling halves prior to reassembly. Check
that both shafts rotate freely.
Refer to the previous section on coupling alignment instructions.
If shims were used originally under either pump brackets or motor feet, be
sure that they are correctly reinstalled.
When reinstalling the fan, slide the hub on the pump shaft so that it is
bottomed. Tighten the setscrew and cap screws. If the fan blades were
removed from the hub, be sure that the side of the blade marked “Blower”
faces the hub when reassembling. When tightening the coupling halves or
the fan hub, tighten the setscrews against the key first, then tighten the
setscrew against the shaft. Clean or remove any dust or grime from the
blades prior to reinstalling.
When replacing the retainer screen, a slight force may be required to push
the cooling coil into the air cylinder so that the pins may be fitted into place.
Be sure that all piping connections are tight.
If the motor was replaced or if motor leads were disconnected, be sure that
pump rotation is proper before starting operation. The air pump should
rotate in a clockwise direction, as viewed from the drive shaft end.
General
Keep the motor and other components free from dust and dirt to prevent
overheating and damage. Motor lubrication should follow manufacturer’s
recommendations.
8-20 Part No. 750-184

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.
A good seal between the heads and the pressure vessel is necessary to
prevent leakage of combustion gases, loss of heat, and to aid in obtaining
operating efficiency. Leaks can also cause hot spots that can lead to
premature refractory failure and/or damage to the door metal.
When opening the heads, either for routine maintenance or for an annual
inspection, do not do so when the boiler or the door is hot. The refractory
will hold its temperature for some time and exposure to ambient temperature
or rapid cooling may cause refractory cracking and/or harm to the boiler and
head metal.
When opening the front head of a CB-LE, either remove the motor and fan
cassette assembly and swing the assembly away from the head. Or, with the
motor and cassette in place, remove the motor to davit arm connecting bolt
to allow swinging the motor and fan cassette with the head.
After confirming that the electrical power and fuel are locked in the off
position, disconnect the fuel lines. Disconnect the main gas line coupling,
the pilot line and the sight port air line. If the boiler is oil fired, remove the
supply and return oil lines and the oil pilot line if necessary. Remove the
head bolts and swing the head.
The opened head should be supported by blocking or jacking to eliminate
possible deformation of the head or hinge area.
Front Head
Inspect the second to third pass baffle gasket. If it is brittle, cracked or
broken, replace the gasket.
Inspect the second to third pass baffle for a good seal at the tube sheet and
the vessel.
If necessary, scrape old cement away and clean out and wire brush the
sealing area to assure an effective bond between the high temperature
cement and the steel. Be sure not to obstruct the tubes with excess cement.
Scrape the old gasket material off the vessel to front head sealing area
(vessel to inner door, CB-OS) and the dry oven to front head sealing area (dry
oven to inner door, CB-OS). Using a wire brush clean off any excess gasket
material or rust. Using Spray Tack spray the area to hold the gasket in place
prior to closing the front head. Use new fasteners when replacing the tadpole
gasket.
Inspect the condition of the blanket insulation on the front head (inner door,
CB-OS). Replace the insulation if loose or torn.
CB-OS only: Replace the gasket on the inner door and secure with
new split clips. Close the inner door and bolt securely in place.
Tighten the bolts evenly around the dry oven using a star pattern.
Part No. 750-184 8-21

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.
Using high temperature cement, fillet the corner of the dry oven to burner
housing contact area. Do not apply the cement more than 1/2 inch out from
the corner. Applying too much cement in this area could block the annulus
burner outlets.
Gasket - dry oven Swing the front head in place. A long punch or prybar might be necessary
to front head to align the bolt holes. Insert bolts hand tighten. After all bolts are threaded,
continue tightening in a star pattern.
After all bolts are threaded, continue tightening in a star pattern.
Gasket - front head
After all bolts are secured, tighten the upper and lower hinge nuts evenly to
to tube sheet
pull the door securely against the vessel. Repeat the star tightening
sequence on the head bolts, to verify gasket sealing.
Baffle, 2nd-3rd pass Do not overtighten. Tighten alternate bolts until the door is secured and gas
tight. After the boiler is back in operation, retighten the bolts to compensate
for any expansion.
Front head
Rear Door
Figure 8-1 Front Head, CB-LE
The rear door is a steel shell containing a horizontal baffle and lined with
insulation material and castable refractory.
Burned or discolored paint on the outer surface of the door does not
necessarily indicate refractory trouble, but may be an indication of other
conditions, such as:
1. Leaking gaskets.
2. Improper seal.
3. Door retaining bolts insufficiently or unevenly tightened.
4. The air line to the rear sight tube may be blocked or loose.
Gasket -
5. Door was repainted with other than heat resistant paint.
burner housing
to inner door Therefore, before assuming that the refractory requires reworking:
1. Check the condition of the tadpole gasket.
Gasket - dry oven
to inner door
2. Check for cracks in the castable refractory.
3. Check the tightness of the door bolts.
4. See that the air line to the sight tube is clear, and that the connections
are tight. If necessary, blow the line clear with an air hose.
Gasket - front head to inner door It is normal for refractories exposed to hot gases to develop thin “hairline”
cracks. It by no means indicates improper design or workmanship. Since
refractory materials expand and contract with changes in temperature, they
Figure 8-2 Front Head, CB-OS
should be expected to show minor cracks due to contraction when examined
at low temperatures. Cracks to approximately 1/8" across may be expected
to close at high temperature. If there are any cracks that are relatively large
(1/8" to 1/4" in width), clean and fill them with high-temperature-bonding
mortar.
If the refractory or blanket insulation require replacement, contact your local
8-22 Part No. 750-184

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. Leaks can also cause hot spots that can lead to
premature refractory failure and/or damage to the door metal.
When opening the door, either for routine maintenance or for an annual
inspection, do not do so when the boiler or the door is hot. The refractory
will hold its temperature for some time and exposure to ambient temperature
or rapid cooling may cause refractory cracking and/or harm to the boiler and
door metal.
! Warning
Be certain that the davit arm is under tension before
opening. Failure to follow these instructions can result in
serious personal injury or death.
Before loosening the door bolts, tighten the nut on the davit stud to ensure
tension on the davit arm. Putting the davit arm under tension will help
eliminate sagging, and will facilitate opening and closing.
The opened door should be supported by blocking or jacking to eliminate
possible deformation of the door.
Part No. 750-184 8-23

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. Remove all dried sealing material.
Remove the old rope from the rear door baffle. Be careful not to chip or crack
the refractory. Apply spray adhesive (P/N 797-1813) to the groove in the
baffle and attach a new length of 1-1/2" diameter fiberglass rope (P/N 853-
1036) to the groove. Be certain that the rope is properly positioned. Wash-
coat the lower half of the rear door refractory prior to closing.
Closing and Sealing
CB-LE — Attach new tadpole gasket with fasteners 841-00507. Apply
spray adhesive 797-1813 around the inner circumference of the gasket and
across the baffle seal area of the tube sheet. Apply blanket insulation 872-
1073 to this area. Refer to Figure 8-3.
CB-OS — Attach new tadpole gasket with fasteners 841-00507. Apply
spray adhesive 797-1813 around the inner circumference of the gasket.
Apply blanket insulation 872-1073 to this area. Refer to Figure 8-3.
Apply spray adhesive to the refractory-to-tubesheet seal area (see detail,
Figure 8-3). Apply blanket insulation 872-1073 to this area.
NOTE:
CB 880- gasket kits do not include blanket insulation. When re-
sealing using a CB-supplied gasket kit, the area around the inside
of the tadpole gasket may be sealed using the supplied rope in
place of the blanket insulation. First, replace tadpole gasket as
above. Coat gasket with an oil and graphite mixture. Apply a small
amount of a pulp mixture, consisting of 872-00026 cement and
water, around the inner circumference of the gasket. Press rope
into this area. After the rope is installed, coat the entire rope and
gasket area with the pulp mixture.
See also Chapter 9 - Parts, pp 9-47 and 9-48.
Figure 8-4 Gasket and Insulation — CB-LE
8-24 Part No. 750-184

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. After the boiler
is back in operation, retighten the bolts to compensate for any expansion.
Loosen the nut on the davit stud to release tension from the davit arm.
U. REFRACTORY
The boiler is shipped with completely installed refractory. The refractory
consists of the cast dry oven, furnace liner, and the rear door. Normal
maintenance requires little time and expense, and prolongs the operating life
of the refractory.
Preventive maintenance through periodic inspection will keep the operator
informed of the condition of the refractory, and will guard against unexpected
and unwanted downtime and major repairs.
Frequent wash coating of the refractory surfaces is recom-mended. High-
temperature-bonding, air-dry type mortar, diluted with water to the
consistency of light cream, is used for wash coating. Recoating intervals will
vary with operating loads and are best determined by the operator when the
boiler is opened for inspection.
Furnace Liner
Maintenance consists of occasional wash coating of the entire liner. Face all
joints or cracks by applying high temperature bonding mortar with a trowel
or fingertips. Wash coating should be done as soon as cracks are detected.
Should segments of the liner burn away or fall out, replace the entire
refractory. Any refractory that may break out should be removed as soon as
detected so that it will not fuse to the bottom of the furnace and obstruct the
flame.
If replacement is necessary, refer to Chapter 9 and order proper replacement
materials. Remove existing refractory. Thoroughly clean the furnace to
remove all old refractory cement or other foreign material to ensure the new
liner seats firmly against the steel. Inspect the furnace metal.
Depending upon the design pressure of the boiler, the furnace may be of the
corrugated type. It is necessary to fill in the corrugation valleys under the
furnace liner tile from 4 o’clock to 8 o’clock with insulating cement. The liner
tile should be fitted tightly against the crown of the corrugation.
Notice
Note: The area between the dry oven and the throat tile
requires a good seal. An improper or poor seal allows air
leaks that can cause overheating and burning of the dry
oven. The area should be inspected semi-annually. Contact
your local Cleaver-Brooks representative for information
and service.
Part No. 750-184 8-25

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.
The liner tile can be fitted tightly against the furnace, since the finished
diameter is not critical.
It is recommended that the tile be dry-fitted, match-marked, removed, and
then reinstalled with the proper amount of refractory cement. Thin joints
(less than 1/16”) are desirable. Generally, it will be necessary to shave a
portion from one or more tiles to obtain a fit. If a fill piece is required, cut it
to fit and install the piece at the bottom of the furnace.
Allow refractory to air dry as long as possible. If immediate use is required,
fire intermittently at a low rate for several hours to thoroughly dry the
refractory.
Inspect the baffle gasket and replace if necessary.
Installing Precast Dry Oven

1. Glue fiberglass rope to the backside of the dry oven (item #2) around the
outside dia. of precast dry oven (item #1) as shown below.
2. Apply trowleze to end of furnace tiles.
3. Fit up the dry oven and tighten in place.
4. Remove excess cement.
Figure 8-5 Dry oven installation
8-26 Part No. 750-184

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.
Complete renewal of grease, when necessary, can be accomplished by
forcing out the old grease with the new grease. Thoroughly wipe those
portions of the housing around the filler and drain plugs (above and below
bearings). Remove the drain plug (bottom) and free the drain hole of any
hardened grease which may have accumulated. With the motor not running,
add new grease through the filler hole until clear grease starts to come out
of the drain hole. Before replacing the drain plug, run the motor for 10 to 20
minutes to expel any excess grease. The filler and drain plugs should be
thoroughly cleaned before they are replaced.
The lubricant used should be clean and equal to one of the good commercial
grades of grease locally available.
Control Linkage
Apply a non-gumming, dripless, high temperature lubricant, such as
graphite or a silicone derivative to all pivot points and moving parts. Work
lubricant in well and wipe excess. Repeat application at required intervals
to maintain freedom of motion of parts.
Solenoid and Motorized Valves

Solenoid valves and motorized valves require no lubrication.
IFGR Lubrication (CB-LE)

Motors should be lightly lubricated at startup, using the grease specified
below or equivalent. Lubricate the motor as follows:
! Warning
Disconnect and lock out electrical power to the boiler before
lubricating the fan motor. Failure to follow these
instructions can cause injury or death.
1. Disconnect and lock out electrical power to the boiler.
2. Wipe clean all grease fittings (fill and drain fittings).
3. Remove the fill and drain plugs from the motor end cap.
4. Free the drain hole of any hard grease. (Use a piece of wire, if necessary.)
5. Add grease using a low-pressure grease gun.
Part No. 750-184 8-27

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. Either too much or too little
can be harmful. The grease cavity should be filled 1/3 to 1/2
full.
6. With the fill and drain plugs still removed, apply electric power to the
boiler, start the motor, and let it run for approximately 30 minutes.
7. Turn boiler off.
9. Wipe excess grease from the motor, and install the fill and drain plugs.
Motor is ready for operation.
10.Reconnect electrical power.
W. OIL HEATERS - ELECTRIC, STEAM, HOT WATER

An annual maintenance of the heaters consists primarily of removing the
heating element from the shell and scraping any accumulation of carbonized
oil or sludge deposits that may have collected on the heat exchanging
surfaces.
Before breaking any of the electrical connections to the electric heating
elements, mark all wires and terminals to assure rapid and correct
replacement of wires.
Finish the cleaning process with a cleaning solvent to cut all hardened
deposits from the heater element. Because of the insulating effect of carbon
and sludge, periodic cleaning is necessary to prevent overheating of the
elements. If operation of the heater becomes sluggish, examine the elements
at once and clean as required.
Inspect the shell or tank each time the heater is removed. Flush all
accumulated sludge and sediment from the tank before reinstalling the
heater.
The condensate from steam oil heaters must be safely discharged to waste.
The waste should be checked periodically for any traces of oil that would
indicate leaking tubes within the heater.
The hot water oil heater contains a heat transfer solution. Oil flows through
an inner tube while boiler water surrounds the outer tube. The space
between the two tubes is filled with the heat transfer solution and is
connected to an expansion chamber on the rear of the heater. A visual
indicator on the chamber reveals the presence of any oil if an oil leak occurs.
A 50/50 solution of permanent antifreeze and water is generally used as the
heat transfer solution. If there is no danger of freezing, plain water may be
used as a replenishment if necessary to refill.
Evidence of oil in either the steam heater condensate or in the water heater
indicator demands prompt repairs.
8-28 Part No. 750-184

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. Any time
maintenance is performed on the burner linkage, the air-fuel ratio should be
checked. Readjustment of the burner may be required due to variations in
fuel composition. A combustion analyzer should be used to adjust air-fuel
ratio for maximum operating efficiency. If your burner requires adjustments,
contact your local Cleaver-Brooks authorized representative for assistance.
CB-LE IFGR Maintenance
Daily • Check visually for free movement of IFGR

linkage.
Quarterly • Manually check for free movement of

IFGR linkage.
• Inspect and clean IFGR damper (oil-fueled
system).
• Inspect and clean fan and burner (oil-
fueled system).
• Grease fan motor.
Semi- • Inspect and clean IFGR damper (gas-

Annual fueled system).
• Inspect and clean fan and burner (gas-
fueled system).
• Open motor/fan cassette to check for free
movement of IFGR linkage and damper
assembly.
Annual • Inspect fan impeller.

• Check emissions.
• Change inlet gasket.
Part No. 750-184 8-29

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.
On a combination fired unit it is an acceptable practice to remove the belt
when gas is being used for extended periods. It is not absolutely necessary
to do this - however, pump and belt life will be extended if the belt is
removed.
8-30 Part No. 750-184

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.
Contact your local Cleaver-Brooks authorized

representative for prompt supply of replacement
parts.
Chapter 9 — Parts
Table Of Contents
Insulated Front Head - CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Insulated Front Head Interior - CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Insulated Inner Door - CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Insulated Rear Head CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Insulated Rear Head CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Dry Oven Model CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Motor and Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Front Head Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Jackshaft Retrofit Assembly Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Mod Motor Linkage Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Air Damper Linkage Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Burner Drawer-Gas Pilot Models 100-600, 125-200HP . . . . . . . . . . . . . . 9-16
Burner Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Control Cabinet (Hawk ICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Control Panel, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Entrance Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Front Head Electrical CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Front Head Electrical CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Straight Electric Oil Heater 60” Heavy Oil. . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Heavy Oil Piping 60” Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Common Oil Parts Heavy Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Side Mounted Air Compressor Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Air Compressor Piping CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Air Line Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Light Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
Light Oil/Air Piping - Front Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Pilot Gas Train 125-150HP CB-LE & 125-175HP CB-OS . . . . . . . . . . . . . 9-38
Pilot Gas Train 200HP CB-LE & CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Pilot Gas Train 225HP CB-OS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Gas Train 125-150 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Gas Train 175 HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
Gas Train 200 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
Gas Train 225 HP CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
Steam Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
Hot Water Temperature Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
Water Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
Fireside Gaskets, CB-LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
Fireside Gaskets, CB-OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9-2 Part No. 750-184

Chapter 9 — Parts
Insulated Front Head - Model CB-LE
Part No. 750-184 9-3

Chapter 9 — Parts
Insulated Front Head Interior - Model CB-LE
9-4 Part No. 750-184

Chapter 9 — Parts
Insulated Inner Door - Model CB-OS
Part No. 750-184 9-5

Chapter 9 — Parts
Insulated Rear Head CB-LE
9-6 Part No. 750-184

Chapter 9 — Parts
Insulated Rear Head CB-LE
Part No. 750-184 9-7

Chapter 9 — Parts
Insulated Rear Head CB-OS
9-8 Part No. 750-184

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

Chapter 9 — Parts
Motor and Impeller Model CB-LE, CB-OS
TABLE ITEM 2 - IMPELLER

BOILER H.P. 60 HZ 50 HZ
125 192-C-42 192-C-43
150 192-C-43 192-C-46
200 192-C-46 192-C-70
NOTE: Impeller size is based on boiler hp, ppm

emission level, boiler operating pressure and alti-
tude. To ensure proper sizing for your application,
contact CB Aftermarket.
BLOWER MOTOR - ITEM 1

60 HZ. 50 HZ.
ODP TEFC & HI-EFF. ODP

BOILER MOTOR MOTOR
H.P. H.P. 200-230- 200-230-460V H.P.
600V 230-380V
460V
125 5 894-3564 894-3561 894-3567 5 894-3558
150 5 894-3564 894-3561 894-3567 5 894-3558
200 10 894-3516 894-3547 894-3525 15 894-3538
Impeller selection - Ohio boilers
Boiler HP 60 Hz 50 Hz
125S 192-C-42 192-C-43
150S 192-C-43 192-C-46
175S 192-C-46 192-C-70
200S 192-C-86 —
225S 192-C-87 —
9-10 Part No. 750-184

Chapter 9 — Parts
Motor & Impeller - Model CB-LE
Part No. 750-184 9-11

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

Chapter 9 — Parts
Jackshaft Retrofit Assembly Kits
CB PART # 274-63 6
1
1 2
2 4
4
6
3
CB PART # 274-220 6
1
1 2
5 4
6 2
3
CB PART# 274-221 6
1
1 2
2
5
4
Part No. 750-184 9-13

Chapter 9 — Parts
Mod Motor Linkage Kits

7 2
3
6
5
4 1
5 8
11
3
2
CB PART # 476-53
Item REQ. Part # Description
1 1 67-16 Activation Rod
2 2 883-17 Ball Joint
3 2 10-288 Ball Joint Bushing
4 1 2-47 Modulation Motor Arm
5 2 869-21 Hex Nut, 1/4” - 20
6 2 869-22 Hex Nut, 3/8” - 24
7 2 860-39 Set Screw
8 1 868-138 Capscrew, 1/4” - 20, 1-1/4” LG
9 2 868-139 Capscrew, 1/4” - 20, 1-1/2” LG
10 Not Used
11 1 2-96 Damper Motor Arm
9-14 Part No. 750-184

Chapter 9 — Parts
Air Damper Linkage Kit

2
3
4
7
5 1
3
4
CB PART # 476-54
Item REQ. Part # Description
1 1 67-109 Damper Linkage Rod
2 2 883-17 Ball Joint
3 2 10-288 Ball Joint Bushing
4 2 869-21 Hex Nut, 1/4” - 20
5 2 869-22 Hex Nut, 3/8” - 24
6 - Not Used
7 2 860-39 Capscrew, 1/4” - 20, 1 1/2” LG
Part No. 750-184 9-15

Chapter 9 — Parts
Burner Drawer-Gas Pilot Models 100-600, 125-200HP CB-LE

4 3 5 40 1
28
30
N
CTIO
36 22
PEN
24 15
DIRE
TO O
46 19 17
31
35 23 41 42 33 18
17"
16-1/4”
14
20 21
9-1/4” 23
16 22
23 11
23
9
1/8”
7/16”
29 43 10 3/16”MAX.
1
3/32” MIN.
1" MIN. 1/4”

8 12 13 39
44 45
2
25
26 27 28 23 7 6
9-16 Part No. 750-184

Chapter 9 — Parts
Burner Drawer - Gas Pilot Models 100-600, 125-200 HP CB-LE
ITEM QTY PART NO. DESCRIPTION
1 1 SEE TABLE NOZZLE-GUN ASSEMBLY

2 1 108-B-47 DAMPER
3 2 851-77 MICA, SHEET, PORT HOLE, #36 GA. X 1-1/2” DIA.
4 1 65-A-11 RETAINER SIGHT HOLE
5 3 860-176 MACHINE SCREW, RD. HD. 10-24 X 1/4” LG.
6 1 858-310 PLUG, PIPE, COUNTER SUNK, 3/4”
7 1 48-A-98 VENTURI, GAS PILOT
8 1 904-36 GROMMET, RUBBER
9 1 SEE TABLE DIFFUSER ASSEMBLY AIR
10 1 90-A-1512 TUBE, BURNER DRAWER
11 1 134-B-47 SPIDER
12 1 34-A-7 GLAND, PACKING
13 1 90-A-1708 TUBE & ADAPTER ASS'Y, GAS PILOT
14 1 59-5768 PLATE, BACK BEARING ASSEMBLY (SEE 59-A-918)
15 1 827-6 BULK CONDUIT, GREENFIELD 3/8” X 11" LG
Burner Gun Assembly
16 1 22-A-122 DIFFUSER, AIR STABILIZER BOILER P/N IT. 1
17 2 860-91 MACHINE SCREW, RD. HD. #10-32 X 1-1/2” LG.
125 30 PPM 251-B-35
18 3 952-92 LOCKWASHER, 1/4” 150 30 PPM 251-B-35
19 2 869-9 NUT, HEX #10-32 200 30 PPM 251-B-37
20 1 56-A-21 PIN-LOCKING 125 & 150 60 PPM 251-B-35
21 1 869-36 NUT, HEX 5/16”-18 200 60 PPM 251-B-37
22 5 860-158 SETSCREW, SOCKET HD. 1/4”-20 X 5/16” LG
23 9 860-39 SETSCREW, SOCKET HD. 1/4”-20 X 3/8” LG
24 2 848-100 BUSHING FIBER
25 1 90-A-1709 TUBE GAS PILOT
26 1 845-194 ELBOW, MALE, 5/8” ODC X 1/2” NPT X 90°
27 1 825-30 COCK, GAS, TEE HEAD
28 2 857-153 NIPPLE, 1/2” X 1-1/2” LG
29 1 435-B-127 ELECTRODE, IGNITION ASS'Y
30 1 836-996 SWITCH, LIMIT
31 1 8-A-3057 BRACKET, LIMIT SWITCH
32 1 848-2 CONNECTOR, BOX, SQUEEZE TYPE
33 6 860-7 MACH, SCREW-RD. HD. 1/4”-20 X 1/2” LG
34 - NOT USED NOT USED
35 1 2-A-31 ARM, DAMPER
36 1 848-16 CONNECTOR, BOX, SQUEEZE TYPE
39 1 73-A-26 SEALER, RING
40 1 868-210 CAPSCREW, SOCKET HD. 1/4”-20 X 1/2” LG
41 1 860-201 MACHINE SCREW, 10-24 NC RD. H. X 1/8”
42 1 860-161 SET SCREW-SOCKET HD. 5/16”-18 NC X 1/2”
43 1 853-1 O-RING
44 1 134-A-53 HOLDER-ELECTRODE
45 1 860-244 SET SCREW-SOCKET HD. 6-32 X 1/8”
46 2 952-117 LOCKWASHER #10
Part No. 750-184 9-17

Chapter 9 — Parts
Burner Housing
17 TUBE SHEET
16 12
BAFFLE SEAL
18
BAFFLE (FRONT EXTENSION)
STUD
1/2" INNER DOOR

14 15 4
NOTES:
BAFFLE ATTACHMENT
4
1. SEAL BAFFLE AT TUBE SHEET AND
SHELL WITH ITEM #12.
13 2. PAINT WITH SYNCRON #5112 ZINCOAT

13 PER INSTRUCTIONS ON DRAWING
#876-A-73 AFTER CUTTING THREADS.
USED ON CB USED ON CB 200
125-150 3. DIFFUSER TO BE FLARED TO MATCH
I.D. OF BURNER OPENING.
DETAIL " A " REFER TO G24SHT1.
25 25
26 27 28 28
26 27
L FURNACE
C
L FURNACE
C
SEE DETAIL "A"
4 4
2 8 2 8 SEE DETAIL "A"
3 13 3 13
3" NPT PLUG
1 2 23 22
1 2
5 5
7 7
FRONT HEAD
FRONT HEAD
19 20 21 24
10 11 6 SEE 9 GAS AND COMBINATION
OIL ONLY NOTE 2
9-18 Part No. 750-184

Chapter 9 — Parts
Burner Housing
ITEM QTY PART NO. DESCRIPTION USED ON
1 8 869-30 NUT, HEX, 3/8"-16 -

2 14 952-93 WASHER, 3/8" -
3 1 32-A-605 GASKET, BURNER DRAWER TO HOUSING -
4 1 SEE TABLE BURNER DRAWER -
5 1 32-A-603 GASKET, BURNER HOUSING TO FRT. HEAD -
6 1 900-79 BULK PIPE, 3" X 13-1/2" LG. TBE. NAT. GAS/COMBINATION OR PROPANE
1 465-B-1330 DOOR, INNER R.H. SWING CB125-200
7
1 465-B-1331 DOOR, INNER L.H. SWING CB125-200
8 6 868-157 CAPSCREW, HEX HD 3/8-16 X 1-1/4" LG -
9 1 853-348 BULK PACKING, 1/4" DIA. X 10 " NAT. GAS/COMBINATION OR PROPANE
10 1 65-A-704 RETAINER, MACHINING NAT. GAS/COMBINATION OR PROPANE
11 3 860-15 SETSCREW, SOC HD 3/8-16 X 1/2" LG NAT. GAS/COMBINATION OR PROPANE
12 6 OZ 872-558 THERMO SILICATE CEMENT -
1 40-D-540 BURNER HOUSING, WELDMENT *NAT. GAS/COMB.-ALL EXCEPT CBW200
1 40-580 BURNER HOUSING, WELDMENT *NAT. GAS/COMB.-CBW 200 ONLY
13
1 40-D-581 BURNER HOUSING, WELDMENT *PROPANE-CB125-150
1 40-582 BURNER HOUSING, WELDMENT *PROPANE-CB200 ONLY
14 4 869-29 NUT, HEX, 1/2" BRASS -
15 8 952-325 WASHER, 1/2" FLAT BRASS -
16 24 841-A-551 RIVET -
17 8 FT 971-291 STRIP, PERFORATED -
18 1 853-394 GASKET, 2" X 96" -
19 1 869-30 NUT, HEX, 3/8"-16 OIL ONLY
20 1 952-93 LOCKWASHER, 3/8" OIL ONLY
21 1 868-157 CAPSCREW HEX HD 3/8-16 X 1-1/4" LG OIL ONLY
22 1 65-A-142 RETAINER, FRONT HEAD COVER OIL ONLY
23 1 32-A-765 GASKET, FRONT HEAD COVER OIL ONLY
24 1 19-A-156 COVER, FRONT HEAD PLATE OIL ONLY
25 1 32-A-497 GASKET, MOUNTING PLATE SCANNER TUBE -
26 4 952-92 LOCKWASHER, 1/4" -
27 2 860-7 MACH. SCREW, 1/4-20 X 1/2" LG. -
28 1 90-A-146 TUBE, SCANNER ASSEMBLY -
TABLE FOR ITEM 4 BURNER DRAWER (SEE NOTE 3)
FUEL 100 200-600 700
H.P. OIL PILOT GAS PILOT GAS PILOT GAS PILOT
125-150 429-D-263 429-D-292 429-D-292 429-D-293
CB200 429-D-257 429-D-294 429-D-294 429-D-295
Part No. 750-184 9-19

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

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

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

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

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

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

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

Chapter 9 — Parts
Straight Electric Oil Heater 60” Heavy Oil - Model CB-LE
15
32
NOTES:
1. ALL DIMENSIONS ARE APPROX.

21
31 2. UNLESS OTHERWISE NOTED, ALL PIPE
TO BE 3/4" SCH. 40 ASTM A120 WELDED
BLACK STL. AND ALL FITTINGS 150# M.I..
3. USE ITEM 27 WITH 836-72 HOTS.
4. USE ITEM 27 WITH 836-65 LOTS.
3 16 17" 5. SUPPLY TEES ONLY IF REQUIRED BY INSURANCE.

REF.
30 6. FOR HAWK DO NOT USE ITEM 10. USE QTY 2 OF ITEM 3.
7. ITEMS 22, 23, 24, & 25 USED FOR NON-HAWK ONLY.

FOR HAWK USE SOLID STATE SENSOR.
" " REFER TO DWG. 146-D-56.
VIEW B-B
8. WELD ITEM 4 TO SADDLE SUPPORT.
VIEW "A-A"
A
4 5 6 8 29
9 1" X 3/4" X 3/4"
C
L HINGE PIN 1" MIN.
SEE NOTE 8
27 SEE NOTE 4
11 12 26
28
9 1/2" X 1/2" X 1/4" 1" X 3/4" X 3/4"

22
SEE NOTE 5 27
6-1/4" 14
11 26 SEE
27 1-1/4" x 3/4" x 1-1/4"
12 NOTE 3
20
B
1-1/4" NPT
23
13 31
8-1/2" 1"
15
MIN. OIL RETURN
25 17 18 19
24 32
2
7 1 7 OIL INLET
A B
22" "A"
"B"
"C"
Part No. 750-184 9-27

Chapter 9 — Parts
Straight Electric Oil Heater 60” Heavy Oil - Model CB-LE

ITEM QTY PART NO. DESCRIPTION USED ON OPTION
1 838-C-81 TANK - HEATER 3 & 5 kw U.S.

QQ
1 1 838-C-35 TANK - HEATER 3 & 5 kw CAN.
QU
1 195-B-238 TANK - HEATER 7-1/2 kw
3
1
2
*
7-A-52
ELEMENT - HEATER
U-BOLT
-
-
QQ/QU
QQ/QU
4 1 8-A-65 BRACKET, PIPE - QQ/QU
5 2 928-45 STRAP - PIPE 3/4" -

6 2 868-405 CAPSCREW - HEX. HD. 1/4-20 x 7/8" -
7 2 8-A-656 HEATER BRACKET - QQ/QU
8 2 869-21 NUT HEX. 1/4-20 -
9 1 507-B-500 TUBING - OIL RETURN (SEE NOTE 6) - QQ/QU
10 1 507-B-501 TUBING - OIL RETURN (SEE NOTE 6) - D3
11 2 845-313 ELBOW FLARED - 90° -
12 2 847-1715 SWIVEL JOINT - 90° - QQ/QU
13 1 843-252 STRAINER - 3/4" N.P.T. - QQ/QU
14 1 850-61 PRESSURE GAUGE - QQ/QU
15 1 940-2116 RELIEF VALVE - 1/2" N.P.T. - QQ/QU
16 4 952-93 LOCKWASHER - 3/8" -
17 1 853-227 GASKET - HEATER -
18 8 952-92 LOCKWASHER - 1/4" -
19 8 868-138 CAPSCREW HEX. HD. 1/4-20 x 1-1/4" -
20 1 847-430 BUSHING - 1-1/4" x 1/2" -
21 1 847-431 BUSHING - 1-1/4" x 3/4" 5 kw ONLY
22 1
* LOTS ALL D3
23 1
* HOTS D3
24 1
* LOPS D3
25
26
1
1
*
847-533
HOPS
COUPLING 1" X 3/4" -

D3
27 3 847-152 BUSHING 3/4" X 1/2" -
28 1 847-530 COUPLING - RED. - 3/4" X 1/2" -
29 2 952-92 LOCKWASHER - 1/4" -
30 4 869-30 NUT, HEX, 3/8"-16 -
31 1 847-426 BUSHING, RED. 1" X 3/4" 5 kw-CAN. ONLY
32 1 847-638 COUPLING - RED. 1-1/4" X 1/2" -
* = SEE TABLE ON PAGE 32
DIM. "A" DIM. "B" DIM. "C" DIM. "D"
125-150 U.S. 9-1/2" 32-1/4" 37-1/4" 17-3/8"
H.P. CANADA 9-1/2" 30" 35" 14-1/2"
200 H.P. - 18" 41-1/4" 47-3/4" 27-3/4"
9-28 Part No. 750-184

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

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

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

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

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

Chapter 9 — Parts
Air Line Piping

1 1 827-8 BULK CONDUIT, 1/2" THINWALL EMT. X "B" LG. APPROX.

2 1 827-8 BULK CONDUIT, 1/2" THINWALL EMT. X "A" LG. APPROX.
3 1 8-A-2833 BRACKET
4 1 928-33 PIPE STRAP, 1/2" CONDUIT
5 1 868-136 CAPSREW, HEX HD. 1/4"-20 X 3/4" LG.

6 1 859-118 ELBOW, STREET, 1/2" X 45 (SEE NOTE 3)
7 1 848-141 COUPLING, 1/2" CONDUIT
8 2 848-325 CONNECTOR, STRAIGHT, 1/2" EMT. CONDUIT
9 1 848-398 COUPLING, UNION, 1/2" EMT. CONDUIT
3 5
VIEW "A-A "
SIGHT PORT & PIPING
REAR HEAD
7 8
9 6
A
8
A 3
1 2
REAR VIEW
9-34 Part No. 750-184

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

Chapter 9 — Parts
Light Oil/Air Piping - Front Head
9-36 Part No. 750-184

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

9-38
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Chapter 9 — Parts
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Part No. 750-184 9-45

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

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Water Column
Part No. 750-184 9-47

Chapter 9 — Parts
Water Column
9-48 Part No. 750-184

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

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

CLEAVER-BROOKS
Model CB-LE Packaged Boiler
250 - 350 HP, Light Oil, Heavy Oil, Gas, or Combination
Operation and Maintenance Manual
Manual Number: 750-91
Release Date: December 2009

Copyright © 2009 by Cleaver-Brooks
All rights reserved. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means without the prior writ-
ten consent of Cleaver-Brooks.
Cleaver-Brooks
11950 West Lake Park Drive
Milwaukee, WI 53224
414-359-0600
Model CB-LE Packaged Boiler
750-91
Table of Contents
CHAPTER 1 Basics of Firetube Operation 1-1

1.1 — Introduction 1-1
1.2 — The Boiler 1-3
1.3 — Construction 1-4
1.4 — Steam Controls (All Fuels) 1-5

1.4.1 — Operating Limit Pressure Control 1-5
1.4.2 — High Limit Pressure Control 1-5
1.4.3 — Modulating Pressure Control 1-6
1.4.4 — Low Water Cutoff and Pump Control 1-6
1.4.5 — Water Column Assembly 1-7
1.4.6 — Water Column Drain Valve 1-7
1.4.7 — Water Gauge Glass Drain Valve 1-7
1.4.8 — Vent Valve 1-7
1.4.9 — Stack Temperature gauge 1-7
1.4.10 — Auxiliary Low-Water Cutoff 1-8
1.4.11 — Safety Valve(s) 1-8
1.5 — Hot Water Controls (All Fuels) 1-9

1.5.1 — Water Pressure and Temperature Gauge 1-9
1.5.2 — Operating Limit Temperature Control 1-9
1.5.3 — High Limit Temperature Control 1-9
1.5.4 — Modulating Temperature Control 1-9
1.5.5 — Low-Water Cutoff 1-9
1.5.6 — Auxiliary Low-Water Cutoff (optional) 1-10
1.6 — IFGR Components 1-10

1.6.1 — Flue Gas Transfer Port, IFGR Damper, & Flange Collar 1-10
1.6.2 — IFGR Damper Linkage 1-10
1.6.3 — Over-Travel Mechanism 1-11
1.6.4 — Fuel Change-Over Linkage 1-11
1.6.5 — Fan/Motor Cassette 1-12
1.6.6 — Burner Drawer 1-12
1.6.7 — Combustion Air Inlet 1-12
1.6.8 — Front Door Insulation 1-12
750-91 (revised 2009) i

Model CB-LE Packaged Boiler Manual
CHAPTER 2 Burner Operation and Control 2-1
2.1 — The Burner 2-1
2.2 — Control and Component Function 2-3
2.3 — Components Common to All Boilers 2-3
2.4 — Controls for Gas Firing 2-5
2.5 — Controls Common to Oil-Fired Boilers 2-9
2.6 — Additional Controls for Heavy Oil 2-13
2.7 — Controls for Combination Burners Only 2-15
2.8 — Combustion Air 2-16
2.9 — Automatic Ignition 2-16
2.10 — Atomizing Air 2-17
2.11 — Oil Fuel Flow: Light Oil 2-17
2.12 — Oil Fuel Flow: Heavy Oil 2-19
2.13 — Gas Fuel Flow 2-21
2.14 — Modulating Firing 2-21
CHAPTER 3 Waterside Care and Requirements 3-1

3.1 — Overview 3-1
3.2 — Water Requirements: Hot Water Boiler 3-1

3.2.1 — Air Removal 3-1
3.2.1.1 — Minimum Water Temperature 3-2
3.2.1.2 — Rapid Replacement of Boiler Water 3-2
3.2.1.3 — Continuous Flow Through the Boiler 3-2
ii 750-91 (revised 2009)

3.2.2 — Water Circulation 3-2
3.2.2.1 — Multiple Boiler Installations 3-3
3.2.2.2 — Pump Location 3-4
3.2.2.3 — Pump Operation 3-4
3.2.3 — Pressure 3-4
3.3 — Water Requirements: Steam Boiler 3-5

3.3.1 — Feed Pump Operation 3-5
3.3.2 — Water Feeder (optional) Operation 3-6
3.4 — Water Treatment 3-6
3.5 — Cleaning 3-7

3.5.1 — Hot Water and Steam Piping 3-7
3.5.2 — Pressure Vessel 3-7
3.6 — Boil-Out of a New Unit 3-8
3.7 — Washing Out 3-10

3.7.1 — Hot Water Boiler 3-10
3.7.2 — Steam Boiler 3-10
3.7.3 — Flushing of Pressure Vessel Interior 3-10
3.8 — Blowdown: Steam Boiler 3-10

3.8.1 — Intermittent Manual Blowdown 3-11
3.8.2 — Continuous Blowdown 3-11
3.8.3 — Frequency of Manual Blowdown 3-11
3.8.4 — Manual Blowdown Procedure 3-12
3.9 — Periodic Inspection 3-13
3.10 — Preparation for Extended Lay-Up 3-14
CHAPTER 4 Sequence of Operation 4-1

4.2 — Circuit and Interlock Controls 4-2
4.3 — Sequence of Operation: Oil or Gas 4-3

4.3.1 — Pre-Purge Cycle 4-3
4.3.2 — Ignition Cycle 4-4
4.3.3 — Run Cycle 4-4
4.3.4 — Burner Shutdown: Post Purge 4-5
750-91 (revised 2009) iii

4.4 — Flame Loss Sequence 4-5
4.4.1 — No Pilot Flame 4-6
4.4.2 — Pilot But No Main Flame 4-6
4.4.3 — Loss of Flame 4-6
CHAPTER 5 Starting and Operating Instructions 5-1

5.1 — Preparation for Startup: All Fuels 5-1
5.2 — Control Settings: Steam and Hot Water 5-2

5.2.1 — Operating Limit Control 5-2
5.2.2 — High Limit Control 5-2
5.2.3 — Modulating Control 5-3
5.2.4 — Low-Water Cutoff and Pump Control 5-3
5.2.5 — Additional Considerations 5-3
5.3 — Gas Pilot 5-3
5.5 — Firing Preparations for No. 2 Oil (Series 100 - 200) 5-5
5.5.1 — Oil Flow 5-5
5.5.2 — Oil Pressure 5-6
5.5.3 — Starting 5-7
5.6 — Firing Preparation for No. 6 Oil (Series 400 - 600) 5-7
5.6.1 — Oil Flow 5-7
5.6.3 — Oil Temperature 5-8
5.7 — Firing Preparations for Gas (Series 200-400-700) 5-9
5.8 — IFGR Setup 5-11
5.9 — Startup, Operating and Shutdown: All Fuels 5-13

5.9.1 — Operating 5-14
5.9.2 — Shutdown 5-15
5.10 — Control Operational Test and Checks 5-15
iv 750-91 (revised 2009)

CHAPTER 6 Adjustment Procedures 6-1
6.1.1 — High Turndown Burner 6-1
6.2 — Linkage: Modulating Motor and Air Damper 6-2
6.3 — Modulating Motor 6-4
6.4 — Modulating Motor Switches: Low-Fire and High-Fire 6-4
6.5 — Burner Operating Controls: General 6-5
6.6 — Modulating Pressure Control: Steam 6-8
6.7 — Operating Limit Pressure Control: Steam 6-8
6.8 — High Limit Pressure Control: Steam 6-8
6.9 — Modulating Temperature Control: Hot Water 6-8
6.10 — Operating Limit Temperature Control: Hot Water 6-9
6.11 — High Limit Temperature Control: Hot Water 6-9
6.12 — Low Water Cutoff Devices: Steam & Hot Water 6-10
6.13 — Combustion Air Proving Switch 6-10
6.14 — Atomizing Air Proving Switch 6-10
6.15 — Gas Pilot Flame Adjustment 6-11

6.15.1 — Measure and Adjust Pilot 6-11
6.16 — Gas Pressure and Flow Information 6-12

6.16.1 — Pressure 6-12
6.16.2 — Gas Flow 6-15
6.16.3 — Pressure Correction 6-15
6.16.4 — Checking Gas Flow 6-16
6.17 — Gas Fuel Combustion Adjustment 6-17

6.17.1 — Standard Burner Low-Fire Adjustment 6-20
6.17.2 — High Turndown Burner Low-Fire Adjustment 6-21
750-91 (revised 2009) v

6.18 — Low-Gas Pressure Switch 6-21
6.19 — High-Gas Pressure Switch 6-21
6.20 — Fuel Oil Pressure and Temperature: General 6-22
6.21 — Fuel Oil Combustion Adjustment 6-23

6.21.1 — Standard Burner Low-Fire Adjustment: Heavy Oil 6-25
6.21.2 — High Turndown Burner Low-Fire Adjustment: Light Oil 6-25
6.22 — Burner Drawer Adjustment 6-25
6.23 — Oil Drawer Switch 6-26
6.24 — Low Oil Temperature Switch 6-27
6.25 — High Oil Temperature Switch (Optional) 6-27
6.26 — Low Oil Pressure Switch (Optional) 6-27
6.27 — Electric Oil Heater Thermostat (400 and 600 Series: Steam) 6-27
6.28 — Steam Oil Heater Thermostat: No. 6 Oil (400 and 600 Series: Steam) 6-28
6.29 — Hot Water Oil Heater Thermostat (400 and 600 Series) 6-28
6.30 — Steam Heater Pressure Regulator (400 and 600 Series: Steam) 6-28
CHAPTER 7 Troubleshooting 7-1

CHAPTER 8 Inspection and Maintenance 8-1

8.1.1 — Periodic Inspection 8-2
8.2 — Fireside Cleaning 8-2
vi 750-91 (revised 2009)

8.3 — Water Level Controls 8-3
8.4 — Water Gauge Glass 8-4
8.5 — Electrical Controls 8-5
8.6 — Flame Safety Control 8-7

8.6.1 — Checking Pilot Flame Failure 8-7
8.6.2 — Checking Failure to Light Main Flame 8-8
8.6.3 — Checking Loss of Flame 8-8
8.7 — Oil Burner Maintenance 8-8

8.7.1 — Oil Strainers 8-8
8.7.2 — Light Oil Strainers 8-8
8.7.3 — Heavy Oil Strainers 8-9
8.7.4 — Cleaning the Oil Nozzle 8-9
8.7.5 — Cleaning Air Purge Nozzle (No. 6 Oil) and Back Pressure Orifice Nozzle (No. 2 Oil) 8-10
8.7.6 — Ignition System 8-10
8.8 — Gas Burner Maintenance 8-10
8.9 — Motorized Gas Valve 8-11
8.10 — Solenoid Valves 8-11
8.11 — Air Control Damper, Linkage, and Cam Spring 8-12
8.12 — Forced Draft Fan 8-13
8.13 — Fan/Motor Cassette Removal 8-15
8.14 — Inspection and Adjustment 8-16
8.15 — Airbox Gasket Installation 8-17
8.16 — Fan/Motor Cassette Installation 8-18
8.17 — Safety Valves 8-19
8.18 — Fuel Oil Metering Valve, Adjusting, and Relief Valves 8-19
8.19 — Air Pump and Lubricating System 8-21
750-91 (revised 2009) vii

8.19.1 — Air Compressor 8-21
8.19.2 — Lubricating Oil 8-21
8.19.3 — Lubricating Oil Strainer and Cooling Coil 8-22
8.19.4 — Air Cleaner 8-22
8.19.5 — Air-Oil Tank 8-22
8.19.6 — Lube Oil Cooling Coil 8-23
8.19.7 — Flexible Coupling Alignment 8-23
8.19.8 — Air Compressor Replacement 8-25
8.19.8.1 — Dismantling 8-25
8.19.8.2 — Reassembly 8-25
8.20 — Refractory 8-26

8.20.1 — Furnace Liner 8-27
8.20.2 — Throat Tile and Liner Installation 8-28
8.20.3 — Installation 8-29
8.20.4 — Rear Door 8-30
8.20.5 — Front Inner Door 8-32
8.21 — Opening and Closing Rear Door 8-32

8.21.1 — Closing and Sealing 8-33
8.22 — Lubrication 8-33

8.22.1 — Electric Motors 8-33
8.22.2 — Control Linkage 8-34
8.22.3 — Solenoid and Motorized Valves 8-35
8.22.4 — IFGR Lubrication 8-35
8.23 — Oil Heater: Electric, Steam, Hot Water 8-35
8.24 — Combustion 8-36
8.25 — Air Pump Belt 8-36
8.26 — Recommended Boiler Inspection Schedule 8-37
CHAPTER 9 Parts 9-1

9.1 — Ordering Parts 9-1
9.2 — Parts Lists and Drawings 9-2

9.2.1 — Air Compressor and Piping 9-2
9.2.2 — Side Mounted Air Compressor Piping 9-3
9.2.3 — Air Line Piping 9-4
9.2.4 — Burner Housing Support & Front Head Plt 9-5
Burner Housing Support & Front Head Plt 9-6
viii 750-91 (revised 2009)

9.2.5 — Control Panel 9-7
9.2.6 — Entrance Box 9-9
9.2.7 — Front Head (Electrical) 9-10
9.2.8 — Front Davit 9-11
9.2.9 — Front Head Insulation 9-12
9.2.10 — Front Head Linkage 9-13
9.2.11 — Gas Train 9-14
9.2.12 — Light Oil/Air Piping 9-16
9.2.13 — Heavy Oil/Air Piping 9-18
9.2.14 — Heavy OIl Alstrom Heater 9-20
9.2.15 — CB-LE IFGR 9-22
9.2.16 — IFGR Impeller 9-24
9.2.17 — Pressure Controls 9-25
9.2.18 — Temperature Controls 9-26
9.2.19 — W.C. - Main & Aux. 9-27
9.2.20 — Vessel Handholes & Manways 9-29
9.2.21 — Rear Head Sealing - Davit 9-30
9.2.22 — Throat Tile and Furnace Liner 9-31
750-91 (revised 2009) ix

x 750-91 (revised 2009)
PREFACE
Safety Precautions
It is essential to read and understand the following safety precautions before attempting to operate the
equipment. Failure to follow these precautions may result in damage to equipment, serious injury, or
death. A complete understanding of this manual is required before attempting to startup, operate, or
maintain the equipment. The equipment should be operated only by personnel who have a working
knowledge and understanding of the equipment.
! Important
The following symbols are used throughout this manual:
! Warning
This symbol indicates a potentially hazardous situation which, if not recognized and addressed,
could result in serious injury or death.
750-91 (revised 2009) xi

! Caution
could result in damage to the equipment.
NOTE: This symbol indicates information that is vital to the operation of the equipment.
! Warning
• 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 injury or death.
To Owners, Operators, and Maintenance Personnel

This operating manual presents information that will help to properly operate and care for the equip-
ment. Study its contents carefully. The unit will provide good service and continued operation if
proper operating and maintenance instructions are followed. No attempt should be made to operate
the unit until the principles of operation and all of the components are thoroughly understood. Failure
to follow all applicable instructions and warnings may result in severe injury or death.
It is the responsibility of the owner to train and advise, in all aspects of safety, not only his or her per-
sonnel, but the contractors’ personnel who are servicing, repairing, or operating the equipment.
Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the
job. The electrical and mechanical devices supplied as part of the unit were chosen because of their
xii 750-91 (revised 2009)

known ability to perform, however, proper operating techniques and maintenance procedures must be
followed at all times. Although these components afford a high degree of protection and safety, oper-
ation of equipment is not to be considered free from all dangers and hazards inherent in handling and
firing of fuel.
Any “automatic” features included in the design do not relieve the attendant of any responsibility.
Such features merely free him of certain repetitive chores and give him more time to devote to the
proper upkeep of equipment.
It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount
of written instructions can replace intelligent thinking and reasoning and this manual is not intended
to relieve the operating personnel of the responsibility for proper operation. On the other hand, a
thorough understanding of this manual is required before attempting to operate, maintain, service, or
repair this equipment.
Because of state, local, or other applicable codes, there are a variety of electric controls and safety
devices which vary considerably from one boiler to another. This manual contains information
designed to show how a basic burner operates.
Operating controls will normally function for long periods of time and we have found that some oper-
ators become lax in their daily or monthly testing, assuming that normal operation will continue indef-
initely. Malfunctions of controls lead to uneconomical operation and damage and, in most cases, these
conditions can be traced directly to carelessness and deficiencies in testing and maintenance.
It is recommended that a boiler room log or record be maintained. Recording of daily, weekly,
monthly, and yearly maintenance activities and recording of any unusual operation will serve as a valu-
able guide to any necessary investigation.
Most instances of major boiler damage are the result of operation with low water. We cannot empha-
size too strongly the need for the operator to periodically check his low water controls and to follow
good maintenance and testing practices. Cross-connecting piping to low water devices must be inter-
nally inspected periodically to guard against any stoppages which could obstruct the free flow of water
to the low water devices. Float bowls of these controls must be inspected frequently to check for the
presence of foreign substances that would impede float ball movement.
The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be
inspected frequently to check for the presence of any mud, sludge, scale, or corrosion.
750-91 (revised 2009) xiii

The services of a qualified water treating company or a water consultant to recommend the proper
boiler water treating practices are essential.
The operation of this equipment by the owner and his or her operating personnel must comply with
all requirements or regulations of the owner’s insurance company and/or other authority having juris-
diction. In the event of any conflict or inconsistency between such requirements and the warnings or
instructions contained herein, please contact Cleaver-Brooks before proceeding.
xiv 750-91 (revised 2009)

CHAPTER 1 Basics of Firetube Operation
1.1 — Introduction
Firetube boilers are available for low or high pressure steam, or for hot water applications. Firetube boilers are typ-
ically used for applications ranging from 15 to 800 horsepower. A firetube boiler is a cylindrical vessel, with hori-
zontal tubes passing through and connected to the front and rear tube sheets. The vessel contains the water and
absorbs the energy generated from the flame. The front door and rear door provide the seal to contain the hot
combustion gasses. Baffles designed into the doors serve to redirect the combustion gasses through the various
firetube passages. The flame originates in the furnace. As the combustion gasses travel down the furnace and
through the various firetube channels, heat from the flame and combustion gasses is transferred to the water.
Transferred energy develops into the required steam or hot water. The primary purpose of the boiler is to supply
energy to the facility’s operations — for heat, manufacturing processes, laundry, kitchen, etc. The nature of the
facility’s operation will dictate whether aa steam or hot water boiler should be used.
The general information in this manual applies directly to Cleaver-Brooks Model CB Boilers in sizes ranging from
400 through 800 boiler horsepower for the following fuels:
Series 100 Light Oil (No. 2) only
Series 200 Light Oil (No. 2) or Gas
Series 400 Heavy Oil (No. 6) or Gas
Series 600 Heavy Oil (No. 6) only
Series 700 Gas only
NOTE: Although the Series 400 or 600 burner is designed and designated to burn No. 6 oil, the burner
will handle grades 4 and 5 equally well, with some possible modifications. While the manual contains per-
tinent information on No. 6 fuel oil, all references to No. 6 fuel should be considered applicable to all
grades of heavy oil.
750-91 (revised 2009) 1-1

FIGURE 1-1. Firetube Boiler (cutaway view)
Rated Capacity 400 through 800 hp

Operating Pressure Steam: 15 - 250 psig, or higher if specified
Hot Water: 30 - 250 psig, or higher if specified
Ignition Automatic
Firing Full Modulation Through Operating Ranges
Burner (Gas) Non-premix, Orificed Type
Air Damper Rotary Type (Electrically Modulated)
1-2 750-91 (revised 2009)

1.2 — The Boiler
The LE option, available on Cleaver-Brooks firetube boilers, reduces nitrogen oxide (NOX) emissions, a major pre-
cursor to ozone pollution (smog). Carbon monoxide (CO) emissions also tend to be lower, die to increased turbu-
lence caused by the addition of the flue gasses into the combustion air stream, thereby improving combustion.
The LE Option is used on Cleaver-Brooks Model CB firetube boilers firing either natural gas and/or light oil, and
is compatible with both hot water and steam systems.
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. In this
approach, the combustion air fan handles both the combustion air and the recirculated flue gasses. Accordingly,
this method is called Induced Flue Gas Recirculation (IFGR) because the flue gas is “induced” into the fan inlet.
The LE Option, with its various levels of IFGR systems, can affect the selection of the combustion air fan, motor,
burner, and other components. Several different system configurations are available, depending on the require-
ments for NOX emissions and the fuels used. All systems use similar primary components, but may have different
linkage controls, IFGR damper, fan, and motor sizes.
Always order genuine Cleaver-Brooks parts from your local Cleaver-Brooks authorized representative.
The boiler and related equipment installation are to be in compliance with the standards of the National Board of
Fire Underwriters. Installation should also conform to state and local codes governing such equipment. Prior to
installation, the proper authorities having jurisdiction are to be consulted, permits obtained, etc. All boilers in the
above series comply, when equipped with optional equipment, to Industrial Risk Insurers (IRI), Factory Mutual
(FM), or other insuring underwriters requirements.
1.2 — The Boiler

The Model CB boiler is a packaged firetube boiler of welded steel construction and consists of a pressure vessel,
burner, burner controls, forced draft fan, damper, air pump, refractory, and appropriate boiler trim.
The horsepower rating of the boiler is indicated by the numbers following the fuel series. Thus, CB700-250 identi-
fies a gas-fired 250 hp boiler.
The firetube construction provides some characteristics that differentiate it from other boiler types. Because of its
vessel size, the firetube contains a large amount of water, allowing it to respond to load changes with minimum
variation in steam pressure.
Firetube boilers are rated in boiler horsepower (BHP), which should not be confused with other horsepower mea-
surements.
Hot water is commonly used in heating applications with the boiler supplying water to the system at 180º F to 220º
F. The operating pressure for hot water heating systems usually in 30 psig to 125 psig.
Steam boilers are designed for low pressure or high pressure applications. Low pressure boilers are limited to 15
psig design, and are typically used for heating applications. High pressure boilers are typically used for process loads
and can have a design pressure of 75 to 350 psig.
750-91 (revised 2009) 1-3

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 thick-
ness or physical characteristics of the pressure vessel parts of the boiler. Typically, the safety valves are set at or
below design pressure. Operating pressure is the pressure of the boiler at which it normally operates. The operating
pressure usually is maintained at a suitable level below the setting of the pressure relieving valve(s) to prevent their
frequent opening during normal operation.
The type of service that your boiler is required to provide has an important bearing on the amount of waterside
care it will require.
! Caution
Waterside care is of prime importance. For specific information or assistance with your water treatment requirements,
contact your Cleaver-Brooks service and parts representative. Failure to follow these instructions could result in equip-
ment damage.
Feedwater equipment should be checked and ready for use. Be sure that all valves, piping, boiler feed pumps, and
receivers are installed in accordance with prevailing codes and practices.
Water requirements for both steam and hot water boilers are essential to boiler life and length of service. Constant
attention to water requirements will pay dividends in the form of longer life, less downtime, and prevention of
costly repairs. Care taken in placing the pressure vessel into initial service is vital. The waterside of new boilers and
new or remodeled steam or hot water systems may contain oil, grease, or other foreign matter. A method of boiling
out the vessel to remove accumulations is described in Chapter 3.
The operator should be familiar with Chapter 3 before attempting to place the unit into operation.
1.3 — Construction
Steam boilers designed for 15 psig and hot water boilers designed for 250º F at 125 psi or less are constructed in
accordance with Section IV, Power Boilers, of ASME Code.
Steam boilers designed for operating pressures exceeding 15 psig are constructed in accordance with Section 1,
Power Boilers, of the ASME Code. hot water boilers designed for operating temperatures above 250º F or 125 psi
are likewise built to ASME Code.
1-4 750-91 (revised 2009)

1.4 — Steam Controls (All Fuels)
FIGURE 1-2. Steam Boiler: Light Oil or Gas Fired
1.4.1 — Operating Limit Pressure Control

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.
1.4.2 — High Limit Pressure Control

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. The high limit pressure control is nor-
mally equipped with a manual reset.
750-91 (revised 2009) 1-5

1.4.3 — Modulating Pressure Control

Senses changing boiler pressures and transmits the information to the modulating motor to change the burner fir-
ing rate when the manual-automatic switch is set on “automatic.”
FIGURE 1-3. Boiler Controls
1.4.4 — Low Water Cutoff and Pump Control

Float-operated control responds to the water level in the boiler. It performs two distinct functions:
• Stops firing of the burner if water level lowers below the safe operating point. Energizes the low-water light in
the control panel, and it also causes the low-water alarm bell (optional equipment) to ring. Code requirements of
some models require a manual reset type of low-water cutoff.
• Starts and stops the feedwater pump (if used) to maintain water at the proper operating level.
FIGURE 1-4. Low Water Cutoff Pump Control.
1-6 750-91 (revised 2009)

! Caution
Determine that the main and auxiliary low water cutoffs and pump control are level after installation and throughout
the equipment’s operating life. Failure to follow these instructions could result in equipment damage.
1.4.5 — Water Column Assembly

Houses the low-water cutoff and pump control and includes the water gauge glass and gauge glass shutoff cock.
1.4.6 — Water Column Drain Valve

Provided so that the water column and its piping can be flushed regularly to assist in maintaining cross-connecting
piping and in keeping the float bowl clean and free of sediment. A similar drain valve is furnished with auxiliary
low-water cutoff for the same purpose.
1.4.7 — Water Gauge Glass Drain Valve

Provided to flush the gauge glass.
FIGURE 1-5. Water Column Assembly & LWCO
1.4.8 — Vent Valve

Allows the boiler to be vented during filling, and facilitates routine boiler inspection as required by ASME Code.
1.4.9 — Stack Temperature gauge

Indicates flue gas outlet temperature.
750-91 (revised 2009) 1-7

1.4.10 — Auxiliary Low-Water Cutoff

Breaks the circuit to stop burner operation in the event boiler water drops below the master low-water cutoff point.
Manual reset type requires manual resetting in order to start the burner after a low-water condition.
1.4.11 — Safety Valve(s)

Prevents buildup over the design pressure of the pressure vessel. The size, rating, and number of valves on a boiler
is determined by the ASME Boiler Code. The safety valve and the discharge piping are to be installed to conform
to the ASME Code requirements. The installation of a valve is of primary importance to its service life. A valve
must be mounted in a vertical position so that discharge piping and code required drains can be properly piped to
prevent buildup of back pressure and accumulation of foreign material around the valve seat area. Apply only a
moderate amount of pipe compound to male threads and avoid overtightening, which can distort the seats. Use
only flat-jawed wrenches on the flats provided. When installing a flange-connected valve, use a new gasket and
draw the mounting bolts down evenly. Do not install or remove side outlet valves by using a pipe or wrench in the
outlet.
FIGURE 1-6. Safety Valve
! Warning
Only properly qualified personnel such as the safety valve manufacturer’s certified representative can adjust or repair
the boiler safety valves. Failure to follow these instructions could result in serious injury or death.
1-8 750-91 (revised 2009)

1.5 — Hot Water Controls (All Fuels)
1.5.1 — Water Pressure and Temperature Gauge

Indicates the internal water pressure and the boiler water temperature.
FIGURE 1-7. Water Pressure and Temperature Gauge & Limit Controls (configurations will vary)
1.5.2 — Operating Limit Temperature Control

Breaks a circuit to stop burner operation on a rise of boiler temperature at a selected setting. It is adjusted to stop
or start the burner at a preselected operating temperature.
1.5.3 — High Limit Temperature Control

Breaks a circuit to stop burner operation on a rise of temperature at a selected setting. It is adjusted to stop burner
at a preselected temperature above the operating control setting. The high limit temperature control normally is
equipped with a manual reset.
1.5.4 — Modulating Temperature Control

Senses changing boiler water temperature and transmits the information to the modulating motor to change the
burner firing rate when the manual-automatic switch is set on “automatic.”
1.5.5 — Low-Water Cutoff

Breaks the circuit to stop burner operation if the water level in the boiler drops below a safe operating point, acti-
vating a low-water light and optional alarm bell if burner is so equipped.
750-91 (revised 2009) 1-9

1.5.6 — 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.

Relieves the boiler of pressure higher than the design pressure or a lower pressure, if designated. Relief valves and
their discharge piping are to be installed to conform to ASME Code requirements.
! Warning
Only properly qualified personnel such as the safety valve manufacturer’s certified representative can adjust or repair
the boiler safety valves. Failure to follow these instructions could result in serious injury or death.
1.6 — IFGR Components
1.6.1 — Flue Gas Transfer Port, IFGR Damper, & Flange Collar
The flue gas transfer port is a tube that allows the flue gasses to travel from the exit of the fourth-pass tubes to the
entrance of the combustion air fan.
The IFGR damper controls the volume of flue gas induced into the combustion air stream. The damper is located
in the flue gas transfer port and is positioned by the control linkage.
1.6.2 — IFGR Damper Linkage

The IFGR damper is positioned by the control linkage. The linkage could consist of a single arm, or it could con-
sist of several arms driven from the jackshaft to provide modulating control.
FIGURE 1-8. Induced Flue Gas Recirculation System
1-10 750-91 (revised 2009)

1.6.3 — Over-Travel Mechanism

The over-travel mechanism has two functions. It allows the linkage to pass through the front door, and it allows
jackshaft rotation to exceed (over-travel) IFGR linkage movement. A set of springs allows the linkage to stay in a
fixed position while the jackshaft rotates.
1.6.4 — Fuel Change-Over Linkage

When a boiler is equipped to fire either gas or oil (dual fuel boilers), and the required NOX levels are below 60 ppm
on natural gas, a dual linkage arrangement is used to provide the different recirculation rates required for each fuel.
Two jackshaft drive arms are provided, one for oil and one for gas. The linkage is manually connected to the appro-
priate arm, based on the fuel being used.
On dual fuel boilers with two jackshaft drive arms, as defined above, a proximity switch is used to prove that the
correct linkage connection is made. (Refer to the wiring diagram provided with the boiler.)
FIGURE 1-9. Damper Linkage
750-91 (revised 2009) 1-11

1.6.5 — Fan/Motor Cassette

The fan and motor assemblies are designed as a cassette so that they can be removed from the front of the boiler
without opening the front door. The front door davit arm can be used to remove the assembly.
FIGURE 1-10. Fan/Motor Cassette
1.6.6 — Burner Drawer

The spudding pattern for the IFGR system may be different than that of a non-IFGR, High-Turndown CB Burner
of the same horsepower (HP) model designation.
1.6.7 — Combustion Air Inlet

The combustion air inlets are located at the top of the front door. Air enters from the rear of the air inlet shrouds,
which reduces the sound level and captures heat from the boiler and stack flue outlet.
1.6.8 — Front Door Insulation

If NOX emissions are below 60 ppm, the front door is insulated inside to control temperature build up. The insula-
tion is held in place with wire mesh.
1-12 750-91 (revised 2009)

CHAPTER 2 Burner Operation and
Control
2.1 — The Burner

The oil burner is of the low pressure, air atomizing (nozzle) type. The gas burner is of the non-premix orifice type.
The burners are ignited by a spark ignited gas pilot. The pilot is of the interrupted type and is extinguished after
main flame is established.
NOTE: A Series 100 boiler is usually equipped with a light oil pilot, although a gas pilot is also available.
Burners equipped to burn oil and gas (combination burners) include equipment for each distinct fuel. Since the
burner uses only one type of fuel at a time, a gas/oil selector switch is incorporated.
Regardless of which fuel is used, the burner operates with full modulation (within its rated operating range). The
burner returns to minimum firing position for ignition. High-pressure boilers (above 15 psi) can be wired for both
low-pressure and high-pressure modulation, which enables the boiler to operate at lower pressure during off-load
hours, but at a somewhat reduced steam output, dependent upon lower steam pressure and steam nozzle sizing.
The flame safeguard and program relay include a flame detector to supervise both oil and gas flames, and to shut
the burner down in the event of loss of flame. The programming portion of the control provides a pre-purging
period, proving of the pilot and main flame, and a period of continued blower operation to post-purge the boiler of
all unburned fuel vapor. Other safety controls shut down the burner under low-water conditions, excess steam
pressure, or water temperature.
Safety interlock controls include combustion and atomizing air proving switches and, depending upon the fuel and
insurance carrier requirements, controls that prove the presence of adequate fuel pressure, plus temperature prov-
ing controls when heated fuel oil is used.
The sequence of burner operation from startup through shutdown is governed by the program relay in conjunction
with the operating, limit, and interlock devices. The devices are wired into the circuitry to provide safe operation
and protect against incorrect operating techniques.
750-91 (revised 2009) 2-1

All CB boilers have the burner assembly attached to the front head. The entire head may be swung open for
inspection and maintenance.
Combustion air is provided by a centrifugal blower located in the front head. Combustion air delivery to the burner
is under the control of the modulating motor. The motor also regulates the flow of fuel through a linkage system
connected to the gas butterfly valve and/or oil through a cam opperated metering valve. Fuel input and air are thus
properly proportioned for most efficient combustion.
FIGURE 2-1. Secondary Air Flow (Standard CB)
Filtered primary air for atomizing fuel oil is furnished independently of combustion air by an air pump. The stan-
dard 78” firetube boiler is equiipped with the belt driven air pump. The CB-LE uses the frame mounted air pump.
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.
Indicator lights signaling load demand, fuel valve, low water, and flame failure conditions are standard equipment.
In addition to the standard basic controls supplied, other devices may be required to meet specific requirements of
an insurance carrier or local code. Refer to the Wiring Diagram (WD) prepared by Cleaver-Brooks for your specific
installation to determine the specific controls in the burner and limit control circuits. The function of individual
components is outlined in this chapter and the electrical sequence is covered in Chapter 3.
2-2 750-91 (revised 2009)

2.2 — Control and Component Function

The term “control” covers the more important valves and components, including, but not limited to, electrical con-
trols 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.
The actual controls furnished with any given boiler will depend upon the type of fuel for which it is equipped, and
whether it is a hot water or steam boiler. Refer to the applicable group or groups within this chapter that apply to
the particular boiler.
NOTE: Boilers with optional features may have control components not listed here.
2.3 — Components Common to All Boilers
Component Description
Forced Draft Fan Motor Drives forced draft fan directly to provide combustion air. Also
referred to as a blower motor.
Forced Draft Fan Provides all air, under pressure, for combustion of pilot fuel and
main fuel, and for purging.
Modulating Motor Operates the rotary air damper and fuel metering valves through a
cam and linkage system to provide proper air/fuel ratios under all
boiler load conditions.
Modulating Motor Transformer (located in the Reduces control circuit voltage (115 Vac) to required voltage (24
modulating motor) Vac) for operation of the modulating motor.
Forced Draft Fan Motor Starter Energizes forced draft fan (blower) motor.
Ignition Transformer Provides high voltage spark for ignition of gas pilot or light oil pilot.
Low Fire Switch An internal auxiliary switch, cam actuated by the motor shaft, which
must be closed to indicate that the air damper and fuel metering
valve are in the low fire position before an ignition cycle can occur.
Atomizing Air Proving Switch A pressure sensitive switch actuated by air pressure from the air
pump. Its contacts close to prove presence of atomizing air. The
fuel valves cannot be energized unless this switch is satisfied.
Manual-Automatic Switch When set at “automatic,” subsequent operation is at the command
of the modulating control, which governs the position of the modu-
lating motor in accordance with load demand. When set at “man-
ual,” the modulating motor, through the manual flame control, can
be positioned at a desired burner firing rate. The primary purpose
of the manual position is for testing and setting the air/fuel ratio
750-91 (revised 2009) 2-3

Manual Flame Control A manually operated potentiometer that permits the positioning of
the modulating motor to a desired burner firing rate when the man-
ual-automatic switch is set on “manual.” It is used primarily for ini-
tial or subsequent setting of fuel input throughout the firing range.
It has no control over the firing rate when the manual-automatic
Burner Switch A manually operated start-stop switch for directly starting and
stopping burner operation.
Flame Detector Monitors gas or oil pilot and energizes the programmer flame relay
in response to a flame signal. It continues to monitor main flame
(oil or gas) after expiration of pilot providing period. a standardly
equipped boiler has a lead sulfide (infrared sensitive) detector.
Combustion Air Proving Switch A pressure sensitive switch actuated by air pressure from the forced
draft fan. Its contacts close to prove presence of combustion air.
The fuel valves cannot be energized unless this switch is satisfied.
Alarm Sounds to notify the operator of a condition requiring attention.
The alarm is available as optional equipment.
Stack Thermometer Indicates temperature of vented flue gasses.
Diffuser A circular plate, located at the furnace end of the burner drawer,
that imparts a rotary swirling motion to combustion air immediately
prior to its entering the flame, thus providing a thorough and effi-
cient mixture with the fuel.
Rotary Air Damper Provides accurate control of combustion air in proportion to fuel
input for various load demands. It consists of two concentric cylin-
ders with openings. The outer is stationary. The inner is rotated,
under control of the modulating motor, to vary the effective size of
the openings where they overlap.
2-4 750-91 (revised 2009)

2.4 — Controls for Gas Firing
Indicator Lights Provide visual information of boiler operation as follows:
• Flame Failure
• Load Demand
• Low Water
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 an proper sequence, the operation of the blower
motor, ignition system, fuel valve(s), and the damper motor. The
sequence includes air purge periods prior to ignition and upon
burner shutdown.
The flame detector portion of the control monitors both oil and gas
flames and provides protection in the event of loss of a flame signal.
The control recycles automatically during normal operation, or fol-
lowing a power interruption. It must be manually reset following a
safety shutdown caused by a loss of flame. An internal checking cir-
cuit, effective on every start, prevents burner operation in the event
anything causes the flame relay to hold in during this period.

Depending upon the requirements of the insurance carrier or other governing agencies, the gas flow control sys-
tem, or gas train, may consist of some, or all, of the items listed below.
Gas Pilot Valve A solenoid valve that opens during the ignition period to admit fuel
to the pilot. It closes after main flame is established. The sequence
of energizing and de-energizing is controlled by the programming
relay. A second gas pilot valve may be required by insurance regula-
tions.
Gas Pilot Vent Valve When a second gas pilot valve is required, a normally open vent
valve (optional equipment) is installed between them. Its purpose is
to vent gas to the atmosphere, should any be present in the pilot
line when the pilot valves are closed. The valve closes when the
pilot valves are energized.
Gas Pilot Shutoff Cock For manually opening or closing the gas supply to the gas pilot
valve.
Gas Pressure Gauge Indicates gas pressure to pilot.
Gas Pressure Regulating Valve Reduces incoming gas pressure to suit the pilot.
Gas Pilot Aspirator Provides complete mixing of gas and air to the pilot.
Gas Pilot Adjusting Cock Regulates the size of the gas pilot flame.
750-91 (revised 2009) 2-5

Gas Modulating Cam An assembly, consisting of a quadrant, a series of adjustable allen-
head screws, and a contour spring, provided for adjustment of gas
input at any point in the modulating range.
Main Gas Cock For manually opening and closing the main fuel gas supply down-
stream of the main gas line pressure regulator. A second shutoff
cock, downstream of the main gas valve(s), is installed to provide a
means of shutting off the gas line whenever a test is made for leak-
age across the main gas valve.
Butterfly Gas Valve The pivoted disc in the valve is actuated by connecting linkage from
the gas modulating cam to regulate the rate of gas flow to the
burner.
Main Gas Valves Electrically actuated shutoff valves that open simultaneously to
admit gas to the burner. The downstream valve is equipped with a
“proof of closure” switch that is connected into the pre-ignition
interlock circuit.
Low Gas Pressure Switch A pressure actuated switch that is closed whenever main gas line
pressure is above a preselected pressure. Should the pressure drop
below the setting, the switch contacts open a circuit causing the
main gas valve(s) to close, or prevent the burner from starting. The
switch is usually equipped with a device that must be manually reset
after being tripped.
High Gas Pressure Switch A pressure actuated switch that is closed whenever main gas line
pressure is below a preselected pressure. Should the pressure rise
above the setting, the switch contacts will open a circuit causing the
main gas valve(s) to close, or prevent the burner from starting. The
switch is usually equipped with a device that must be manually reset
after being tripped.
Leakage Connection The body of the gas valve has a plugged opening that is used when-
ever it is necessary to conduct a test for possible leakage across the
closed valve.
2-6 750-91 (revised 2009)

FIGURE 2-2. Gas Train (configurations may vary)
FIGURE 2-3. Gas Modulating Cam
750-91 (revised 2009) 2-7

FIGURE 2-4. Secondary Air Flow with Gas Train
2-8 750-91 (revised 2009)

2.5 — Controls Common to Oil-Fired Boilers

The following items are applicable to all oil-fired or gas and oil-fired boilers. Additional controls for No. 6 oil are
listed in section 2.9 — Automatic Ignition.
FIGURE 2-5. Front of Burner Drawer.
Oil Drawer Switch Opens the limit circuit if oil drawer burner gun is not latched in the
forward position required for burning oil.
Atomizing Air Proving Switch Pressure actuated switch whose contacts are closed when sufficient
atomizing air pressure from the air pump is present for oil firing. Oil
valve(s) will not open, or will not remain open, unless switch con-
tacts are closed.
Atomizing Air Pressure Gauge Indicates the atomizing air pressure at the burner gun.
Oil Solenoid Valve Opens when energized through contacts in the programmer and
allows fuel oil flow from the oil metering valve to the burner nozzle.
A light oil fired burner uses two valves operating simultaneously.
750-91 (revised 2009) 2-9

Fuel Oil Controller An assembly combining into a single unit the gauges, regulators,
and valves required for regulating the flow of fuel oil. All controllers
have the following integral parts. In addition to these, the controller
used on a No. 6 oil fired burner has additional components
described in section 2.1.
• Oil Metering Valve: Valve metering stem moves to increase or
decrease the orifice area to regulate the supply of fuel oil to the
burner nozzle in accordance with boiler load variances. Stem
movement is controlled by the modulating motor through link-
age and the oil metering cam.
• Oil Modulating Cam: Assembly consisting of a quadrant, a series
of adjustable allen-head screws and a contour spring provided
for adjustment of oil input at any point in the modulating range.
• Oil Burner Pressure Gauge: Indicates pressure of the fuel oil at
the metering valve.
• Oil Pressure Regulator: For adjustment of the pressure of oil at
the metering valve.
Oil Relief Valve Maintains a constant oil supply pressure to the fuel oil controller by
bypassing excess fuel oil.
Terminal Block
Fuel Oil Strainer Prevents foreign matter from entering the burner system.
Gas Pilot See section 2.4 for description of the various components.
Light Oil Pilot Valve: When a light oil pilot is furnished, a solenoid valve is provided to
control flow of fuel to the pilot nozzle. It is energized through pro-
grammer contacts. It is de-energized to shut off pilot fuel flow after
main flame is ignited and established.
Back Pressure Orifice A restriction located in the oil return line immediately downstream
of the fuel oil controller to create back pressure (100 and 200 series
only).
2-10 750-91 (revised 2009)

Air Pump Module Assembly Provides the compressed air required to atomize the fuel oil for
proper combustion. It is started automatically by the programmer’s
sequence. Components include:
• Air Pump Motor: Drives the air pump and an air cooling fan.
The motor is started and stopped simultaneously with the
forced draft fan motor.
• Air Pump: Provides air for atomization of the fuel oil.
• Air Filter: The filter cleans the air supply prior to entering the air
pump.
• Check Valve: Prevents lubricating oil and compressed air from
surging back through the pump and air filter when the pump
stops.
• Air-Oil Receiver Tank: Holds a supply of oil for lubricating the
air pump. The receiver tank also separates lube oil from the
atomizing air before delivery to the nozzle.
• Lube Oil Level Sight Glass: Indicates the level of lubricating oil
in the air-oil receiver tank.
• 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.
• Lube Oil Fill Pipe and Strainer: Used when adding oil to the air-
oil receiver tank.
Low Oil Pressure Switch (optional) Switch contacts open when the fuel oil pressure drops below
selected pressure. Switch will interrupt the limit circuit upon loss of
sufficient fuel oil pressure for correct combustion.
Fuel Oil Pump Transfers fuel oil from the storage tank and delivers it under pres-
sure to the burner system.
FIGURE 2-6. Oil Control Valve Assembly - Light Oil
750-91 (revised 2009) 2-11

FIGURE 2-7. Oil Control Valve Assembly - Heavy Oil
FIGURE 2-8. Air Pump Components
2-12 750-91 (revised 2009)

2.6 — Additional Controls for Heavy Oil

The oil heater is provided to heat heavy oil to the point where it can be effectively atomized and burned. Most
heavy oil heaters utilize an electric heater to reduce the viscosity of the heavy oil until steam or hot water is available
to the oil heater shell.
Heavy oil heaters, operating with hot water, will have additional controls.
Heater Switch Manually provides power to the oil heater system.
Oil Heater (electric) Used for heating sufficient fuel oil for low-fire flow during cold
starts before steam or hot water is available for heating. The heater
must be turned off during extended boiler lay-up, or at any time the
fuel oil transfer pump is stopped.
Electric Oil Heater Thermostat Senses fuel oil temperature and energizes or de-energizes the elec-
tric oil heater to maintain required temperature of the fuel oil.
Steam Oil Heater Thermostat Senses fuel oil temperature and controls the opening and closing of
the steam heater valve to maintain the required temperature of the
fuel oil.
Oil Heater Shell (steam/hot water) Heats fuel oil through medium of steam or hot water. Electric
heater is housed in the steam heater, but is housed separately on a
hot water heater. Steam oil heaters on 15 psi boilers operate at boiler
pressure. Steam oil heaters furnished on high pressure boilers are to
be operated at less than 15 psi. Operation is accomplished with a
steam pressure regulator valve.
Oil Return Excess oil returned to the heavy oil supply tank.
Oil Inlet From Supply Tank Heavy oil inlet from the supply tank.
Steam Heater Check Valve Prevents oil contamination of the waterside of pressure vessel
should any leakage occur in the oil heater.
Steam Trap Drains condensate and prevents loss of steam from the steam oil
heater. Condensate must be piped to a safe point of discharge.
Check Valve (steam heater discharge) Prevents air entry during shutdown periods when cooling action
may create vacuum within steam heater.
Steam Heater Pressure Regulator Adjust to provide reduced (usually less than 15 psi) steam pressure
to the heater to properly maintain the required fuel oil temperature.
The regulator and the pressure gauge are not furnished on 15 psi
units.
Steam Heater Solenoid Valve A normally open solenoid valve opened by the steam oil heater ther-
mostat to allow flow of steam to the steam heater to maintain tem-
perature of fuel oil.
Steam Pressure Gauge Indicates steam pressure entering the heater.
Oil Relief Valve allows release of excessive pressure to the return side of the oil line
piped to the tank.
750-91 (revised 2009) 2-13

Low Oil Temperature Switch Thermostatic switch that prevents burner from starting, or stops
burner firing if fuel oil temperature is lower than required for oil
burner operation.
Oil Supply Pressure Gauge Indicates fuel oil pressure in the oil heater and supply pressure to
the fuel oil controller’s pressure regulator.
FIGURE 2-9. Oil Heating Assembly (Steam)
In addition to the components of the fuel oil controller identified in section 2.5, the following are used with a
heavy oil fired burner.
High Oil Temperature Switch (optional) Switch contacts open when fuel oil temperature raises above a
selected temperature. Switch will interrupt the limit circuit in the
event fuel oil temperature rises above the selected point.
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.
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 tem-
perature of fuel oil.
Fuel Oil Thermometer Indicates temperature of fuel oil being supplied to the fuel oil con-
troller.
Back Pressure Valve For adjustment of oil pressure on the downstream side of the
metering valve. Also regulates rate and return oil flow.
Oil Return Pressure Gauge Indicates oil pressure on the return side of the fuel oil controller.
2-14 750-91 (revised 2009)

2.7 — Controls for Combination Burners Only
Manual Bypass Valve Provided as a timer saver in establishing oil flow. When open, it per-
mits circulation of oil through the supply and return lines. The valve
MUST be closed prior to initial light off.
Orifice Oil Control Valve Valve may be opened prior to startup to aid in establishing fuel oil
flow through the controller. The valve MUST be closed prior to
initial light off. Its disc has an orifice to permit a continuous circula-
tion of hot fuel oil through the controller.
Air Purge Valve Solenoid valve opens simultaneously with closing of oil solenoid
valve at burner shutdown, allowing compressed air to purge oil
from the burner nozzle and adjacent piping. The oil is burned by
the diminishing flame, which continues burning for approximately 4
seconds after the oil solenoid valve closes.
Air Purge Orifice Nozzle Limits purging air to proper quantity for expelling unburned oil at
normal delivery rate.
Air Purge Orifice Nozzle Filter Filters the purging air of any particles that might plug the air purge
orifice nozzle.
Air Purge Check Valve Valve check prevents fuel oil from entering the atomizing air line.
Air Purge Relay When energized, control operation of air purge valve.

Burners equipped to burn either oil or gas include equipment for each fuel. The Gas-Oil Selector Switch engages
the appropriate interlocks and controls for gas or oil operation. Chapter 4 details the required mechanical functions
of each fuel system.
750-91 (revised 2009) 2-15

2.8 — Combustion Air

Air for combustion of fuel (referred to as “secondary” air) is furnished
by the forced draft fan mounted in the boiler head. In operation, air
pressure is built up in the entire head and is forced through a diffuser
plate for a thorough mixture with the fuel for proper combustion. The
supply of secondary air to the burner is governed by automatically throt-
tling the output of the fan by regulating the rotary air damper. The
damper provides the proper amount of air for correct ratio of air to fuel
for efficient combustion at all firing rates.
FIGURE 2-10. Secondary Air Flow Diagram
2.9 — Automatic Ignition

Oil or gas burners are ignited by an interrupted type pilot. The pilot flame is ignited automatically by an electric
spark.
In the case of a combination burner, the gas pilot is used to ignite either the main gas flame or the oil flame.
At the beginning of the ignition cycle, and governed by the program relay, the pilot solenoid valve and ignition
transformer are simultaneously energized.
The ignition transformer supplies high voltage current for the igniting spark. A gas pilot has a single electrode and
a spark arcs between the tip of the electrode and the wall of the tube surrounding it. The pilot solenoid valve and
the transformer are de-energized after main flame is ignited and established.
Fuel for the gas pilot is supplied from the utility’s main, or from a tank (bottle) supply. Secondary air flows into and
mixes with the pilot gas stream to provide an adequate flame.
Insurance regulations may require two gas pilot solenoid valves with a normally open vent valve between them.
The vent valve closes when the gas pilot valves open, and opens when the gas pilot valves shut to vent gas, should
any be present in the pilot line during the de-energized period of the gas pilot valves.
2-16 750-91 (revised 2009)

2.10 — Atomizing Air

Air for atomizing the fuel oil (referred to as “primary” air) is pumped by the air pump into the air-oil receiver tank
and delivered under pressure through a manifold block to the oil burner nozzle.
The atomizing air mixes with the fuel oil just prior to the oil leaving the nozzle.
Atomizing air pressure is indicated by the air pressure gauge on the burner gun.
Air pressure from the pump also forces sufficient oil from the tank to the pump bearings to lubricate them and also
to provide a seal and lubrication for the pump vanes. As a result, the air delivered to the tank contains some lube
oil, however, most of it is recovered 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. Further explana-
tion is given in chapter 5.
2.11 — Oil Fuel Flow: Light Oil

Fuel oil is delivered into the system by a supply pump which delivers part of its discharge to the oil burner. Excess
oil is returned to the oil storage tank through the fuel oil relief valve and oil return line. Normally the pump oper-
ates only while the burner is in operation, although a positioning switch is often provided so that either continuous
or automatic pump operation can be obtained (See Figure 2-10).
The oil flows through a fuel oil strainer to prevent any foreign material from flowing through the control valves
and nozzle. The fuel oil controller contains in a single unit, a metering valve, a regulator, and a gauge required to
regulate the pressure and flow of oil to the burner. The adjustable regulator controls the pressure. To assist in the
regulation, back pressure is created by an orifice nozzle located in the oil return line immediately downstream of the
fuel oil controller.
The programming relay energizes or de-energizes the solenoid oil valves to permit or cut off oil flow to the burner.
Two valves, operating simultaneously, are used. The valves are closed when de-energized. They cannot be opened
(energized) unless the combustion air proving switch and the atomizing air proving switch are closed. The two
switches are satisfied, respectively, by sufficient combustion air pressure from the forced draft fan and pressurized
air from the air pump.
The oil flow to the burner is controlled by the movement of the metering stem in the oil metering valve, which var-
ies the flow to meet load demands. The metering valve and the air damper are controlled simultaneously at all times
by the modulating motor to proportion combustion air and fuel for changes in load demand.
750-91 (revised 2009) 2-17

FIGURE 2-11. Light Oil Flow Diagram
2-18 750-91 (revised 2009)

2.12 — Oil Fuel Flow: Heavy Oil

Fuel oil is delivered into the system by the fuel oil supply pump which delivers part of its discharge to the oil heater.
The remainder of the fuel oil returns to the oil storage tank through a fuel oil relief valve and oil return line (see
Figure 2-11).
The combination electric and steam oil preheater is controlled by thermostats. The electric oil heater thermostat
energizes the electric heater, which is provided to supply heated oil on cold starts. The steam heater thermostat
controls operation of the steam solenoid valve to permit a flow of steam to the heater when steam is available.
A hot water boiler is equipped to heat the oil with hot water from the boiler, unless other preheating equipment is
utilized. The electric heater, which is housed separately, is sized to provide heated oil on a cold start. The hot water
thermostat controls the operation of a pump that supplies hot water to the oil heater when hot water is available.
The heated oil flows through a fuel oil strainer to prevent any foreign matter from entering the control valves and
nozzle.
The fuel oil controller contains, in a single unit, the necessary valves, regulators and gauges to regulate the pressure
and flow of oil to the burner.
The program relay energizes or de-energizes the solenoid oil valve to permit or cut off oil flow to the burner. The
oil solenoid is closed when de-energized. It cannot be opened (energized) unless the combustion air proving
switch, the atomizing air proving switch, and the low oil temperature and any pressure switches are closed. They are
satisfied, respectively, by sufficient combustion air pressure from the forced draft fan, pressurized air from the air
pump, and sufficient oil temperature and pressure.
Oil flow to the burner is controlled by the movement of the metering stem of the oil metering valve, which varies
the flow to meet load demands. The metering valve and the air damper are controlled simultaneously at all times by
the modulating motor to proportion combustion air and fuel for changes in load demand.
Oil is purged from the burner gun upon each burner shutdown. The air purge solenoid valve opens as the fuel
valve closes, diverting atomizing air through the oil line. The air assures a clean nozzle and line for subsequent
restart.
750-91 (revised 2009) 2-19

FIGURE 2-12. No. 6 Heavy Oil Flow Diagram (Steam-Electric Heater)
2-20 750-91 (revised 2009)

2.13 — Gas Fuel Flow

Metered gas from the utility flows through the pressure regulator at a reduced pressure suitable to burner require-
ments, through the main gas shutoff cock, main gas valve(s), and modulating butterfly gas valve to the non-premix
orifice-type burner.
The main gas valve is of the normally closed type, and is opened (energized) in proper sequence by the program-
ming relay.
The butterfly gas valve modulates the flow of gas from low through high fire settings. The position of the butterfly
valve disc is governed by the gas modulating cam. The butterfly gas valve, and the air control damper are controlled
simultaneously by the modulating motor to proportion combustion air and fuel for changes in load demand.
The gas flow rate required for rated burner input depends upon the heating value (Btu/cubic foot) of the gas sup-
plied. The gas pressure regulator adjusts the gas pressure (flow rate) to the entrance of the gas train. The regulator
is not always supplied with the burner, but may be provided by others.
The main gas valves cannot be energized (opened) unless the combustion air proving switch is closed to indicate a
sufficient supply of combustion air. The low gas pressure and high gas pressure switches must be closed to prove
sufficient, but not excessive, gas fuel pressure.
2.14 — Modulating Firing

The modulating motor, through a linkage arrangement, controls the air damper and the butterfly gas valve, or the
oil metering valve, to maintain a constant air/fuel ratio throughout the firing range.
During burner operation, the motor is controlled by a modulating pressure control on a steam boiler, or by a mod-
ulating temperature control on a hot water boiler. A manually operated potentiometer is provided to permit posi-
tioning of the motor at the desired burner firing rate. The potentiometer is used primarily for initial or subsequent
checking and setting of fuel input. Normal operation should be with the manual-automatic switch in the “auto-
matic” position and under the control of the modulating control.
The modulating motor (commonly called a damper motor) is reversible. It has an internal limit switch that restricts
shaft rotation to 90º. During normal operation the motor will move in either direction or stop at any position
within the range.
The motor potentiometer is electrically connected to a matching potentiometer in the modulating control. Chang-
ing steam pressure or water temperature alters the electrical resistance of the modulating controller potentiometer.
The change in resistance compels an integral balancing relay to start, stop, or reverse the motor rotation. Rotation
in either direction continues until the resistance ratio of the two potentiometers is equal.
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. A low-fire switch, integral to the motor, is actuated by the rotation
750-91 (revised 2009) 2-21

of the motor. The switch must be closed to establish that the damper and fuel metering valves are in the low-fire
position before the programmer commences into the ignition period. During this time, neither the manual flame
control nor the modulating control have any control over the damper motor, regardless of their setting.
An optionally equipped boiler uses a second integral switch to establish that the motor has driven the damper to an
open position during the pre-purge period. The second integral switch closes, as high fire position is approached,
to complete an internal circuit in the programmer to allow continuation of the programming cycle.
2-22 750-91 (revised 2009)

CHAPTER 3 Waterside Care and
Requirements
3.1 — Overview
The operator should be familiar with this chapter 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.
Feedwater equipment should be checked and ready for use. Be sure that all valves, piping, boiler feed pumps, and
receivers are installed in accordance with prevailing codes and practices.
Water requirements for both steam and hot water boilers are essential to boiler life and length of service. It is vital
care be taken in placing the pressure vessel into initial service. The waterside of new boilers and new or remodeled
steam or hot water systems may contain oil, grease, or other foreign matter. A method of boiling out the vessels to
remove the accumulations is described later in this chapter.
Boilers, as a part of a hot water system, require proper water circulation. The system must be operated as intended
by its designer in order to avoid thermal shock or severe, possibly damaging, stresses from occurring to the pres-
sure vessel.
NOTE: This manual only covers boilers using water. Glycol solutions have different operating requirements, circula-
tion rates, temperatures, etc.
3.2 — Water Requirements: Hot Water Boiler
3.2.1 — Air Removal

The hot water outlet includes a dip tube which extends 2 to 3 inches into the boiler. The dip tube reduces the pos-
sibility of air, which may be trapped at the top of the shell, from entering into the system. Oxygen or air released in
the boiler will collect or be trapped at the top of the boiler shell.
750-91 (revised 2009) 3-1

The air vent tapping on the top center line of the boiler should be piped into the expansion or compression tank.
Air trapped at the top of the boiler will find its way out of the boiler through the tapping.
3.2.1.1 — Minimum Water Temperature

The minimum recommended boiler water temperature is 170º F. When water temperatures lower than 170º F are
used, the combustion gasses are reduced in temperature to a point where water vapor condenses, causing corrosion
in the boiler and possible breeching.
Condensation is more severe on a unit that operates intermittently and which is greatly oversized for the actual
load. Condensation can be minimized by maintaining the boiler water temperatures above 170º F.
A temperature of 170º 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. (The elec-
tric preheater on the boiler must provide additional heat to the oil if boiler water temperature is not maintained
above 200º F.
NOTE: If the operating water temperature going to the system must be lower than 170º F, the operating boiler water
temperature should be a minimum of 170º F (200º F if used to preheat No. 6 oil) and mixing valves should be used to
avoid damage to the equipment.
3.2.1.2 — Rapid Replacement of Boiler Water

The system layout and controls should be arranged to prevent the possibility of pumping large quantities of cold
water into a hot boiler, which will cause shock or thermal stresses. Water temperature in a boiler of 200º F or 240º
F cannot be completely replaced with 80º F water in a few minutes time without causing thermal stress. The same
fact applies to periods of normal operation, as well as during initial startup.
NOTE: The circulating pumps should be interlocked with the burner so that the burner cannot operate unless the cir-
culating pump is running in order to avoid damage to the equipment.
When individual zone circulating pumps are used, it is recommended that they be kept running, even though the
hear users do not require hot water. The relief device or bypass valve will thus allow continuous circulation through
the boiler and can help prevent rapid replacement of boiler water with cold zone water.
3.2.1.3 — Continuous Flow Through the Boiler

The system should be piped and the controls arranged to allow water circulation through the boiler under all oper-
ating conditions. The operation of three-way valves and system controls should be checked to be sure that the
boiler will not be bypassed. Constant circulation through the boiler eliminates the possibility of stratification within
the unit and results in more even water temperatures to the system.
A rule of thumb of 3/4 to 1 gpm per boiler horsepower can be used to determine the minimum continuous flow
rate through the boiler under all operating conditions. The operator should determine that a flow of water exists
through the boiler before initial firing or refiring after the boiler has been drained.
3.2.2 — Water Circulation

The following chart shows the maximum gpm circulation rate of boiler water in relation to full boiler output and
system temperature drop.
3-2 750-91 (revised 2009)


SIZE PUT (1000)
(BHP) BTU/HR 10 20 30 40 50 60 70 80 90 100
15 500 100 50 33 25 20 17 14 12 11 10
20 670 134 67 45 33 27 22 19 17 15 13
30 1,005 200 100 67 50 40 33 29 25 22 20
40 1,340 268 134 89 67 54 45 38 33 30 27
50 1,675 335 168 112 84 67 56 48 42 37 33
60 2,010 402 201 134 101 80 67 58 50 45 40
70 2,345 470 235 157 118 94 78 67 59 52 47
80 2,680 536 268 179 134 107 90 77 67 60 54
100 3,350 670 335 223 168 134 112 96 84 75 67
125 4,185 836 418 279 209 168 140 120 105 93 84
150 5,025 1,005 503 335 251 201 168 144 126 112 100
200 6,695 1,340 670 447 335 268 224 192 168 149 134
250 8,370 1,675 838 558 419 335 280 240 210 186 167
300 10,045 2,010 1,005 670 503 402 335 287 251 223 201
350 11,720 2,350 1,175 784 587 470 392 336 294 261 235
400 13,400 2,680 1,340 895 670 535 447 383 335 298 268
500 16,740 3,350 1,675 1,120 838 670 558 479 419 372 335
600 20,080 4,020 2,010 1,340 1,005 805 670 575 502 448 402
700 23,430 4,690 2,345 1,565 1,175 940 785 670 585 520 470
800 26,780 5,360 2,680 1,785 1,340 1,075 895 765 670 595 535
FIGURE 3-1. Maximum Circulating Rate Chart
3.2.2.1 — Multiple Boiler Installations

When multiple boilers are used, care must be taken to ensure adequate or proportional flow through the boilers.
Proportional flow can best be accomplished by use of balancing valves and gauges in the supply line from each
boiler. If balancing valves or orifice plates are used, a significant pressure drop (3 to 5 psi) must be taken across the
balancing device to accomplish the purpose.
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.
The net result would be that the common header water temperature to the system would not be up to the desired
point.
750-91 (revised 2009) 3-3

3.2.2.2 — Pump Location

It is recommended that the system circulating pumps take suction from the outlet connection on the boiler, and
that they discharge to the system load in order to put the boiler and the expansion tank on the suction side of the
pump. The suction side is preferred because it decreases air entry into the system and does not impose the system
head on the boiler.
It is common practice to install a standby system circulating pump. The main circulating pumps are usually located
adjacent to the boilers in the boiler room.
3.2.2.3 — Pump Operation

Pumps are normally started and stopped by manual switches. It is also desirable to interlock the pump with the
burner so that the burner cannot operate unless the circulating pump is running.
3.2.3 — Pressure
The design of the system and usage requirements 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 ensure that the proper
relationship of pressure-to-temperature exists within the boiler so that all of the boiler’s internal surfaces are fully
wetted at all times. For this reason, the internal boiler pressure, as indicated on the water pressure gauge, must be
held to the level identified on Figure 3-2.
FIGURE 3-2. Internal Boiler Pressure
3-4 750-91 (revised 2009)

3.3 — Water Requirements: Steam Boiler
When initially firing a newly installed boiler, or when cutting an existing boiler into an operating system, the boiler
or boilers to be cut into operation MUST be pressurized equal to the system and/or other boilers prior to opening
the header valves.
It is advisable to have a thermometer installed in the return line to indicate return water temperature. Knowing the
supply water temperature, the boiler system differential can be established. With knowledge of the pumping rate,
the operator can easily detect any excessive load condition and take appropriate corrective action.Special caution
must be taken to guard against any condition, or combination of conditions, that might lead to the transfer of cold
water to a hot boiler or hot water to a cold boiler. It cannot be over emphasized that rapid changes in temperature
within the boiler can, and sometimes do, cause damage.
3.3.1 — 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. After opening the valves, momentarily energize the feed pump motor to
establish correct pump rotation. With the correct rotation established, close the boiler feed pump entrance switch.
The pump should shut down when the water level reaches the proper level (see Figure 3-3).
FIGURE 3-3. Low Water Cutoff Sight Gauge
Feedwater pumps must have adequate capacity to maintain required water level under all operating conditions.
Check the feedwater pumps periodically and maintain as necessary to prevent unexpected breakdowns.
NOTE: Prior to operating the pump, carefully check the alignment of the flexible coupling, if one is used. A properly
aligned coupling will last a long time and provide trouble-free mechanical operation.
750-91 (revised 2009) 3-5

3.3.2 — 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. If the valves are installed, it is illegal to operate the boiler with
closed or unsealed open valves.
! Warning
The isolation valves and the water column piping must be locked open during operation. Failure to do so may result in
a low water condition. Failure to follow these instructions could result in serious injury or death.
3.4 — Water Treatment

Properly treated boiler feed water, coupled with good engineering and operating practices, lead to maximum effec-
tiveness and long trouble-free life of pressure vessels, at the lowest operating cost. Contact your local Cleaver-
Brooks authorized representative for information on how to prevent the presence of unwanted solids and corro-
sive gasses.

• Prevent hard scale deposits or soft sludge deposits, which reduce heat transfer and can lead to overheated metal
and costly downtime and repairs.
• eliminate corrosive gasses in the supply or boiler water.
• Prevent intercrystalline cracking or caustic embrittlement of boiler metal.
• Prevent carryover and foaming.
Accomplishment of the above objectives generally requires proper feedwater treatment before and after introduc-
tion of the water into the boiler. The selection of pre-treatment processes depends upon the water source, its
chemical characteristics, amount of makeup water needed, plant operating practices, etc. Treating methods include
filtering, softening de-mineralizing, deaerating, and preheating. After-treatment involves chemical treatment of the
boiler water.
Because of the variables involved, no single boiler compound can be considered a “cure-all” nor is it advisable to
experiment with homemade treating methods. Sound recommendations and their employment should be aug-
mented by a periodic analysis of the feedwater, boiler water, and condensate.
The internal or waterside surfaces of the pressure vessel should be inspected with enough frequency to determine
the presence of any contamination, accumulations of foreign matter, corrosion, and/or pitting. If any of the condi-
tions are detected, contact your local Cleaver-Brooks authorized representative for advice on corrective action.
3-6 750-91 (revised 2009)

3.5 — Cleaning
A properly sized water meter should be installed in the raw water make-up line in order to accurately determine the
amount of raw water admitted to the boiler (steam or hot water) and to aid in maintaining proper waterside condi-
tions.
3.5 — Cleaning
3.5.1 — Hot Water and Steam Piping

Steam and water piping systems connected to the boiler may contain oil, grease, or foreign matter. The impurities
must be removed in order to prevent damage to pressure vessel heating surfaces. On a steam system, the conden-
sate should be wasted until tests show the elimination of undesirable impurities. During the periods 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. For more information, contact your local Cleaver-Brooks autho-
rized representative.
On a hot water system, chemical cleaning is generally necessary and the entire system should be drained after treat-
ment. Consult your local Cleaver-Brooks authorized representative for recommendations, cleaning compounds,
and application procedures.
3.5.2 — Pressure Vessel

The waterside of the pressure vessel must be kept clean from grease, sludge, and foreign material. Such deposits, if
present, will shorten the life of the pressure vessel, will interfere with efficient operation and functioning of control
of safety devices, and quite possibly cause unnecessary and expensive re-work, repairs, and downtime.
The installation and operating conditions that the boiler will be subjected to should be considered and cleaning of
the waterside of the pressure vessel should be provided during the course of initial start-up.
The pressure vessel and the steam and return lines or hot water piping represent, in effect, a closed system.
Although the steam and return (condensate) lines or the hot water piping system may have been previously cleaned,
it is possible that:
• Cleaning has been inadequate.
• Partial or total old system is involved.
• Conditions may prevent adequate cleaning of piping.
The pressure vessel waterside should be inspected on a periodic basis. An inspection will reveal true internal condi-
tions and serve as a check against conditions indicated by chemical analysis of the boiler water. Inspection should
be made three months after initial starting and at regular 6-, 9-, or 12-month intervals thereafter. The frequency of
further periodic inspections will depend upon the internal conditions found.
If any unwanted conditions are observed, contact you local Cleaver-Brooks authorized representative for recom-
mendations.
750-91 (revised 2009) 3-7

Any sludge, mud, or sediment found will need to be flushed out. If excessive mud or sludge is noticed during the
blowdown, the scheduling or frequency of blowdown may need to be revised. The need for periodic draining or
washout will also be indicated.
Any oil or grease present on the heating surfaces should be removed promptly by a boil-out with an alkaline deter-
gent solution.
NOTE: Temperature of initial fill of water for hydrostatic tests, boil-out, or for normal operation should be as stated
in the ASME Boiler Code.
3.6 — Boil-Out of a New Unit

The internal surfaces of a newly installed boiler may have oil, grease, or other protective coatings used in manufac-
turing. Such coatings must be removed because they lower the heat transfer rate and could cause over-heating of a
tube. Before boiling out procedures 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 is strongly recommended when handling
or mixing caustic chemicals. Do not permit the dry material or the concentrated solution to come in contact with skin
or clothing. Failure to follow these instructions could result in serious injury or death.
Your local Cleaver-Brooks authorized representative will be able to recommend a cleaning or boil-out procedure.
In the event such service is unavailable or is yet unscheduled, the following information may be of assistance.
Several chemicals are suitable for boil-out. One combination often used is soda ash (sodium carbonate) and caustic
soda (sodium hydroxide) at the rate of 3 to 5 pounds each per 1,000 pounds of water, along with a small amount of
laundry detergent added as a wetting agent.
The suggested general procedure for cleaning a boiler is (refer to Figure 3-4 to determine water capacity):
1. Have sufficient cleaning material on hand to complete the job.
2. When dissolving chemicals:
a) warm water should be put into a suitable container
b) slowly introduce the dry chemical into the water, stirring at all times until completely dissolved
c) add the chemical slowly and in small amounts to prevent excessive heat and turbulence
3. An overflow pipe should be attached to one of the top boiler openings and routed to a safe point of discharge.
A relief or safety valve tapping is usually used.
4. Water relief valves and steam safety valves must be removed before adding the boil-out solution so that neither
it nor the grease which it may carry will contaminate the valves. Use care in removing and reinstalling the valves.
(Refer to Chapter 8, section 8.-13 for valve installation instructions.)
5. All valves in the piping leading to or from the system must be closed to prevent the cleaning solution form get-
ting into the system.
3-8 750-91 (revised 2009)

6. Fill the pressure vessel with clean water until the top of the tubes is 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.
7. The boiler should then be fired intermittently at a low rate sufficient to hold solution just at the boiling point.
Boil the water for at least five hours. Do not produce steam pressure.
Water - Gallons Water - Weight

Generator Sizes Normal Flooded Normal Flooded
250 HP 1280 1665 10670 13880
300 HP 1560 2020 13000 16840
350 HP 1855 2410 15465 20090
FIGURE 3-4. Water Capacity and Weights
8. Allow a small amount of fresh water to enter the boiler to create a slight overflow that will carry off surface
impurities.
9. Continue the boil and overflow process until the water clears. shut the burner down.
10. Let the boiler cool to 120º F or less.
! Warning
Be sure to drain the hot water to a safe point of discharge to avoid scalding. Failure to follow these instructions could
result in serious injury or death.
11. Remove handhole plates and wash the waterside surfaces thoroughly using a high pressure water stream.
12. Inspect the surfaces. If they are not clean, repeat the boil-out.
13. After closing the handholes and reinstalling the safety or relief valves, fill the boiler and fire it until the water is
heated to at least 180º F to drive off any dissolved gasses, which might otherwise corrode the metal.
The above procedure may be omitted in the case of a unit previously used or known to be internally clean. How-
ever, consideration must be given to the possibility of contaminating materials entering the boiler from the system.
On a steam system, the condensate should be wasted until tests show the elimination of undesirable impurities.
During the period that condensate is wasted, be sure make-up water is treated to prevent an accumulation of
unwanted materials or corrosion.
On a hot water system, chemical cleaning is generally necessary and the entire system should be drained after treat-
ment. Consult your local Cleaver-Brooks authorized representative for recommendations, cleaning compounds,
and application procedures.
750-91 (revised 2009) 3-9

3.7 — Washing Out
3.7.1 — 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 of sludge, sediment, scale, etc. on the pressure vessel waterside.
If the operator is absolutely certain that the system is tight, then an annual waterside inspection may be sufficient.
However, if there is any doubt, the pressure vessel waterside should be inspected no later than three months after
initially placing the boiler into operation, and periodically thereafter as indicated by conditions observed during
inspections.
3.7.2 — Steam Boiler

No later than three months after initially placing the boiler into operation and starting service, and thereafter as
conditions warrant, the pressure vessel should be drained after being properly cooled to near ambient temperature.
Handhole covers should be removed and waterside surfaces should be inspected for corrosion, pitting, or forma-
tion of deposits.
3.7.3 — Flushing of Pressure Vessel Interior

Upon completion of the inspection, the pressure vessel interior should be flushed out, as required, with a high
pressure hose. If deposits are not fully removed by flushing, a consultation may be required with your local Cleaver-
Brooks authorized representative. In extreme cases, it may be necessary to resort to acid cleaning. Professional
advice is recommended if acid cleaning is required.
The inspections will indicate the effectiveness of the feedwater treatment. The effectiveness of treatment, the water
conditions, and the amount of fresh water make-up required are all factors to be considered in establishing fre-
quency of future pressure vessel washouts. Contact your local Cleaver-Brooks authorized representative for more
information.
3.8 — Blowdown: Steam Boiler

Boiler water blowdown is the removal of some of the concentrated water from the pressure vessel and its replace-
ment with feedwater so that the lowering of the concentration of solids in the boiler water occurs.
Solids are brought in by the feedwater even though the water is treated prior to use through external processes that
are designed to remove unwanted substances which contribute to scale and deposit formations. However, none of
the processes can remove all 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.
3-10 750-91 (revised 2009)

Scale has a low heat transfer value and acts as an insulation barrier. Scale retards heat transfer, which not only
results in lower operating efficiency, and consequently higher fuel consumption, but more importantly, can cause
overheating of boiler metal. Overheating of boiler metal can result in tube failures or other pressure vessel metal
damage and lead to boiler down-time and costly repairs.
Scale is caused primarily be calcium and magnesium salts, silica, and oil. Any calcium and magnesium salts in the
boiler water are generally precipitated by the use of sodium phosphate, along with organic materials, to maintain the
precipitates or “sludge” in a fluid form. The solids such as sodium salts and suspended dirt don not readily form
scale. But as the boiler water boils off as relatively pure steam, the remaining water is thickened with the solids. If
the concentration is permitted to accumulate, foaming and priming will occur and the sludge can cause harmful
deposits that bring about overheating of the metal.
The lowering or removal of the concentration requires the use of boiler water blowdown. The two principal types
of blowdown are intermittent manual blowdown and continuous blowdown.
3.8.1 — Intermittent Manual Blowdown

Manual or sludge blowdown is necessary for the operation of the boiler regardless of whether or not continuous
blowdown is employed.
The blowdown tappings are located at the bottom or lowest part of the boiler in order to lower the dissolved solids
in the pressure vessel water, and to remove a portion of the sludge that accumulates in the lower part of the vessel.
Equipment generally consists of a quick opening valve and a shutoff valve. The valves and necessary piping are not
normally furnished with the boiler, but supplied by others. All piping must be to a safe point of discharge. Piping
must be properly supported and free to expand.
3.8.2 — Continuous Blowdown

Continuous blowdown is used in conjunction with a surface blow-off tapping (furnished on 60” diameter and
larger units) and is the continuous removal of concentrated water.
The surface blow-off opening, when furnished, is on the top center line of the pressure vessel. It is provided with
an internal collecting pipe terminating slightly below the working water level for the 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.
The flow control valve and piping are generally provided by others. All piping must be to a safe point of discharge.
3.8.3 — Frequency of Manual Blowdown

When continuous blowdown is utilized, manual blowdown is primarily used to remove suspended solids or sludge.
The continuous blowdown removes sediment and oil from the surface of the water along with a prescribed amount
of dissolved solids.
750-91 (revised 2009) 3-11

When surface or continuous blowdown is not utilized, manual blowdown is used to control the dissolved or sus-
pended solids in addition to the sludge.
In practice, the valve(s) of the bottom blowdown are opened periodically in accordance with an operating schedule
and/or chemical control tests. From the standpoint of control, economy and results, frequent short blows are pre-
ferred to infrequent lengthy blows. The length and frequency of the blowdown is particularly important when the
suspended solids content of the water is high. With the use of frequent short blows a more uniform concentration
of the pressure vessel water is maintained.
In cases where the feedwater is exceptionally pure, or where there is a high percentage of return condensate, blow-
down may be employed less frequently since less sludge accumulates in the pressure vessel. When dissolved and/or
suspended solids approach or exceed predetermined limits, manual blowdown to lower the concentrations is
required.
It is generally recommended that a steam boiler be blown down at least once in every eight-hour period, but fre-
quency may vary depending upon water and operating conditions. The blowdown amounts and schedule should be
recommended by your local Cleaver-Brooks authorized representative.
A hot water boiler does not normally include openings for surface blowdown and bottom blowdown since blow-
downs are seldom practiced. The need remains to be alert to system water losses and corresponding amount of raw
water make-up. A water meter is recommended for water make-up lines.
3.8.4 — Manual Blowdown Procedure

Blowdown is most effective at a point when the generation of steam is at the lowest rate and feedwater input is also
low, thus providing a minimum dilution of the boiler water with low concentration feedwater.
1. 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 slow
opening globe type valve downstream. Valves will vary depending upon pressure involved and make or manu-
facturer. If seatless valves are installed, follow the manufacturer’s recommendations.
If a quick opening valve and globe type of slow opening valve are in combination, the former is normally
opened first and closed last with blow down accomplished with the globe or slow opening valve.
2. When opening the second or downstream valve, crack it slightly to allow the lines to warm, then continue open-
ing slowly.
! Caution
Do not pump the lever action valve open and closed, as water hammer is apt to break the valve bodies or pipe fittings.
Failure to follow these instructions could cause damage to the equipment.
The length of each blow should be determined by actual water analysis. Lowering the water in the gauge glass
approximately 1/2” is often acceptable as a guide to adequate blow. However, lowering the water 1/2” should
not be interpreted as a rule since water analysis procedures should prevail. If the glass cannot be viewed by the
party operating the valve, another operator should watch the glass and direct the valve operator.
3. Close the downstream (slow opening) valve first and as fast as possible.
4. Close the valve next to the boiler.
3-12 750-91 (revised 2009)

3.9 — Periodic Inspection
5. Slightly crack the downstream valve and then close it tightly.
Under not circumstances should a blow-off valve be left open and the operator should never leave until the blow-
down operation is completed and the valves are closed.

Insurance regulations or local laws will require a periodic inspection of the pressure vessel by an authorized inspec-
tor. Sufficient notice is generally given to permit removal of the boiler from service and preparation for inspection.
! Warning
To avoid the hazard of electrical shock, we recommend the use of a low voltage flashlight during an internal inspection.
Preferably, inspectors should work in pairs. Failure to follow these instructions could result in serious injury or death.
When shutting down the boiler, the load should be reduced gradually and the pressure vessel cooled at a rate that
avoids damaging temperature differential that can cause harmful stresses. Vessels should not normally be drained
until all pressure is relieved - 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. Some heat, however, may be desirable to dry out the interior of the boiler.
If the internal inspection is being made at the request of an authorized inspector, it is well to ask the inspector
observe the conditions prior to cleaning or flushing of waterside surfaces.
Be certain that a supply of manhole and handhole gaskets is available, along with any other gaskets or items needed
to place the unit back into operation after inspection.
Have available information on the boiler design, dimensions, generating capacity, operating pressure or tempera-
ture, time in service, defects found previously, and any repairs or modifications. Also have available for reference
records of previous inspections.
Be prepared to perform any testing required by the inspector including a hydrostatic test.
After proper cooling and draining of the vessel, flush out the waterside with a high pressure water hose. Remove
any scale or deposits from the waterside surfaces and check for internal or external corrosion and leakage.
The fireside surface should also be thoroughly cleaned so that metal surfaces, welds, joints, tube ends, fittings and
any previous repairs can be readily checked.
Be sure that steam valves, and valves to expansion tank (hot water), feedwater valves, blow-off valves, all fuel valves,
and electrical switches are shut off prior to opening handholes, manhole, and front or rear doors. Adequately vent
the pressure vessel prior to entry.
Clean out the low-water cutoff piping, the water level controls and cross-connecting pipes. Replace the water gauge
glass and clean out the water cocks. Also check and clean the drain and the blowdown valves and piping.
750-91 (revised 2009) 3-13

Check all water and steam piping and valves for leaks, wear, corrosion, and other damage. Replace or repair as
required.
3.10 — Preparation for Extended Lay-Up

Many boilers used for heating or seasonal loads or for standby service may have extended periods of non-use. Spe-
cial attention must be given to idle boilers so that neither waterside nor fireside surfaces are allowed to deteriorate
from corrosion.
Too many conditions exist to lay down definite rules. There are two methods of storage: wet or dry. Your local
Cleaver-Brooks authorized representative can recommend the better method depending upon circumstances in the
particular installation.
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.
Although pollution control regulations may continue to limit the permissible sulphur content of fuel oils, care must
be taken to avoid corrosion problems that sulphur can cause, especially in a boiler that is seasonally shut down.
Dormant periods, and even frequent shutdowns, expose the fireside surfaces to condensation below the dew point
during cooling. Moisture and any sulphur residue can form an acid solution. Under certain conditions, and espe-
cially in areas with high humidity, the corrosive effect of the acid will be serious enough to eat through or severely
damage boiler tubes or other metal heating surfaces during the time that a boiler is out of service.
The condition does not generally occur during normal firing operation, because the high temperature of operation
vaporizes any condensation. However, proper boiler operation must be maintained, especially with a hot water
boiler, to prevent the flue gasses from falling below the dew point.
At the start of lay-up, thoroughly clean the fireside by removing any soot or other products of combustion from
the tubes, tube sheets, and other fireside surfaces. Brushing will generally suffice. Sweep away or vacuum any accu-
mulation. The fireside surfaces may be flushed with water. However, all moisture must be eliminated after flushing
and the surface dried by blowing air or applying some form of heat. It is good practice to protect the cleaned sur-
faces by coating them with an anti-corrosive material to prevent rust.
T prevent condensation from forming in the control cabinet, keep the control circuit energized. For extended lay-
up periods, especially where high humidity or large swings in ambient temperature occur, the control should be
removed and stored in a dry atmosphere.
Dry storage is generally employed when the boiler will be out of service for a significant period of time, or where
freezing temperatures may exist. In the dry storage method the boiler must be thoroughly dried because any mois-
ture would cause corrosion. Both fireside and waterside surfaces must be cleaned of all scale, deposits, soot, etc.
Steps must be taken to eliminate moisture by placing moisture-absorbing materials such as quick lime (at 2 pounds
for 3 cubic feet of volume) or silica gel (at 5 pounds for 30 cubic feet of volume) on trays inside the vessel. Fireside
surfaces may be coated with an anti-corrosive material, or grease or tar paint. Refractories should be brushed clean
and wash-coated. All openings to the pressure vessel, such as manhole and handholes, should be shut tightly. Feed-
3-14 750-91 (revised 2009)

water and steam valves should be closed. Damper and vents should be closed to prevent air from reaching fireside
surfaces. Periodic inspection should be made and absorption materials renewed.
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.
Variables preclude definite recommendations. However, it is suggested that the pressure vessel be drained, thor-
oughly cleaned internally, and re-filled to overflowing with treated water. If deaerated water is not available, the unit
should be fired to boil the water for a short period of time. Additional chemicals may be suggested by your local
Cleaver-Brooks authorized representative to minimize corrosion. Internal water pressure should be maintained at
greater than atmospheric pressure. Nitrogen is often used to pressurize the vessel. Fireside surfaces must be thor-
oughly cleaned and the refractory should be wash-coated.
750-91 (revised 2009) 3-15

3-16 750-91 (revised 2009)

CHAPTER 4 Sequence of Operation
4.1 — Overview
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 compo-
nents to provide an overall operating sequence.
NOTE: The make or model of the program relay provided will vary depending upon job specifications. The following
sequence applies regardless of the make or model. Please refer to the Wiring Diagram (WD) prepared by Cleaver-
A. The burner and control system are in starting condition when the following conditions exist:
• The operating limit pressure control (steam boiler) or the operating limit temperature control (hot water boiler)
and high limit pressure or temperature control are below their cutoff setting.
B. All entrance switches are closed and power is present at the line terminals of:
• Oil pump motor starter (if provided)
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 program relay. Chapters 6 and 7 contain operating instruc-
tions and specific information on setting and adjusting the controls.
750-91 (revised 2009) 4-1

4.2 — Circuit and Interlock Controls

The burner control circuit is a two-wire system designed for 115 Vac, 60 Hz, single-phase power.
The electrical portion of the boiler is made up of individual circuits with controls that are wired in a manner
designed to provide a safe workable system. The program relay provides connection points for the interconnection
of the various circuits.
The controls used vary depending upon the fuel oil or gas and the specific requirement of applicable regulatory
bodies. Refer to the boiler wiring diagram to determine the actual controls provided. The circuits and controls nor-
mally used in the circuits are identified in the following table and are referred to in Section 4.3.
Circuit Components
Limit Circuit • Burner switch (BS)
• Gas-oil selector switch (GOS) - combination burner only
• Oil drawer switch (ODS) - oil burner
• Low oil temperature switch (LOTS) - nos. 5 and 6 oil only
• Low gas pressure switch (LGPS)
• LE proximity switch interlock
Blower Motor Starter Circuit • Blower motor starter (BMS)
• Air compressor motor starter (ACMS) - if provided
• Air purge valve (APV) - nos. 5 and 6 oil only
Running Interlock Circuit • Blower motor starter interlock (BMSI)
• Atomizing air proving switch (AAPS) - if provided
Low Fire Proving Circuit • Low fire switch (LFS)
Pilot Ignition Circuit • Gas pilot valve (GPV)
• Gas pilot vent valve (GPVV) - if provided
Flame Detector Circuit • Flame detector (FD)
• Main gas vent valve (MGVV) - if provided
• Oil valve (OV)
4-2 750-91 (revised 2009)

4.3 — Sequence of Operation: Oil or Gas
Circuit Components
Firing Rate Circuit • Damper motor transformer (DMT)
High Fire Proving Circuit • High fire switch (HFS)
Running Interlock and Limit Circuit • Low oil pressure switch (LOPS)
To comply with requirements of insurance underwriters such as Factory Mutual (FM), Industrial Risk Insurers
(IRI), or others, additional interlock devices may be used.

The following sequence occurs with power present at the program relay (PR) input terminals and with all other
operating conditions satisfied.
4.3.1 — Pre-Purge Cycle

When the burner switch (BS) is turned “on,” and controls wired in the “limit” and “fuel valve interlock” circuits are
closed and no flame signal is present, the “blower motor start circuit” is powered energizing the blower motor
starter (BMS). The load demand light (LDL) turns on. When firing oil, the air compressor motor starter (ACMS - if
provided) is also powered. the air purge valve (APV - nos. 5 and 6 oil only) remains de-energized.
At the same time, the program relay signals the modulating damper motor (MDM) to open the air damper. The
damper begins to open and drives to its full open or high fire position. Opening the damper motor allows a flow of
purging air through the boiler prior to the ignition cycle.
On certain boilers the circuitry will include a high fire switch (HFS). The purpose of the switch is to prove that the
modulating damper motor (MDM) has driven the damper to the open position during the pre-purge cycle. In this
instance, the “high fire proving circuit” is utilized.
The controls wired into the “running interlock circuit” must be closed within 10 seconds after the start sequence.
In the event any of the controls are not 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.
750-91 (revised 2009) 4-3

To assure that the system is in low fire position prior to ignition, the low fire switch (LFS) must be closed to com-
plete the “low fire proving circuit.” The sequence will stop and hold until the modulating damper motor (MDM)
has returned to the low fire position and the contacts of the low fire switch (LFS) are closed. Once the low fire
switch is closed, the sequence is allowed to continue.
NOTE: The ignition trial cannot be started if flame or a flame simulating condition is sensed during the pre-purge
period. A safety shutdown will occur if flame is sensed at this time.
4.3.2 — Ignition Cycle

The ignition transformer (IT) and gas pilot valve (GPV) are energized from the appropriate pilot ignition terminal.
NOTE: An oil-fired burner may be equipped with an oil pilot rather than a gas pilot. The ignition sequence of both is
identical.
The pilot flame must be established and proven by the flame detector (FD) within a 10 second period in order for
the ignition cycle to continue. If for any reason this does not happen, the system will shut down and safety lockout
will occur.
NOTE: Depending upon the requirements of the regulatory body, insurer, or fuel being burned, either the 10 or 15
second pilot ignition terminal may be used. Both provide the same function but differ in time interval allowed for
proving main flame ignition. Refer to the boiler wiring diagram.
With a proven pilot, the main fuel valve(s) (OV or MGV) is energized and the main fuel valve light (FVL) in the
panel is lighted. The main flame is ignited and the trial period for proving the main flame begins. It lasts 10 seconds
for light oil and natural gas, and 15 seconds for heavy oil. At the end of the proving period, if the flame detector
still detects main flame, the ignition transformer and pilot valve are de-energized and pilot flame is extinguished.
NOTE: If the main flame does not light, or stay lit, the fuel valve will close. The safety switch will trip to lock out the
control. Refer to flame loss sequence (see Section 4.4) for description of action.
! Warning
The cause for loss of flame or any other unusual condition should be investigated and corrected before attempting to
restart. Failure to follow these instructions could result in serious injury or death.
4.3.3 — 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). This allows operation in ranges above low fire.
With the manual-automatic switch (MAS) set at automatic, subsequent modulated firing will be at the command of
the modulating control (MC), which governs the position of the modulating damper motor (MDM). The air
4-4 750-91 (revised 2009)

4.4 — Flame Loss Sequence
damper and fuel valves are actuated by the motor through a linkage and cam assembly to provide modulated firing
rates.
NOTE: Normal operation of the burner should be with the switch in the manual-automatic position and under the
direction of the modulating control. The manual position is provided for initial 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. Excess air flow subjects
the pressure vessel metal and refractory to undesirable conditions. The effectiveness of nozzle purging is lost on a No.
6 oil burner.
The burner starting cycle is now complete. The LDL and FVL lights on the panel remain lit. Demand firing contin-
ues as required by load conditions.
4.3.4 — Burner Shutdown: Post Purge

The burner will fire until steam pressure or water temperature in excess of demand is generated. With modulated
firing, the modulating damper motor (MDM) should return to the low fire position before the operating limit con-
trol (OLC) opens. When the limit control circuit is opened, the following sequence occurs:
1. The main fuel valve circuit is de-energized, causing the main fuel valve (MGV or OV) to close.
2. The flame is extinguished.
3. The control panel lights (LDL and FVL) are turned off.
4. The blower motor continues to run to force air through the boiler for the post purge period.
5. On a No. 6 oil burner, the air purge valve (APV) is powered from the blower motor start circuit via the contacts
of the air purge relay (APR) to provide an air purge of the oil nozzle. The damper motor returns to the low fire
position if it is not already in that position.
6. The blower motor start circuit is de-energized at the end of the post purge cycle and the shutdown cycle is com-
plete.
The program relay is now ready for subsequent recycling, and when steam pressure or water temperature drops to
close the contacts of the operating control, the burner again goes through its normal starting and operating cycle.

The program relay will recycle automatically each time the operating control closes, or after a power failure. It will
lockout following a safety shutdown 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 pre-purge period.
The control will prevent startup or ignition if limit circuit controls or fuel valve interlocks are open. The control
will lock out upon any abnormal condition affecting air supervisory controls wired in the running interlock circuit.
750-91 (revised 2009) 4-5

! Caution
The lockout switch must be manually reset following a safety shutdown. The cause for loss of flame or any unusual
condition should be investigated and corrected before attempting to restart. Failure to follow these instructions could
cause damage to the equipment.
4.4.1 — No Pilot Flame

The pilot flame must be ignited and proven within a 10-second period after the ignition cycle begins. If not proven
within this period, the main fuel valve circuit will not be powered and the fuel valve(s) will not be energized. The
ignition circuit is immediately de-energized and the pilot valve closes, the reset switch lights and lockout occurs
immediately.
The blower motor will continue to operate. The flame failure light and the alarm bell (optional) are energized 10
seconds later.
The blower motor will be de-energized. The lockout switch must be manually reset before operation can be
resumed. (Refer to the previous caution notice.)
4.4.2 — Pilot But No Main Flame

When the pilot flame is proven, the main fuel valve circuit is energized. Depending upon the length of the trial-for-
ignition period, the pilot flame will be extinguished 10 or 15 seconds later. The flame detecting circuit will respond
to de-energize the main fuel valve circuit within 2 to 4 seconds to stop the flow of fuel. The reset switch lights and
lockout occurs immediately. The blower motor will continue to operate.
The flame failure light and alarm bell (optional) are energized 10 seconds later.
4.4.3 — Loss of Flame

If a flame outage occurs during normal operation and/or the flame is no longer sensed by the detector, the flame
relay will trip within 2 to 4 seconds to de-energize the fuel valve circuit and shut off the fuel flow. The reset switch
lights and lockout occurs immediately. The blower motor continues operation. The flame failure light and alarm
bell (optional) are energized 10 seconds later.
If the burner will not start, or upon a safety lockout, the troubleshooting section in the operating manual and the
technical bulletin should be referred to for assistance in pinpointing problems that may not be readily apparent.
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 bulletin.
4-6 750-91 (revised 2009)

Knowledge of the system and its controls will make troubleshooting much easier. Costly down time or delays can
be prevented by systematic checks of the actual operation against the normal sequence to determine the stage at
which performance deviates from normal. Following a routine may possibly eliminate overlooking an obvious con-
dition, often one that is relatively simple to correct.
Remember, a safety device, for the most part, is doing its job when it shuts down or refuses to operate. NEVER
attempt to circumvent any of the safety features.
Preventive maintenance and scheduled inspection of all components should be followed. Periodic checking of the
relay is recommended to see that a safety lockout will occur under conditions of failure to ignite either pilot or main
flame, or from loss of flame.
750-91 (revised 2009) 4-7

4-8 750-91 (revised 2009)

CHAPTER 5 Starting and Operating
Instructions
5.1 — Preparation for Startup: All Fuels

The instructions in Chapter 5 are all based upon installation being complete and all electrical, fuel, water, and vent
stack connections are made.
The operator should be familiar with the burner, boiler, and all controls and components. To quickly locate and
identify the various controls and components mentioned the following paragraphs, refer to the illustrations and the
contents of Chapters 1, 2, and 3. Instructions for adjusting major components are given in Chapter 6 — Chapter 6
should be reviewed prior to firing. The wiring diagram should also be thoroughly reviewed, along with the firing
sequence outlined in Chapter 4.
! Warning
Be sure the starting instructions are read completely and thoroughly understood before attempting to operate the
boiler, rather than performing each operation as it is read for the first time. Failure to follow these instructions could
Verify supply of fuel and proper voltage. Check for blown fuses, open circuit breakers, dropped out overloads, etc.
Check reset of all starters and controls having manual reset features. Check the lockout switch on the programmer
and reset if necessary.
The boiler should be filled with water to the proper operating level using water of ambient temperature. Be sure
that treated feedwater is available and use. In heating applications, the entire system should be filled and vented.
Refer to Chapter 3 for water requirements. On a steam boiler, open the test valve to vent air displaced during filling.
Leave the test valve open until the escape of steam is noted after the burner is operating.
750-91 (revised 2009) 5-1

! Warning
Prior to firing a boiler, be sure that discharge piping from safety valves or relief valves, and discharge piping from all
blowdown and drain valves, is piped to a SAFE point of discharge, so that emission of hot water or steam cannot pos-
sibly cause injury. Failure to do so could result in serious injury or death.
Check all linkage for full and free movement of the damper and metering valves and cams. The check can be done
by loosening the linkage at the damper motor connecting arm and manipulating the linkage by hand.
Check for rotation of all motors by momentarily closing the motor starter or relay. The blower impeller rotation is
counterclockwise when viewed from the front of the boiler. The air pump rotation is clockwise when viewed from
its drive end. When operating a standard 78” boiler, the fan motor and air pump should rotate counterclockwise.
Before operating the boiler feed pump or oil supply pump, be sure all valves in the line are open or properly posi-
tioned.
For safety reasons, perform a final pre-startup inspection, especially checking for any loose or incomplete piping or
wiring or any other situations that might present a hazard.
NOTE: The pressure vessel support legs are welded to mounting skids in front and secured by bolts at the rear of the
pressure vessel. The bolts are tightened for shipment. When the boiler is installed, and prior to initial firing, the bolts
securing the rear legs to the skid must be loosened to allow for expansion and contraction caused by differences in
temperature between pressure vessel and skids and to avoid damage to the equipment.
5.2 — Control Settings: Steam and Hot Water

See Chapter 6 for adjustment instructions for the following controls:
5.2.1 — Operating Limit Control

Inspect the operating limit control for proper setting.
• The operating limit pressure control of a steam boiler should be set slightly above the highest desired steam
pressure, but at least 10% lower than the setting of the safety valve.
• The operating limit temperature control on a hot water boiler should be set slightly above the highest desired
water temperature and within the limits of the pressure vessel.
5.2.2 — High Limit Control

Inspect the high limit control for proper setting.
• On a high pressure steam boiler, the control should be set approximately 10 psig above the operating limit pres-
sure control setting, if feasible, or midway between the operating limit pressure and the safety valve setting. The
setting on a low pressure steam boiler may be 2 or 3 psig above the operating limit setting, but must not exceed
the safety valve setting.
5-2 750-91 (revised 2009)

5.3 — Gas Pilot
• On a hot water boiler, the high limit temperature control should be 5º to 10º F above the operating limit tem-
perature control setting but within the limits of the design pressure of the pressure vessel.
5.2.3 — Modulating Control

Inspect the modulating control for proper setting. The control must be set and adjusted so that the modulating
motor returns to low fire position before the operating limit control opens. It is further desirable to have its low
point setting somewhat below the cut-in setting of the limit control so that the burner operates in low fire position
for a brief period on each start rather than immediately driving to a high fire position.
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 ther-
mometer.
5.2.4 — Low-Water Cutoff and Pump Control

Inspect the low-water cutoff and pump control as well as the auxiliary low-water cutoff (if equipped with this
optional device). Check for freedom of float movement. Float movement can be verified by observing the level of
water in the gauge glass when the water supply has been cut off either by the stopping of the feed pump or by the
closing of a valve, and the restarting of the pump or opening of the valve when water is drained from the pressure
vessel. The importance of proper functioning of low-water controls cannot be over-emphasized. Be sure that the
control and the piping are level.
5.2.5 — Additional Considerations

The settings of controls relating to fuel, either oil or gas, are covered in subsequent sections.
In the event the boiler is equipped with optional control devices not listed here, be certain to ascertain that their
settings are correct. If additional information is required, see your local Cleaver-Brooks authorized representative.
On initial startup or whenever the boiler is placed into operation from a “cold” start, the manual-automatic selector
switch should be set at “manual” and the manual flame control set at “close.” After the boiler is in operation and
thoroughly warmed, the selector switch should be turned to “automatic,” so that the burner firing rate may be con-
trolled by the modulating control in accordance with load demands.
5.3 — Gas Pilot

The gas pilot should be checked for satisfactory performance prior to initial firing. Follow the pilot flame adjust-
ment instructions given in Chapter 6.
On initial starting attempts, several efforts might be required to fully bleed the pilot line. While checking pilot
adjustment, observe whether the pilot flame is extinguished promptly when the burner switch is opened. A linger-
ing flame indicates a leaking gas pilot valve, which is a condition requiring correction before proceeding.
750-91 (revised 2009) 5-3


The supply and pressure of the atomizing air on an oil-fired burner should be checked. Before starting, inspect the
oil pump lube oil level. Add oil if necessary to bring the level to the midpoint or slightly higher in the sight glass.
Use SAE 20 detergent oil of a grade mentioned in Chapter 8 and fill in accordance with instructions given there.
FIGURE 5-1. Atomizing Air Compressor
Check the oil level of the air intake strainer. When operating a standard 78” boiler, make certain that the V-velt
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. If the
burner is a combination fuel burner, be sure that the gas/oil selector switch is set to “oil.” Turn the burner switch
on. The burner will cycle to the low fire pre-purge position and stop there.
FIGURE 5-2. Atomizing Air Pressure Gauge
5-4 750-91 (revised 2009)

5.5 — Firing Preparations for No. 2 Oil (Series 100 - 200)
Observe the reading on the air pressure gauge. With no oil flow, the pressure should be a minimum of 7 psi.
If there is no pressure, determine the cause and correct it before proceeding. Check for obstructions in the air inlet
line, incorrect rotation (air pump rotation is clockwise), or a loose oil nozzle or other leaks. If the pressure is much
higher without any oil flow, check for obstruction in the discharge line or at the oil nozzle.
The air pressure will increase when an oil flow exists. At low firing rate, the air pressure may rise to 12 psi or more.
NOTE: The air pressure should not exceed 35 psi at high fire. Greater air pressure causes excessive wear of the air
pump., increases lube oil usage, and can overload the motor, thus causing damage to the equipment.
NOTE: Abnormally high pressure indicated on the nozzle air pressure gauge is an indication that the burner nozzle
has become clogged. In the event of clogging check the nozzle and clean as necessary.
After air flow has been verified, turn the burner switch off and return the run/test switch to the “run” position.

Prior to initial firing, oil flow and pressure should be established and verified. Atomizing air pressure should also be
established as outlined in Section 5.4. The schematic flow diagram (see Chapter 2) indicates the flow of fuel and
atomizing air.
If the burner is a combination fuel model, be certain that the main gas shutoff cock is closed and set the gas/oil
selector switch to “oil.” Insert the burner drawer gun into its most forward position and latch it in place.
5.5.1 — Oil Flow

1. Open all valves in the oil suction and oil return lines.
2. If the oil supply tank is located above the level of the pump and flow to the pump is by gravity, then it will usu-
ally be necessary to vent the suction line to allow oil to fill the line. Venting the suction line can generally be
accomplished by cracking a union fitting, or by opening the cap of the oil strainer using care to prevent spillage
of oil. Tighten the fitting or the cap as soon as oil flow appears.
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.
Non-lubricating fluids such as kerosene should not be used for priming.
3. Prior to priming the suction line and the initial start, check to make certain that all plugs, connections, etc., have
been securely tightened to prevent leaks.
4. If the fuel oil supply originates from a pressurized loop, it is assumed that the pressure of the loop will be at a
minimum of 75 psi. Under these conditions, the relief valve at the terminal block should be adjusted to the point
where it becomes inoperative (or removed and openings plugged). To render inoperative, turn the adjusting
screw in as far as possible.
5. A standard equipped boiler has a selector switch incorporated in the oil pump motor starter. Momentarily ener-
gize the starter to check for proper pump rotation. With the rotation verified, operate the pump to determine
that oil circulation exists.
750-91 (revised 2009) 5-5

6. Observe the regulated oil pressure gauge for indication that flow is established. If no pressure shows on the
gauge after a few moments, stop the oil pump and re-prime.
If the supply tank is lower than the pump, it is possible that the initial priming of the suction line, followed by
operation of the pump, will not establish oil flow. This might be caused by obstruction in the suction line, exces-
sive lift, inadequate priming, suction line leaks, etc.
If oil flow is not readily established, avoid prolonged operation of the pump to minimize risk of damage to
internal parts of the pump.
NOTE: If oil flow is not established after a second or third priming attempt, a full investigation is required to deter-
mine the cause.
7. A vacuum (or a compound pressure-vacuum) gauge should be installed at the suction port of the pump and its
reading observed and recorded for future guidance. If a vacuum condition exists, the reading will reveal the
tightness of the system. It is advisable to maintain the vacuum reading at less than 10” Hg.. A vacuum in excess
of 10” Hg. may allow oil to vaporize, causing cavitation, loss of prime, and unstable firing condition.
FIGURE 5-3. No.2 Fuel Oil Control
5.5.2 — Oil Pressure

1. Oil supply pressure is regulated by adjusting the pressure relief valve at the oil terminal block. A pressure gauge
should be installed in the terminal block and the relief valve adjusted to obtain a minimum reading of 75 psi
when the burner is firing at maximum rate.
2. When oil is supplied from a pressurized loop to a multiple boiler installation, the relief valve in the loop should
be properly adjusted to provide this reading. In this circumstance, the relief valve at the terminal block should
be adjusted to the point when it will be inoperative (or removed and openings plugged). To render inoperative,
turn the adjusting screw in as far as possible.
3. Adjustment may also be required to the regulator on the fuel oil controller. The pressure regulating valve is
equipped with tubing that directs and adds atomizing air pressure to the 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.
5-6 750-91 (revised 2009)

5.6 — Firing Preparation for No. 6 Oil (Series 400 - 600)
4. The pressure gauge will indicate a higher reading when the flame is present and will increase as the firing rate
increases. After the burner is firing and when the air pump is running, final adjustment can be made at the fuel
oil controller.
5. Final regulation of oil flow to the nozzle can be done later, if necessary, by adjusting the metering cam screws as
outlined in Chapter 6.
5.5.3 — Starting
When all the conditions covered in Sections 5.1, 5.2, 5.3, 5.4, and 5.5 are assured, the burner is ready for firing.
Refer to Section 5.8 for further starting and operating information.

Prior to initial firing, oil flow, pressure, and temperature should be established and verified. Atomizing air pressure
should also be established as outlined in Section 5.4. The schematic flow diagram (see Chapter 2) indicates the flow
of fuel and atomizing air.
NOTE: Prior to firing, attach combustion analysis instruments and monitor consistently throughout the startup
sequence. Refer to the adjustment procedures in Chapter 6.
If the boiler is a combination fuel model, be certain that the main gas shutoff cock is closed and set the gas/oil
selector switch to “oil.” Insert the burner drawer gun into its most forward position and latch it in place.
5.6.1 — Oil Flow

2. Open the bypass valve on the fuel oil controller until oil flow is established. Normally, the orifice valve is left in
a closed position. however, on cold starts, it may be opened for brief periods to aid in establishing oil flow. The
bypass and orifice valves must be returned to the closed positions as soon as oil flow is established as indicated
by a reading on the oil supply pressure gauge. Do not at temp to set pressures while valves are open.
FIGURE 5-4. No. 6 Fuel Oil Control
750-91 (revised 2009) 5-7

3. Momentarily energize the fuel oil pump starter to check for proper pump rotation. With the rotation verified,
prime the suction line strainer with oil and turn the fuel oil pump switch to the “ON” position.
4. Check the oil supply pressure gauge for indication that oil flow is established. If no pressure shows on the gauge
after a few moments, stop the oil pump and re-prime. Heavy oil in the storage tank must be at a temperature to
produce an oil viscosity that will allow the oil to flow through the oil pump and suction line. If oil flow is not
established after several attempts, the conditions preventing oil flow must be determined and corrected to avoid
damage to the pump’s internal mechanism.
5. A vacuum gauge should be installed in the oil suction line and its reading observed and recorded for future
guidance.

Oil pressure is regulated at several points. The first is at the relief valve at the oil heater. The relief valve should be
set so 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. Since the air pump is not running at this time, only tentative adjustments can be made. Without the
air supply, adjust the fuel oil pressure regulator so that the burner oil gauge registers approximately 35 psi. Adjust
the back pressure relief valve so that its gauge reads about 10 psi less than the burner gauge.
After the burner is firing, further adjustments can be made, if necessary, to the valves.
The pressure gauges will indicate higher readings when a flame is present. The pressure will increase as the firing
rate increases. The pressure reading on the two gauges on the controller will, despite the fluctuation, retain a nearly
constant difference of 10 psi.
Final regulation of oil flow to the nozzle can be done, if necessary, by adjusting the metering cam screws as outlined
in Chapter 6.
5.6.3 — Oil Temperature


Oil Burner Pressure Gauge 30 - 45 psi
! Caution
Before turning on the electric oil heater switch, be certain that the heater shell is filled with fuel oil and the flow is
established. Failure to follow these instructions could result in equipment damage.
1. After determining that the heater shell is filled and that fuel oil circulation exists, turn the oil heater switch to
“on.”
2. Adjust the electric oil heater thermostat to maintain oil temperature at approximately 200º F.
5-8 750-91 (revised 2009)

5.7 — Firing Preparations for Gas (Series 200-400-700)
The electric heater on burners equipped for No. 6 fuel oil is sized so that it is capable of supplying heated oil at
a rate no greater than that required for low fire operation and is primarily supplied for convenience on cold
starts. Heating coils utilizing either steam or hot water are supplied to provide sufficient heat so that higher rates
of firing can be accomplished once steam pressure or hot water is available. In normal operation, the thermostat
governing the electric heating element is kept at a lower setting than the thermostat governing admission of
steam to the heater, or of hot water circulation, so that heating is not performed electrically except when steam
or hot water is not available.
3. Set the steam thermostat or the hot water thermostat to maintain an oil temperature of 220º - 230º F. The elec-
tric heater will be turned off automatically as soon as steam or hot water provides heat.
NOTE: The temperatures listed are tentative. The composition of the fuel oil in a given grade can vary, necessitating a
higher or lower preheating temperature. The viscosity of the oil at the nozzle should be less than 300 SSU and prefera-
bly less than 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. Review this chapter for additional information.
4. Close the manual bypass valve after the temperature rise on the fuel oil controller thermometer is noted. Be cer-
tain that hot oil is moving through the controller. The orifice gate valve must also be closed. If the temperature
drops, open the orifice gate valve until a rise is noted, then close it.
5. Once the correct setting of the heater thermostats has been established, set the low oil temperature switch at the
point approximately 30º F lower than the normal burning temperature. If the system is equipped with a high oil
temperature switch, it should be set to open at 20º to 30º F higher than normal burning temperature.
NOTE: The maximum oil temperature allowed in the system is 250º F.
5.6.4 — Starting
When all the conditions covered in Sections 5.1, 5.2, 5.3, and 5.4 are assured, the burner is ready for firing. Refer to
Section 5.8 for further starting and operating information.

1. Prior to initial starting, check the linkage attached to the gas butterfly valve to assure that movement is free from
binding.
2. Verify the presence and availability of gas. On a new installation, representatives of the gas utility should be pres-
ent when gas first flows into the system to supervise purging of the new gas line, unless they have already done
so.
3. Determine that the pilot is operating properly, as outlined in Section 5.3.
4. Determine that sufficient pressure exists at the entrance to the gas train by installing a test gauge downstream of
the regulator.
5. The gas pressure regulator must be adjusted to the proper pressure level. Since the regulator is generally sup-
plied by others, adjustment should proceed according to instructions supplied by its manufacturer.
It is necessary for the operator to know the burner requirements in gas quantity and pressure. The information
can generally be found on the Dimension Diagram (DD) supplied by Cleaver-Brooks for the specific installa-
tion. Should the information not be readily available, consult the Cleaver-Brooks Service Department, and be
750-91 (revised 2009) 5-9

prepared to provide the correct boiler serial number. Chapter 6 contains additional information along with stan-
dard gas flow and pressure requirements.
6. If the burner is a combination fuel model, set the gas/oil switch to “gas.” Withdraw the oil burner gun and latch
it in its rearward (OUT) position.
FIGURE 5-5. Latch Oil Burner Gun “IN” and “OUT” Positions
7. On initial startup, it is recommended that the main gas shutoff cock remains closed until the programmer has
cycled through pre-purge and pilot sequences. When the fuel light on the control panel comes on, observe the
action of the motorized gas valve stem to determine that it opens when energized.
8. As soon as it is confirmed, turn the burner switch “OFF” and let the programmer finish its cycle.
9. Check that the gas valve has closed.
10. Again, turn the burner “ON.”
11. When the fuel valve light flows, slowly open the main gas cock. Main flame should ignite unless there is air pres-
ent in the line.
12. If the flame is not established within about 5 seconds, turn the burner switch “OFF” and allow the programmer
to recycle normally for a new lighting trial. Several efforts may be necessary to “bleed” air from the line.
! Warning
Do not repeat unsuccessful lighting attempts without rechecking the burner and pilot adjustments. Failure to follow
these instructions could result in serious injury or death.
NOTE: The burner and control system is designed to provide a “pre-purge” period of fan operation prior to establish-
ing ignition spark and pilot flame. Do not attempt to alter the system or to take any action that might circumvent the
feature.
13. Once the main flame is established, turn the burner switch to the “OFF” position and observe that the flame is
extinguished promptly. The flame may continue to burn for a second or two after normal shutdown due to the
gas remaining downstream from the fuel valve.
14. If the flame continues to burn for a longer period or during blower motor spindown, it could indicate a main
gas valve leak. Immediately turn the burner switch off and close the main gas cock.
5-10 750-91 (revised 2009)

5.8 — IFGR Setup
15. Investigate and correct the cause of the valve leakage before relighting the burner.
NOTE: The main gas valve should provide a tight seal, provided nothing prevents tight closure. Foreign material may
be present in either the new or renovated gas lines unless adequate care is taken in cleaning and purging.
When the conditions covered in Section 5.7 and in Sections 5.1, 5.2, and 5.3 are assured, the burner is ready for fir-
ing. Refer to Section 5.8 for further starting and operating information.
5.8 — IFGR Setup
NOTE: Initial IFGR linkage settings and adjustments must be established by a Cleaver-Brooks authorized representa-
tive. Setup of the LE option requires simultaneous consideration of air-to-fuel ratios and NOX levels. This can only be
accomplished with proper combustion emissions monitoring equipment with NOX, O2, CO, and smoke spot measur-
ing capability.
It is recommended that the final “installed” settings be recorded for future reference. The settings should be
marked on the linkage as well.
Normally, once the system has been set and adjusted, the settings should not be changed unless conditions (includ-
ing boiler settings) change. In that case, it will be necessary to contact your local Cleaver-Brooks authorized repre-
sentative for assistance.
After the IFGR system is initially set up, it will start up with the boiler as an integrated boiler system. After shut-
down periods in which maintenance and/or adjustments have been performed on the fuel cams, fuel and air link-
ages, or IFGR control linkages, the recommended approach to startup is as follows:
1. Set all boiler components to their initial settings as discussed in the appropriate chapters of this manual.
2. Check fan impeller and motor rotation. Correct rotation is counterclockwise when viewed from the front of the
boiler.
3. Verify that all the IFGR components are set to the settings recorded on the Startup Report (as noted by the
Cleaver-Brooks authorized representative during original set up). Be sure that all linkages are secure.
4. Start and warm the boiler as described in this manual.
5. Adjust the boiler components as described in this manual to achieve proper boiler operation.
Refer to Chapter 8 for instructions on cassette removal and installation.
NOTE: The IFGR system can be equipped with either a single or dual linkage arm, depending on the number of fuels
used and the NOX levels desired. All single-fueled boilers have a single drive arm. Dual-fueled boilers may or may not
have a dual arm, depending on the options purchased.
750-91 (revised 2009) 5-11

FIGURE 5-6. Jackshaft Linkage Settings
FIGURE 5-7. Overtravel Linkage Settings
5-12 750-91 (revised 2009)

5.9 — Startup, Operating and Shutdown: All Fuels
FIGURE 5-8. Flange Collar and Damper Settings (Top View)

Depending upon the fuel being burned, the applicable previous sections in this chapter should be reviewed for pre-
liminary instructions.
1. When firing with oil, be certain that the burner gun is in its most forward position and latched in place. When
firing with gas, the burner gun should be properly withdrawn and latched in place. The fuel selector switch
should be, accordingly, set to either oil or gas.
2. Set the manual-automatic switch to “manual” and turn the manual flame control to “close.”
3. Turn the burner switch to “ON.” The load demand light should glow. The low-water level light should remain
out, indicating a safe water level in the boiler. The programmer is now sequencing. See Chapter 4 for sequence
details.
NOTE: On an initial starting attempt, several efforts might be required to accomplish “bleeding” of fuel lines, main,
or pilot. If ignition does not then occur, do not repeat unsuccessful attempts without rechecking the burner and pilot
adjustment.
750-91 (revised 2009) 5-13

4. 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 resetting the lockout switch.
! Warning
Do not re-light the pilot or attempt to start the main burner, either oil or gas, if the combustion chamber is hot and/or
if gas or oil vapor combustion gasses are present in the furnace or flue passages. Failure to follow these instructions
! Warning
The burner and control system is designed to provide a “pre-purge” period of fan operation prior to establishing igni-
tion spark and pilot flame. Do not attempt to alter the system or take any action that might circumvent the “pre-purge”
feature. Failure to follow these instructions could result in serious injury or death.
5. After main flame ignition, the burner should be set on manual control at its low-fire setting (that is, with manual
flame control at “close”) until the boiler is properly warmed. Close the steam header.
In the case of a steam boiler, CLOSE the test valve when the steam begins to appear.
A hot water boiler must have a continuous flow of system water through the vessel during the warmup period.
The entire water content of the system and boiler must be warmed prior to increasing fuel input.
6. If the flame at low-fire provides insufficient heat to reach normal operating pressure or temperature after 30
minutes, gradually increase the firing rate by turning the manual flame control in one point increments to no
higher than the third cam screw. Operate at the increased fuel input rate for a period of time until an increase is
noted in pressure or temperature.
7. After the boiler is thoroughly warmed, turn the manual flame control to high-fire. At this point a combustion
analysis should be made, with instruments, and fuel flow regulated as required. Refer to the adjustment proce-
dures in Chapter 6. After making the high-fire adjustment, manually decrease the firing rate, stopping at each
cam screw to analyze combustion gasses, and adjust as required.
To properly perform the testing and adjusting, it is necessary that the burner be allowed to fire at a maximum rate
long enough to achieve desired results.
5.9.1 — Operating
Normal operation of the burner should be with the switch in the automatic position and under the direction of the
modulating control. The manual position is provided for initial 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.
NOTE: The hot flame to cool air cycling subjects the pressure vessel metal and refractory to undesirable conditions.
With the switch set at “automatic,” the burner will operate on a modulating basis according to the load demand.
The burner will continue to operate with modulated firing until the operating limit pressure or temperature is
reached, unless:
5-14 750-91 (revised 2009)

5.10 — Control Operational Test and Checks
• The burner is manually turned “off.”

• The low-water condition is detected by low-water level control.
• The electrical or fuel supply is interrupted.
• The combustion air pressure or atomizing air pressure drops below minimum level.
NOTE: There can be other reasons for shutdown, such as motor overload, flame outages, tripped circuit breakers,
blown fuses, or through other interlock devices in the circuitry.
When the burner is shut down normally, by either the operating limit control or by manually switching the burner
off, the load demand light no longer glows.
Shutdown through conditions causing safety or interlock controls to open will actuate the flame failure light (and
alarm if so equipped) and the load demand light will remain lit. The cause of this type of shutdown will have to be
located, investigated, and corrected before operation can be resumed. Refer to the “troubleshooting” section in
Chapter 7.
5.9.2 — 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 de-energized and the flame is extinguished. The timer begins operation and the blower motor con-
tinues running to force air through the furnace in the post-purge period.
At the end of the programmed post-purge period, the blower motor is turned off. The air pump motor of an oil-
fired burner is also turned off. The timer has returned to its original starting position and stops. The unit is ready to
restart.
! Warning
It is advisable to check for tight shut-off of fuel valves. Despite precautions and strainers, foreign material in either new
or renovated fuel lines may lodge under a valve seat and prevent tight closure. The situation is especially true in new
installations. Promptly correct any conditions causing leakage. Failure to follow these instructions could result in seri-
ous injury or death.

Proper operation of the various controls should be verified and tested when the boiler is initially placed into ser-
vice, or whenever a control is replaced. Periodic checks should be made thereafter in accordance with a planned
maintenance program.
The operating limit control may be checked by allowing steam pressure or water temperature to increase until the
burner shuts down. Depending upon the load, it may be necessary to manually increase the firing rate to raise steam
pressure to the burner shut off point. If the load is heavy, the header valve can be closed or throttled until the pres-
750-91 (revised 2009) 5-15

sure increases. Observe the steam gauge to check the cutoff pressure as the operating limit control shuts the burner
down. Slowly open the header valve to release steam pressure and check the cut-in setting as the burner restarts.
Check the modulating control for the desired operating pressure range. See Chapter 6 for instructions on the
adjustment of controls.
The water temperature on a hot water boiler that may be operating at less than full load may be raised by manually
increasing the firing rate until the burner shuts down through the action of the operating limit control. Observe the
thermometer to verify the desired settings at the point of cut-out and again when the burner restarts. Return the
manual automatic switch to “automatic” and check the modulating control for the desired temperature range. See
Chapter 6 for instructions on the adjustment of the controls.
Check the proper operation and setting of the low-water cutoff (and pump operating control, if used).
Proper operation of the flame failure device should be checked at startup and at least once a week thereafter. Refer
to 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.
Check for tight shutoff of all fuel valves. Despite precautions and strainers, foreign material may lodge under a
valve seat and prevent tight closure. Promptly correct any conditions that cause leakage.
5-16 750-91 (revised 2009)

CHAPTER 6 Adjustment Procedures
6.1 — Overview
Each Cleaver-Brooks boiler is tested for correct operation before shipment from the factory. However, variable
conditions such as burning characteristics of the fuel and operating load conditions may require further adjustment
after installation to assure maximum operating efficiency and economy.
A combustion efficiency analysis made during the initial startup will help to determine what additional adjustments
are required in a particular installation.
Prior to placing the boiler into service, a complete inspection should be made of all controls, connecting piping,
wiring, and all fastenings such as nuts, bolts, and setscrews to be sure that no damage has occurred, or that adjust-
ments have not changed during shipment and installation.
The adjustment procedures in Chapter 6 apply to standard components furnished on steam or hot water boilers
fired with gas and/or the various grades of oil.
6.1.1 — High Turndown Burner

In order to reduce stress on boiler components and to improve boiler operating efficiency, burners have been
designed for enhanced fuel turndown capabilities. A High Turndown Burner (HTB) is installed on boilers equipped
to fire light oil (Series 100), or gas (Series 700), or both (Series 200). Air and fuel inlets, the diffuser, and the air
damper control linkage have been modified for these burners.
NOTE: Observe that proper air damper linkage and fuel metering adjustment procedures are followed for standard
(Series 400 or 600) or HTB (Series 100, 200, or 700) burners to avoid damage to the equipment. The burner series is
identified on the boiler data plate affixed to the front head of the boiler.
Contact your local Cleaver-Brooks authorized representative or the Cleaver-Brooks Service Department for recom-
mendations covering special controls that are not included in Chapter 6.
750-91 (revised 2009) 6-1

6.2 — Linkage: Modulating Motor and Air Damper

The linkage consists of various arms, connecting rods, and swivel ball joints that transmit motion form the modu-
lating motor to the metering cam(s), rotary air damper, and gas butterfly valve.
NOTE: On combination gas and oil boilers, the gas butterfly valve might not be used. Also on combination gas and
oil boilers, the oil metering valve might not be used.
When properly adjusted, a coordinated movement of the damper and metering cams within the limits of the mod-
ulating motor travel is attained to provide proper fuel-air ratios through the firing range.
In linkage adjustments there are several important factors that must serve as guides.
• The modulating motor must be able to complete its full travel range.
! Caution
Do not restrict the full travel of the modulating motor. Failure to follow these instructions could result in equipment
damage.
• Initial adjustment should be made with the motor in full closed position, that is with the shaft on the power end
of the motor in its most counterclockwise position.
• 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 farther that arm will travel.
• Over-travel linkage, where used, should not be required in order to extend its spring to the fullest stretch.
With the modulating motor in the low-fire position, the arm on its shaft should be at an angle of 45º below the hor-
izontal. The driven arm on the jackshaft should also be 45º below horizontal. Secure both arms and fit the connect-
ing linkage rod in place between them.
Position the oil and/or gas modulating cams on the jackshaft so that the cam follower assembly is between the first
and second cam adjusting screws (under the first adjusting screw for High Turndown Burners). In this position,
fuel delivery is at low-fire rate. Tighten the set screws to secure the cams on the jackshaft.
FIGURE 6-1. Rotary Air Damper
6-2 750-91 (revised 2009)

FIGURE 6-2. Complete Linkage Assembly: Combination Gas and Oil
The stop screw in the rotary air damper limits damper travel at both closed (low-fire) and fully opened (high-fire)
positions. The screw is provided so that it is possible to tell, even with the burner in place, whether the damper
rotor is in fully opened or closed position. Rotating the damper clockwise to the stop screw closes the damper.
Rotating the damper counterclockwise to the stop screw opens the damper. Normally, the rate of flow of air
through the damper with the rotor in low-fire position is about one-third of maximum for a standard burner or
one-sixth for a HTB.
The amount of angular movement controlling the rate of air flow is determine by the location of the ends of the
rotary air damper rod in both the jackshaft arm and the air damper arm. When the air damper is in low-fire posi-
tion, the jackshaft arm should be at 45º (47-1/2º for HTB) and the rotary air damper arm should be at an angle of
approximately 60º below the horizontal. This will ensure that the angular movement of the damper starts slowly,
increasing in rate as the high fire position is approached.
Prior to initially firing a boiler it is advisable to check for free movement of the linkage. The damper motor must be
allowed to complete its full stroke and the damper must move freely from low- to high-fire position. Adjustment of
linkage connected to a gas butterfly valve is describe in Section 6.17.
750-91 (revised 2009) 6-3

6.3 — Modulating Motor

The modulating motor has a 90º shaft rotation. The motor manufacturer also provides a 160º stroke model for
other applications. If a replacement is obtained from someone other than a Cleaver-Brooks Service or Parts repre-
sentative, it may have an incorrect stroke. To prevent damage, determine the 90º stroke prior to installing a replace-
ment.
The stroke may be determined by powering the motor and connecting terminals R-B to actually determine the
stroke as the motor drives to an open position.
FIGURE 6-3. Modulating Motor
6.4 — Modulating Motor Switches: Low-Fire and High-Fire

The modulating motor contains either one or two internal switches, depending upon application. The micro-
switches are actuated by adjustable cams attached to the motor shaft.
Factory replacement motors have the cams preset. The low-fire start switch is set to make the red and yellow leads
at approximately 8º on motor closing. The high-fire purge air proving switch (located in the modulating motor) is
set to make red and blue tracer leads at approximately 60º 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.
6-4 750-91 (revised 2009)

6.5 — Burner Operating Controls: General
NOTE: Adjustments to the boiler operating controls should be made by an authorized Cleaver-Brooks Service Tech-
nician. Refer to the appropriate boiler operation and maintenance manual for specific information on boiler startup
and operation.
The standard boiler operating control package consists of three separate controls.
1. High Limit Control: Senses the hot water temperature or steam pressure. It is used as a safety limit to turn the
burner off in the event the operating limit control fails. The high limit control should be set sufficiently above
the operating limit control to avoid nuisance shutdowns.
2. Operating Limit Control: Senses temperature or pressure and automatically turns the burner on to initiate the
startup sequence when required and turns the burner off to initiate the shutdown sequence when the demand is
satisfied. The control must be set to initiate startup only at the low-fire position.
3. Modulating Control: Senses changes in the hot water temperature or steam pressure and signals the modulat-
ing motor to control the flow of fuel and air to the burner. With either steam or hot water boilers, the modulat-
ing control must be set to ensure the burner is at its minimum low-fire position before the operating limit
control either starts or stops the burner.
When adjusting or setting controls, first be sure all control devices are securely mounted and level. With the tem-
perature sensing control, make sure the sensing bulb is properly bottomed in its well and is secured against move-
ment. Be sure the connecting tubing is not kinked.
The dial settings are generally accurate, although it is not unusual to have a slight variation between a scale setting
and an actual pressure gauge or thermometer reading. Always adjust the control setting to agree with pressure
gauge or thermometer readings. Accurate instrument readings are required. When necessary use auxiliary test
equipment to set controls.
Burner controls correctly set to match load demands will provide operational advantages and achieve the following
desirable objectives:
• The burner will be operating in low-fire position prior to shutdown.
• The burner will operate at low-fire for a brief period on each start during normal operation.
• Elimination of frequent burner on-off cycling.
750-91 (revised 2009) 6-5

Separate and independent controls affect modulated firing and burner on-off cycling.
FIGURE 6-4. Firing Graph
The burner will be “on” whenever the pressure or temperature is less than point B (see Figure 6-4) and “off ”
whenever pressure or temperature is greater than point A. The distance between points A and B represents the
“on-off ” differential of the operating limit control.
In normal operation, the burner will shut down whenever the pressure or temperature rises above setting A. At that
point the switch in the operating limit control will open. As the pressure or temperature drops back to B, the oper-
ating limit control closes and the burner will restart. The modulating control will signal the modulating motor to be
in a low-fire position. If the load demands exceed the low fire input potential, the modulating control will increase
the firing rate proportionately as pressure or temperature falls toward point D. The modulating motor will stop at
any intermediate point between C and D whenever the fuel input balances the load requirement.
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 high-fire. In the event pressure or temperature drops
while the burner is firing at high-fire, it indicates that the load exceeds the capacity of the boiler.
The firing graph (Figure 6-4) shows that point B and point C do not coincide. Extreme load conditions could
require the points be closely matched.
6-6 750-91 (revised 2009)

When set as shown, with a time lag between B and C, the burner will be in a low-fire position upon a restart and
will fire at that rate for a short period of time before falling pressure or temperature requires an increase in the fir-
ing rate.
NOTE: On-off cycling in excess of 8 cycles per hour will shorten the life of the combustion air motor and cause
excessive wear on switch gear and pilot electrodes.
If points B and C overlap when restart occurs, the burner would drive to a higher firing position immediately after
the main flame was proven.
NOTE: It is not recommended that the boiler controls be set so as to overlap the modulating control range and oper-
ating control range.
When firing a cold boiler, it is recommended that the burner be kept at low-fire, under manual flame control, until
normal operating pressure or temperature is reached. If the burner is not under manual control on a cold start, it
will immediately move toward high-fire as soon as the program control releases the circuit that holds the burner in
low-fire. The modulating control will be calling for high-fire and the burner will move to that position as rapidly as
the damper motor can complete its travel.
NOTE: Rapid heat input can subject the pressure vessel metal and refractory to undesirable conditions.
Do not operate the boiler in excess of 90% of the safety valve relief setting. The closer the operating pressure is to
the safety valve relief pressure, the greater the possibility of valve leakage. continued leakage, however slight, will
cause erosion and necessitate early safety valve replacement. The control settings on a hot water boiler must be
within the temperature limits of the boiler.
Ideally, the boiler operating controls should be set under actual load conditions. Especially under new construction
conditions, the boiler is initially started and set to operate under less than full load requirements. As soon as possi-
ble thereafter, the controls should be reset to provide maximum utilization of the modulating firing system. To
accomplish maximum utilization, and assuming that air/fuel combustion ratios have been set, make the required
adjustments to the controls to bring the boiler pressure or temperature up to meet the load requirements.
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.
When the modulating control is set and the burner is in full high-fire, the scale setting of the modulating pressure
control on a steam boiler will indicate the low point of the modulating range. The scale setting of the modulating
temperature control on a hot water boiler will have a reading that indicates the midpoint of the modulating range.
The operating limit control should now be adjusted and the differential established. In an installation that does not
require a very close control of steam pressure or water temperature, the adjustable differential should be set as wide
as conditions permit, since a wide setting will provide less frequent burner cycling.
The high limit control provides a safety factor to shut the burner off in the event the operating limit control should
fail. The setting of the control should be sufficiently above the operating limit control to avoid nuisance shutdowns.
The setting, however, must be within the limits of the safety valve settings and should not exceed 90% of the valve
setting. The control requires manual resetting after it shuts off the burner.
750-91 (revised 2009) 6-7

In the setting of the controls, consideration must be given to the time required for a burner restart. Each start,
requires a pre-purge period, plus the fixed time required for proving the pilot and main flame. In addition, approx-
imately one-half minute is required for the damper motor to travel from low to high-fire. The time lag may allow
pressure or temperature to drop below desirable limits.
6.6 — Modulating Pressure Control: Steam

Turn the adjusting screw until the indicator is opposite the low point of the desired modulating range. Modulated
firing will range between the low point and a higher point equal to the modulating range of the particular control.
• in 0 - 5 psi controls the range is 1/2 lb
• in 5 - 150 psi controls the range is 5 lbs
! Caution
To prevent burner shutdown at other than low-fire setting, adjust the modulating pressure control to modulate to low-
fire BEFORE the operating limit pressure control shuts off the burner. Failure to follow these instructions could result
in damage to the equipment.
6.7 — Operating Limit Pressure Control: Steam

Set the “cut-out” (burner off) pressure on the main scale using the large adjusting screw. Set the differential on the
short scale by turning the small adjusting screw until the indicator points to the desired difference between cut-out
and cut-in pressures. The “cut-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.
6.8 — High Limit Pressure Control: Steam

Set the “cut-out” (burner off) pressure on the main scale using the adjusting screw. The control will break a circuit
when pressure reaches this point. The setting should be sufficiently above the operating limit pressure control to
avoid shutdowns, and preferably not exceed 90% of safety valve setting. The control requires manual resetting after
tripping on a pressure increase. To reset, allow pressure to return to normal and then press the reset button.
6.9 — Modulating Temperature Control: Hot Water

Turn the knob on the front of the case until the pointer indicates the desired setpoint temperature. The desired set-
point is the center point of a proportional range. The control has a 3º to 30º differential and may be adjusted to
vary the temperature range within which modulating action is desired.
6-8 750-91 (revised 2009)

6.10 — Operating Limit Temperature Control: Hot Water
FIGURE 6-5. Hot Water Controls
With the cover off, turn the adjustment wheel until the pointer indicates the desired range.
! Caution
To prevent burner shutdown at other than low-fire setting, adjust the modulating pressure control to modulate to low-
fire BEFORE the operating limit pressure control shuts off the burner. Failure to follow these instructions could result
in damage to the equipment.

Set “cut-out” (burner off) temperature on the scale by inserting a screwdriver through the cover opening to engage
the slotted head adjusting screw. The “cut-in” (burner on) temperature is the cut-out temperature minus the differ-
ential. The differential is adjusted from 5º to 30º F.
6.11 — High Limit Temperature Control: Hot Water

Set the “cut-out” (burner off) temperature on scale using the adjusting screw. The control will break the circuit and
lock out on a rise in water temperature above the setting. The setting should be sufficiently above the operating
limit temperature to avoid unnecessary shutdowns. On a 30 psig hot water boiler, the setting is not to exceed 240º
F. The control requires manual resetting after tripping on a temperature increase. To reset, allow the water temper-
ature to drop below the cut-out setting less differential, and then press the manual reset button.
750-91 (revised 2009) 6-9

6.12 — Low Water Cutoff Devices: Steam & Hot Water

No adjustment is required since LWCO controls are preset by the original manufacturer. However, if the water
level is not properly maintained, inspect the devices immediately and replace as required.
6.13 — Combustion Air Proving Switch

Air pressure against the diaphragm actuates the switch which, when made, completes a circuit to prove the pres-
ence of combustion air. Since the pressure of the combustion air is at its minimum value when the damper is full
open, the switch should be adjusted under that situation. It should be set slightly below the minimum pressure, but
not too close to that point to cause nuisance shutdowns.
The run/test switch on the program relay should be set to TEST. Turn the burner switch on. The blower will start
(provided that all limit circuits are completed) and the programmer will remain in the low-fire (damper closed) por-
tion of the pre-purge.
NOTE: On an oil fired boiler, the atomizing air proving switch (AAPS) must also be closed.
On a combination fuel fired burner, the fuel selector switch could be set at “gas” to eliminate the atomizing air proving
switch from the circuitry.
To have the modulating damper motor drive to high-fire (damper open), remove the cover from the motor and
remove the wire from terminal W.
Slowly turn down the Combustion Air Proving Switch (CAPS) adjusting screw until it breaks the circuit. Here the
programmer will lock out and must be manually reset before it can be restarted. Add a half turn or so to the adjust-
ing screw to remake its circuit.
Recycle the program relay to be sure that normal operation is obtained. Replace the wire on terminal W and re-
install the cover. Return the test switch to the RUN position.
6.14 — Atomizing Air Proving Switch

The air pressure against the diaphragm actuates the switch which, when closed, completes a circuit to prove the
presence of atomizing air. Since the pressure of the atomizing air is at its minimum value when there is no fuel pres-
ent at the nozzle, adjustment of the switch should be done while the unit is running but not firing. The control
should be set slightly below the minimum pressure, but not too close to that point to cause nuisance shutdowns.
The control adjustment may be made during the pre-purge period of operation by stopping the programmer during
the pre-purge period through the use of the TEST switch. Refer to the control instruction bulletin for details.
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.
6-10 750-91 (revised 2009)

6.15 — Gas Pilot Flame Adjustment
Since the adjustment of the air switch may be made either during the damper closed or damper open position of
pre-purge, it is also possible to make the adjustment with the relay stopped in the damper open position in a similar
manner to the adjustment of the combustion air proving switch described in Section 6.13.
After making the adjustment, recycle the control to be sure that normal operation is obtained. The TEST switch
must be set to RUN position.

The size of the gas pilot flame is regulated by adjusting the gas flow through the pilot gas regulator and the pilot
adjusting cock on the front of the burner. The flame must be sufficient to ignite the main flame and to be seen by
the flame detector. But an extremely large flame is not required. An overly rich flame can cause sooting or carbon
buildup on the flame detector. Too small a flame can cause ignition problems.
Although it is possible to visibly adjust the size of the pilot flame, it is preferable to obtain a microamp or voltage
reading of the flame signal.
The correct voltage or microamp readings can be found in the information supplied with the flame safeguard sys-
tem.
The program relay used may be of the type that provides message information that includes a constant flame signal
of DC voltage. In this case a separate DC voltmeter is not required.
6.15.1 — Measure and Adjust Pilot

1. When making a pilot adjustment, turn the manual-automatic switch to “manual” and the manual flame control
to “close.”
2. Open both the cutoff cock and the pilot adjusting cock. The main gas cock should remain closed.
The regulator in the pilot line, if provided, is to reduce the gas pressure to suit the pilot’s requirement of
between 5” to 10” WC. Regulator adjustment is not critical, however, with a lower pressure the final adjustment
of the pilot flame with adjusting cock is less sensitive.
3. Connect the micro-ammeter.
4. Turn the burner switch on. Let the burner go through the normal pre-purge cycle. When the ignition trial
period is signaled, set the test switch to the TEST position to stop the sequence.
5. If the pilot flame is not established within 10 seconds, turn off the burner switch. Repeat the lighting attempt.
NOTE: On an initial starting attempt, portions of the fuel lines may be empty and require “bleeding” time. It is better
to accomplish this with repeated short lightning trial 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.
6. When the pilot flame is established, and with the pilot adjusting cock wide open, remove the flame detector
from the burner plate. The pilot flame can then be observed through this opening.
750-91 (revised 2009) 6-11

! Warning
Wear a protective shield or suitable glasses and keep eyes sufficiently away from the sight tube opening to avoid serious
personal injury. Never remove the flame detector while the main burner is firing.
Failure to follow these instructions could result in serious injury or death.
7. To make the final adjustment, slowly close the gas pilot adjusting cock until the flame can no longer be seen
through the sight tube. Then slowly open the cock until a flame providing full sight tube coverage is observed.
The adjustment must be accomplished within the time limit of the safety switch or approximately 30 seconds
after the detector is removed. If the control shuts down, manually reset it. Replace the detector and repeat the
process from step 6.
8. When a suitable flame is obtained, replace the detector. Observe the reading on the micro-ammeter. The read-
ing should be between 2-1/4 and 5 microamps when using a lead sulfide detector and a standard amplifier. See
the flame signal table in the manufacturer's bulletin for values of other combinations.
The flame signal indicated on the annunciator type relay should not be less than 10 Vdc, and may be as high as
20 Vdc or greater.
The reading must be steady. If the reading fluctuates, recheck the adjustment. Be sure that the flame detector is
properly seated and that the lens is clean.
10. If main flame has not been previously established, proceed to do so in accordance with proper instructions.
11. The reading of the main flame signal should also be checked. Observe the flame signal for pilot alone, pilot and
main burner flame together, and the main burner flame at high, low, and intermediate firing rate positions.
Readings should be steady and in the range indicated in Step 8. If there are any deviations, refer to the trouble-
shooting section in the technical bulletin.
6.16 — 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 pres-
sure of the gas to a level that produces a steady, dependable flame that yields highest combustion efficiency at rated
performance yet prevents overfiring. Once the optimum pressure has been established, it should be recorded and
periodic checks made to verify that the regulator is holding the pressure at this level. Occasional modification in
fuel composition or pressure by the supplier may, at times, require readjustment to return the burner to peak effi-
ciency. Since the gas pressure regulator itself is usually furnished by others, detailed adjustment instructions and
adjusting procedures recommended by the manufacturer should be followed.
6.16.1 — Pressure
The gas supplied must provide not only the quantity of gas demanded by the unit, but must also be at a pressure
high enough to overcome the pressure-loss due to the frictional resistance imposed by the burner system and the
control valves.
6-12 750-91 (revised 2009)

The pressure required at the entrance to the burner gas train for rated boiler output is termed “net regulated pres-
sure.” The gas pressure regulator must be adjusted to achieve the pressure to assure full input.
Pressure Required at Gas Train Entrance with Two Valves and 3” Pipe
Boiler HP Standard HTB LE
250 17.5” WC 22.0” WC 23.0” WC
300 23.0” WC 31.0” WC 32.5” WC
350 32.5” WC 42.5” WC 45.0” WC
FIGURE 6-6. Minimum Net Regulated Gas Pressure for Rated Boiler Output
The pressure requirement varies with boiler size, altitude, and type of gas train. The pressures listed are based on
1000 Btu/cu. ft. natural gas at elevations up to 700 feet above sea level. For installation at higher altitudes, multiply
the selected pressure by the proper factor from Figure 6-7.
Altitude
Feet Above Sea Level Correction Factor
1000 1.04
2000 1.07
2500 1.09
3000 1.11
4000 1.16
5000 1.21
6000 1.25
7000 1.30
8000 1.35
9000 1.40
FIGURE 6-7. Pressure/Altitude Correction Factors
750-91 (revised 2009) 6-13

High Fire Input Low Fire Input

Boiler HP Btu/hr (GAS) Btu/hr (GAS)
250 CB & CB-LE 10,461,000 1,461,000
300 CB & CB-LE 12,553,000 1,255,300
350 CB & CB-LE 14,645,000 1,464,500

Boiler HP Btu/hr (OIL) Btu/hr (OIL)
250 CB & CB-LE 10,461,000 1,307,625
300 CB & CB-LE 12,553,000 1,569,125
350 CB & CB-LE 14,645,000 1,830,625
FIGURE 6-8. Standard Burner Required Input

Boiler HP Btu/hr Btu/hr
250 gas 10,460,000 1,046,000
300 gas 12,555,000 1,255,500
350 gas 14,645,000 1,464,500
250 oil 10,460,000 1,307,500
300 oil 12,555,000 1,569,400
350 oil 14,645,000 1,830,600
FIGURE 6-9. High Turndown Burner Required Input
Regulator Inlet Pressure

(psig) Pressure Factor
1 1.05
2 1.11
3 1.18
4 1.25
5 1.32
6 1.39
7 1.45
8 1.53
9 1.59
10 1.66
11 1.72
6-14 750-91 (revised 2009)


12 1.81
13 1.86
14 1.93
15 2.00
FIGURE 6-10. Pressure Correction Factors
6.16.2 — Gas Flow

The volume of gas flow is measured in terms of cubic feet and is determined by a meter reading. The gas flow rate
required for maximum boiler output depends on the heating value (Btu/cu. ft.) of the gas supplied and boiler effi-
ciency. The supplying utility can provide the information.
EFFICIENCY
GAS FLOW = INPUT

GAS Btus/Ft3
= OUTPUT x 100
EFFICIENCY x GAS BTUs/Ft3
6.16.3 — Pressure Correction

The flow rate outlined in Section 6.16 is based on a “base” pressure, which is usually atmospheric or 14.7 psia.
Meters generally measure gas in cubic feet at “line” or supply pressure. The pressure at which each cubic foot is
measured and the correction factor for the pressure must be known in order to convert the quantity indicated by
the meter into the quantity which would be measured at “base” pressure.
To express the volume obtained from an actual meter reading into cubic feet at base pressure, it is necessary to mul-
tiply the meter index reading by the proper pressure factor obtained from Figure 6-10.
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. This answer indicates the number of
cubic feet at line pressure which must pass through the meter to deliver the equivalent number of cubic feet at base
pressure.
For example, assume that a 600 horsepower boiler is installed at 2,000 feet above sea level, is equipped with a stan-
dard gas train and a high turndown burner, and that 1,000 Btu natural gas is available with in incoming gas pressure
of 3 psig. The pressure and flow requirements can be determined as follows:
750-91 (revised 2009) 6-15

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 37.5” WC gas pressure at sea level. Figure 6-7 indicates a correction factor of 1.07
for 2,000 feet. Multiplying results in a calculated net regulated gas requirement of approximately 40.1” WC. This is
the initial pressure to which the regulator should e adjusted. Slight additional adjustment can be made later, if nec-
essary, to obtain the gas input needed for burner rating.
FLOW
Since the gas flow rate is based on standard conditions of flow, correction must be made for the supply pressure
through the meter of 3 psig. Determine the flow rate by dividing the Btu content of the gas into the burner input
(Figure 6-8) and “correct” this answer by applying the correction factor for 3 psig (Figure 6-9).
Btu/hr input = CFH (Cubic feet/hour)
Btu/cu. ft.
OR
25,100,000 = 25,100 CFH (at 14.7 lb atmospheric base pressure)

1,000
THEN
25.100 = 21,271 CFH

1.18
This is the CFH (at line pressure) that must pass through the meter so that the equivalent full input requirement of
25,100 CFH (at base pressure) will be delivered.
6.16.4 — Checking Gas Flow

Your gas supplier can generally furnish a gas meter flow chart from which gas flow can be determined. After a
short observation period, the information aids in adjusting the regulator to increase or decrease flow as required to
obtain the rating.
Final adjustment of the gas fuel is carried out be means of the adjusting screws in the gas modulating cam, while
performing a combustion efficiency analysis. See Section 6.17 for details.
NOTE: The information given in this section is for all practical purposes sufficient to set and adjust controls for gas
input. Your gas supplier can, if necessary, furnish exact correction factors that take into consideration Btu content,
exact base pressure, specific gravity, temperature, etc. of the gas used.
6-16 750-91 (revised 2009)

6.17 — Gas Fuel Combustion Adjustment

After operating for a sufficient period of time to assure a warm boiler, adjustments should be made to obtain effi-
cient combustion.
NOTE: All adjustment should be done by a qualified boiler operator or your local Cleaver-Brooks service representa-
tive.
Burner efficiency is measured by the amount or percentage of O2 present in the flue gas. O2 readings determine the
total amount or excess air in the combustion process, above the point of stoichiometric combustion or perfect
combustion. Stoichiometric combustion is a term used to describe a condition when there is the exact amount,
molecule for molecule, of air for the fuel burned. This can be accomplished under laboratory conditions, however,
it’s not practical to attempt to meet this condition in a boiler. Stoichiometric combustion, however, is the reference
point used when setting air/fuel ratios in a boiler.
There must always be excess air in the combustion process to account for changes in boiler room temperature and
atmospheric conditions, and to ensure the combustion is on the proper side of the combustion curve (see Figure 6-
11).
Proper setting of the air/fuel ratios at all rates of firing must be established by the use of a combustion or flue gas
analyzer.
The appearance or color of the gas flame is not an indication of its efficiency, because an efficient gas flame will
vary from transparent blue to translucent yellow.
FIGURE 6-11. Flue Gas Analysis for Natural Gas
Most flue gas analyzers in use today measure the content, by percentage of oxygen (O2) and carbon monoxide
(CO) either by percent or parts per million (ppm). Carbon dioxide (CO2) is not normally measured with today’s flue
gas analyzers, but may be displayed via a calculation.
750-91 (revised 2009) 6-17

The O2 levels through the entire firing range of the burner, low-fire to high-fire should be tested. The burner man-
ufacturer’s recommendations on turndown should also be followed and the turndown range of the burner should
not be exceeded.
It is important to understand what the readings shown on an instrument refer to when setting combustion in a
boiler. To assist with this understanding Figure 6-11 shows the relationship between O2 levels (excess air) and the
products of combustion for a typical flue gas analysis (natural gas).
One of the products of combustion is CO2 (carbon dioxide). This is shown in percentage.
Another product of combustion is CO (carbon monoxide) and is shown in both percentage and parts per million
(ppm). The maximum CO level standardly allowed is less than 400 ppm. However, this may change subject to local
regulations.
The percent O2 recorded on an instrument equates to percent excess air, i.e., 3% O2 is approximately 15% excess
air and 4% O2 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 O2 readings of between 3% and 4% be attained with less than 400 ppm CO, at
high-fire.
Using information from section 6.16, determine the standard conditions of gas pressure and flow for the boiler
size and attached gas train. Calculate the actual pressure and flow through the use of correction factors that com-
pensate for incoming gas pressure and altitude.
Basically, gas adjustments are made with a gas pressure regulator, which controls the pressure and with the butterfly
gas valve which directly controls the rate of flow.
FIGURE 6-12. Butterfly Gas Valve
6-18 750-91 (revised 2009)

In initially setting the linkage:

1. Back off the low fire stop screw on the butterfly valve so that the valve is closed.
2. Then run the screw out to touch the arm, and give it two complete turns.
3. Adjust the connecting rod so that the override tension is released and so that the arm is now just touching the
stop screw.
4. Tighten the locknuts on all ball joints.
The low fire setting should be regarded as tentative until the proper gas pressure for high-fire operation is estab-
lished. To reach high-fire rate:
1. Turn the manual flame control switch toward “OPEN” in minor increments while monitoring combustion for
overly rich or lean conditions.
2. At high-fire the gas butterfly valve should be open as wide as indicated by the slot on the end of the shaft. Set
and lock the high-fire stop screw so that it is just touching the valve arm.
3. Determine the actual gas flow from a meter reading.
4. With the butterfly valve open and with regulated gas pressure set at the calculated pressure, the actual flow rate
should be close to the required input. If corrections are necessary, increase or decrease the gas pressure by
adjusting the gas pressure regulator, following the manufacturer’s directions for regulator adjustment.
When proper gas flow is obtained, take a flue gas reading. The O2 should be between 3% and 4% at high-fire.
If the fuel input is correct, but the O2 values do not fall within this range, the air damper travel may need to be
adjusted. Adjustment of the air damper linkage is described in Section 6.2.
With the high-fire air/fuel ratio established, the gas pressure regulator needs no further adjusting.
After being certain that the air control damper and its linkage are correctly adjusted to provide the proper amount
of secondary air, and after adjusting the gas pressure regulator, final adjustment can be made, if necessary, to the gas
modulating cam to obtain a constant air/fuel ratio throughout the entire firing range.
NOTE: Be sure to loosen the cam foot locking screws before adjusting any cam screws or teh cam feet may be dam-
aged.
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 decrease it. Flow rate is highest when the cam follower
assembly is closest to the jackshaft.
750-91 (revised 2009) 6-19

FIGURE 6-13. Fuel Modulating Cam
Through the manual flame control switch, position the cam so that the adjusting screw adjacent to the end or high-
fire screw contacts the cam follower. Perform a combustion analysis at this point. If an adjustment is necessary,
turn the adjustment screw accordingly to increase or decrease fuel flow. Take a combustion reading to verify input.
Repeat as necessary until the desired flow is obtained. Repeat the process, stopping at each adjusting screw, until
the low-fire adjusting screw is reached.
NOTE: Do not use any lubricant on the adjusting setscrews. The setscrews have a nylon locking insert intended to
provide locking torque and resistance to loosening and a lubricant could damage the equipment.
6.17.1 — Standard Burner Low-Fire Adjustment

The fuel input should be adjusted using the low-fire cam screw, to approximately 25% of that at high-fire (see Fig-
ure 6-8). At low-fire the O2 flue gas reading should be between 6% and 7%.
It may be necessary to readjust the setting of the low-fire stopscrew to obtain the proper air/fuel ratio at the low-
fire rate. To ensure that the low-fire position of the gas butterfly valve is always the same, allow one turn of the stop
screw for overtravel.
If the air damper needs to be adjusted in order to provide the correct low-fire air/fuel ratio, combustion must be
rechecked at higher firing rates and adjusted as required.
If all cam screws are properly adjusted, none will deviate from the general overall contour of the cam face.
6-20 750-91 (revised 2009)

6.18 — Low-Gas Pressure Switch
6.17.2 — High Turndown Burner Low-Fire Adjustment

The fuel input should be adjusted using the low-fire cam screw, to approximately 10% of that at high-fire (see Fig-
ure 6-9). At low-fire the O2 flue gas reading should be between 9.5% and 11%. When adjusting a high turndown
burner equipped with IFGR, the O2 readings should be 6% to 7%.
It may be necessary to readjust the setting of the low-fire stopscrew in order to obtain the proper air/fuel ratio at
low-fire. To ensure that the low-fire position of the gas butterfly valve is always the same, allow a half turn of the
stop screw for overtravel.
If the air damper must be reset to meet the low-fire air/fuel requirements, combustion at higher firing rates must be
rechecked.
The second cam adjusting screw may need to be adjusted in order to maintain a smooth cam profile. If all screws
are properly adjusted, none will deviate from the general overall contour of the cam face.

Adjust the scale setting to slightly below the normal burning pressure. The control circuit will be broken when
pressure falls below this point. Since gas line distribution pressure may decrease under some conditions, shutdowns
may result if the setting is too close to normal. However, regulations require that the setting may not be less than
50% of the rated pressure downstream of the regulator.
Manual resetting is necessary after a pressure drop. Press the reset lever after pressure is restored. Be sure that the
mercury switch equipped control is level.
6.19 — 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.
750-91 (revised 2009) 6-21

Manual resetting is necessary after a pressure rise. Press the reset lever after pressure falls. Be sure that the mercury
switch equipped control is level.
FIGURE 6-14. Gas Train Pressure Switches
6.20 — Fuel Oil Pressure and Temperature: General

Variations in burning characteristics of the fuel oil may occasionally require adjustments to assure highest combus-
tion efficiency. The handling and burning characteristics may vary from one delivery of oil to another. Therefore, it
is recommended that the oil system be inspected from time to time to verify that pressures and viscosity are at the
proper operating levels.
Because of variation in oils, including chemical content, source, blends, and viscosity characteristics, the tempera-
tures and pressures listed in Chapter 5, and mentioned in the adjusting of the controls in the following paragraphs,
will vary and thus may be regarded as tentative and to be changed to provide best firing conditions. Figure 6-15 is
an oil viscosity-temperature chart. It may be used as a guide, although your oil supplier will be able to give you more
exact information based on an analysis of the oil.
Review of the applicable maintenance instructions given in Chapter 8 will aid in maintaining an efficient fuel sys-
tem.
NOTE: To prevent oil heater coking, the fuel oil pump must be in operation during all times that an oil heater is in ser-
vice. During any time that the oil pump is not operating, the oil heating system must be electrically shut down by man-
ually turning the oil heater switch to the “off ” position.
When the boiler is shut down, or switched over to gas firing, the pump must operate for a sufficient period of time
to cool the oil heater. Similarly, if an electric, steam, or hot water oil heater is removed for servicing, the tempera-
ture of the heater should be reduced by circulating oil until it has cooled.
6-22 750-91 (revised 2009)

6.21 — Fuel Oil Combustion Adjustment
FIGURE 6-15. Oil Viscosity Chart

After operating for a sufficient period of time to assure a warm boiler, adjustments should be made to obtain effi-
cient combustion.
NOTE: All adjustment should be done by a qualified boiler operator or your local Cleaver-Brooks representative.
Burner efficiency is measured by the amount or percentage of O2 present in the flue gas. O2 readings determine the
total amount or excess air in the combustion process, above the point of stoichiometric combustion or perfect
combustion. Stoichiometric combustion, however, is the reference point used when setting air/fuel ratios in a
boiler.
There must always be excess air in the combustion process to account for changes in boiler room conditions and to
ensure the combustion is on the proper side of the combustion curve.
Proper setting of the air/fuel ratios at all rates of firing must be established by the use of a combustion gas analyzer.
Efficient combustion cannot be solely judged by flame condition or color, although they may be used in making
approximate settings. Combustion settings should be done so that there is a bright sharp flame with no visible haze.
Most flue gas analyzers in use today measure the content, by percentage, of oxygen (O2) and in some cases, smoke.
Carbon dioxide (CO2) is not normally measured with modern gas analyzers, but may be displayed as a calculation.
750-91 (revised 2009) 6-23

The O2 levels through the entire firing range of the burner, low-fire to high-fire should be tested. The burner man-
ufacturer’s recommendations on turndown should also be followed and the turndown range of the burner should
not be exceeded.
It is required to set the burner to operate with a reasonable amount of excess air to compensate for minor varia-
tions in the pressure, temperature, or burning properties of oil. 15% to 20% excess air is considered reasonable.
This would result in an O2 reading of 3% to 4% at high-fire.
Final adjustment to fuel input must be made to produce a minimum of smoke. A maximum smoke spot density of
a No. 2 for light oil, or a No. 4 for heavy oil is acceptable, as measured in conformance to ASTMD 2156-63T.
Through the use of the manual flame control, slowly bring the unit to high-fire by stages while monitoring com-
bustion for overly rich or lean conditions. At the high-fire position, the air damper should be fully opened and the
air and oil pressure readings should be on the order of the readings given in Chapter 5.
Take a flue gas analysis reading. If necessary, adjust the fuel oil controller to increase or decrease oil pressure.
Adjustments to the pressure should be done before attempting to adjust the screws in the metering cam. Ideally,
the cam profile spring should be as close to the cam casting as practical. It is more desirable to lower the oil pres-
sure to reduce flow, if necessary, than to extend the adjusting screws to an extreme position in an effort to cut back
flow.
After being certain that the air control damper and its linkage are operating properly, final adjustment can be made,
if necessary, to the oil modulating cam to obtain a constant air/fuel ratio through the entire firing range.
NOTE: Be sure to loosen the cam foot locking screws before adjusting any cam screws or teh cam feet may be dam-
aged.
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 fuel at that setting. The adjustment is made to the metering cam by means of
adjusting screws, which are turned out (counterclockwise from the hex-socket end) to increase the flow of fuel and
in (clockwise from the hex-socket end) to decrease it. Flow rate is highest when the cam follower assembly is clos-
est to the jackshaft.
If oil pressure, primary air pressure, and linkages are properly adjusted, the metering cam should require minimal
adjustment.
Using the flame control switch, position the cam so that the adjusting screw adjacent to the end, high-fire screw,
contacts the cam follower. Make a combustion analysis at this point.
If an adjustment is necessary, turn the adjustment screw accordingly to increase or decrease fuel flow. Take a com-
bustion reading to verify input. Repeat as necessary until the desired flow is obtained. Continue this pressure, stop-
ping at each adjusting screw, until the low-fire position is reached.
NOTE: Do not use any lubricant on the adjusting setscrews. These have a nylon locking insert intended to provide
locking torque and resistance to loosening and a lubricant could damage the equipment.
6-24 750-91 (revised 2009)

6.22 — Burner Drawer Adjustment
6.21.1 — Standard Burner Low-Fire Adjustment: Heavy Oil

The fuel input should be adjusted with the low-fire cam screw, to approximately 25% of that at high-fire. At low
fire the O2 flue gas reading should be between 7% and 8%.
6.21.2 — High Turndown Burner Low-Fire Adjustment: Light Oil

Fuel input at low-fire should be approximately 12.5% of that at high-fire. The low-fire screw should be adjusted to
obtain the necessary input for the fuel turndown required. At low-fire the O2 flue gas reading should be between
7% and 9%. The second cam adjusting screw may need to be adjusted in order to maintain a smooth cam profile.

There are relatively few adjustments that can be made to the burner, however, a check should be made to assure
that all components are properly located, and that all holding screws are properly tightened.
The diffuser location on gas fired boilers is quite important. There should be 1/4” distance between the edges of
the diffuser fins and gas outlet tubes (spuds) (see Figure 6-16). The setting of an oil fired burner is less exacting and
the diffuser should be located with the skirt approximately 1-1/8” from the end of the burner tube.
FIGURE 6-16. Standard Burner
When the proper diffuser location is ascertained, the setting of the nozzle in relation to the diffuser should be
checked. This generally is set at time of manufacture and seldom needs altering. It is most important that oil spray
does not impinge upon the diffuser. The distance that the nozzle is behind the diffuser has some latitude, and indi-
vidual installations may require a slight deviation. The spacing indicated is 2”.
750-91 (revised 2009) 6-25

Check the setting of the ignition electrode(s) for proper gap and position. Be sure that the porcelain insulator is not
cracked and that ignition cable connections are tight.
FIGURE 6-17. Burner Drawer With Gas Pilot
The oil nozzle tip should be seated tightly in the body with the swirler and the seating spring in place. See Section
8.7 for additional nozzle tip information.
Check to see that the flame detector sight tube and the gas pilot tube extend through their respective openings in
the diffuser face.
6.23 — Oil Drawer Switch

The integral contacts of the control are closed by proper positioning and latching of the oil drawer in its forward
position. Adjustment of the switch must be such that its contacts open if the oil drawer is not properly positioned
for oil firing. The switch is electrically removed from the circuit when a combination fuel burner is fired on gas.
6-26 750-91 (revised 2009)

6.24 — Low Oil Temperature Switch

The LOTS prevents the burner from starting, or stops its operation, if the temperature of the oil is below normal
operating temperature.
To adjust the control:

1. Insert a screwdriver into the center slot in the control cover and turn the dial until the fixed (center) pointer is
approximately 30º F lower than the oil heater thermostat setting.
2. Turn the differential adjusting screw (located above dial) until the movable indicator is approximately 5º F above
the setting on the main scale.
On a hot water boiler, the low oil temperature switch is an integral part of the electric oil heater. The switch is non-
adjustable and is factory set at approximately 40º F below the maximum operating temperature of the heater.
6.25 — High Oil Temperature Switch (Optional)

The HOTS prevents the burner from starting, or stops its operation, if the temperature of the oil exceeds the nor-
mal operating temperature.
To adjust, turn the dial until the pointer is approximately 25º F above the normal operating temperature. The con-
trols generally have a set differential and will close 5º F below the setpoint.
6.26 — Low Oil Pressure Switch (Optional)

The LOPS prevents burner ignition, or stops its operation, when the oil pressure is below the setpoint. Adjust the
control by turning the screw on top of the control case to an indicated pressure 10 psi below the established pri-
mary oil pressure setting indicated on the oil supply pressure gauge. The switch will remain in a closed position as
long as the oil pressure exceeds this setting. The control normally used automatically resets when pressure is
restored after a drop.
6.27 — Electric Oil Heater Thermostat (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.
The final setting of this thermostat should be at a temperature approximately 15º F lower than the steam heater
thermostat. This eliminates the electric heater operation when the steam heater is functioning. The electric heater is
sized to provide sufficient heated oil for low-fire operation on cold starts before steam is available.
750-91 (revised 2009) 6-27

6.28 — 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.
The final setting of the thermostat should provide oil at a sufficient temperature for efficient combustion based on
flue gas analysis. There is no need to heat the oil in excess of the temperature.
6.29 — Hot Water Oil Heater Thermostat (400 and 600 Series)
To adjust the thermostat, insert a screwdriver into the center slot in the control cover and turn the dial until the
pointer is at the desired temperature level. The control generally has a set differential, and will close 5º F below the
setpoint.
The thermostat contacts close to energize the booster water pump, which pumps water from the boiler through the
heater. On cold starts, it is normal practice to manually close the valve in the pump discharge line until the boiler
water temperature exceeds the temperature of fuel oil entering the heater.
The electric oil heater on a hot water boiler burning No. 6 oil and equipped with a hot water oil heater has a built-
in adjustable thermostat. The maximum temperature setting is stamped on its dial. The desired temperature can be
obtained by turning the adjusting screw. The thermostat should be set at a temperature approximately 15 degrees
lower than the hot water heater thermostat. Such a temperature prevents the electric heater from operation when
the water heater is functioning. The electric heater is sized to provide sufficient heated oil for low-fire operation on
cold starts before hot water is available.
6.30 — Steam Heater Pressure Regulator (400 and 600 Series: Steam)
The regulator is provided on a boiler designed to operate at pressures above 15 psi and reduces boiler steam pres-
sure to the level necessary for proper operation of the steam oil heater. The pressure should be reduced to a point
that permits sufficient temperature to heat the oil, while allowing as continuous a steam flow as possible. Pressure
that is too high will result in frequent cycling of the steam solenoid valve.
It is best to adjust the regulator under typical flow conditions. To do so, it is suggested that the globe valve in the
steam supply line be closed so that there is no pressure on the regulator. Turn out the adjusting screw fully to
relieve compression on the regulator spring, thus closing the regulator. With steam at normal pressure, open the
globe valve and then set the secondary pressure by turning the adjusting screw or handle until the downstream
gauge shows the desired pressure.
6-28 750-91 (revised 2009)

CHAPTER 7 Troubleshooting
7.1 — Overview
! Warning
Troubleshooting should be performed only by personnel who are familiar with the equipment and who have read and
understand the contents of this manual. Failure to follow these instructions could result in serious injury or death.
! Warning
Disconnect and lock out the main power supply in order to avoid the hazard of electrical shock. Failure to follow these
instructions could result in serious injury or death.
sequence applies regardless of the make or model. Please refer to the Wiring Diagram (WD) prepared by Cleaver-
Chapter 7 assumes that the unit has been properly installed and adjusted, and that it has been running for some
time. It is further assumed that the operator has become thoroughly familiar with both burner and manual by this
time. The points under each heading are set down briefly as possible causes, and suggestions or clues to simplify
locating the source of trouble. Methods of correcting the trouble, once it has been identified, may be found else-
where in this manual.
If the burner will not start or operate properly, the troubleshooting chapter should be referred to for assistance in
pinpointing problems that may not be readily apparent.
750-91 (revised 2009) 7-1

Troubleshooting
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 programmer and other controls in the system may be obtained by studying the contents of this
manual. Knowledge of the system and its controls will make troubleshooting much easier. Costly downtime or
delays can be prevented by systematic checks of actual operation against the normal sequence to determine the
stage at which performance deviates from normal. following a routine may possibly eliminate overlooking an obvi-
ous condition, often one that is relatively simple to correct.
If an obvious condition is not apparent, check the continuity of the circuits with a voltmeter or test lamp. Each cir-
cuit can be checked and the fault isolated and corrected. Most circuitry checking can be done between appropriate
terminals on the terminal boards in the control cabinet or the entrance box. Refer to the schematic wiring diagram
for terminal identification.
Problem Possible Cause(s)

BURNER DOES NOT 1. No voltage at program relay power input terminals.
START A. Main disconnect switch open.
3. Limit circuit not completed - no voltage at end of limit circuit program relay
terminal.
A. Pressure or temperature is above setting of operation control. (Load
demand light will not glow.)
1) Low-water light (and alarm horn) should indicate this condition.
2) Check manual reset button (if provided) on low-water control.
C. Fuel pressure must be within settings of low pressure and high pressure
switches.
D. Oil fired unit - burner gun must be in full forward position to close oil
drawer switch.
7-2 750-91 (revised 2009)

7.1 — Overview

C. Loose terminal on ignition cable - or cable shorted.
A. lack of fuel - no gas pressure, closed valve, empty tank, broken line, etc.
D. Too much air.
3. Low-fire switch open in low-fire proving circuit.
A. Combustion or atomizing air proving switches defective or not properly
set.
PILOT FLAME, BUT NO 1. Insufficient pilot flame.

MAIN FLAMW 2. Gas fired unit:
3. Oil fired unit:
C. No fuel.
E. Check oil nozzle, gun, and lines.
BURNER STAYS IN LOW- 1. Pressure or temperature above modulating control setting.

FIRE 2. Manual-automatic switch in wrong position.
3. Inoperative modulating motor.
750-91 (revised 2009) 7-3

Troubleshooting

DURING FIRING 2. Defective fuel valve, loose electrical connection.
5. If the programmer lockout switch has not tripped, check the limit circuit for
an opened safety control.
D. The flame failure light is energized by ignition failure, main flame failure,
inadequate flame signal, or open control in the running interlock circuit.
7. Improper air/fuel ratio (lean fire):
C. Fluctuating fuel supply:
1) Temporary obstruction in fuel line.
2) Temporary drop in gas pressure.
3) Orifice gate valve open.
MODULATING MOTOR 1. Manual-automatic switch in wrong position.

DOES NOT OPERATE 2. Linkage loose or jammed.
3. Motor does not drive to open or close during pre-purge or close on burner
shutdown:
A. Motor defective.
4. Motor does not operate on demand:
A. Manual-automatic switch in wrong position.
C. Motor defective.
E.Damper motor transformer defective.
7-4 750-91 (revised 2009)

CHAPTER 8 Inspection and Maintenance
8.1 — Overview
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. Fail-
ure to follow these instructions could result in equipment damage.
A well planned maintenance program will help avoid unnecessary downtime or costly repairs, promote safety, and
aid boiler inspectors. An inspection schedule with a listing of procedures should be established. It is recommended
that a boiler room log or record be maintained. Recording of daily, weekly, monthly, and yearly maintenance activi-
ties provides a valuable guide and aids in obtaining economical and lengthy service from Cleaver-Brooks equip-
ment. A sample boiler inspection schedule is provided at the end of this chapter. It is important to realize that the
frequency of inspection will depend on variable conditions such as load, fuel, system requirements, boiler environ-
ment (indoor/outdoor), etc.
Good housekeeping helps maintain a professional appearing boiler room. Only trained and authorized personnel
should be permitted to operate, adjust, or repair the boiler and its related equipment. The boiler room should be
kept free of all material and equipment not necessary to the operation of the boiler or heating system.
Even though the boiler has electrical and mechanical devices that make it automatic or semi-automatic in opera-
tion, the devices require systematic and periodic maintenance. Any automatic feature does not relieve the operator
from responsibility, but rather frees the operator from certain repetitive chores providing time to devote to upkeep
and maintenance.
Alertness in recognizing an unusual noise, improper gauge reading, leaks, etc., can make the operator aware of a
developing malfunction and permit prompt corrective action that may prevent extensive repairs or unexpected
downtime. Any leaks — fuel, water, steam, exhaust gas — should be repaired promptly and under conditions that
750-91 (revised 2009) 8-1

observe necessary safety precautions. Preventive maintenance measures, such as regularly checking the tightness of
connections, locknuts, setscrews, packing glands, etc., should be included in regular maintenance activities.
8.1.1 — Periodic Inspection

Insurance regulations and local laws require periodic inspection of the pressure vessel by an authorized inspector.
Section 3.8 in Chapter 3 contains information relative to the inspection.
Inspections are usually, though not necessarily, scheduled for periods of normal boiler downtime, such as an off
season. This major inspection can often be used to accomplish maintenance, replacement or repairs that cannot
easily be done at other times. Inspection also serves as a good basis for establishing a schedule for annual, monthly,
or other periodic maintenance programs.
While the inspection pertains primarily to the waterside and fireside surfaces of the pressure vessel it provides the
operator an excellent opportunity for detailed inspection and check of all components of the boiler, including pip-
ing, valves, pumps, gaskets, refractory, etc. Comprehensive cleaning, spot painting or repainting, and the replace-
ment 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.
Replacement spare parts, if not on hand, should be ordered sufficiently prior to shutdown.
NOTE: Cleaver-Brooks genuine parts should be used to ensure proper operation. Contact your local Cleaver-Brooks
representative for parts information and ordering.
Cleaver-Brooks boilers are designed, engineered, and built to provide long life and excellent service. Good operat-
ing practices and conscientious maintenance and care will assure efficiency and economy from their operation, and
will contribute to many years of performance.
A total protection plan includes a Planned Maintenance Program that covers many of the items included in this
chapter.
For information regarding a total protection plan, contact your local Cleaver-Brooks authorized representative.
8.2 — 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 that will deteriorate fireside metal.
Cleanout should be performed at regular and frequent intervals, depending upon load, type, and quality of fuel.
internal boiler temperature, and combustion efficiency. A stack temperature thermometer can be used as a guide to
cleanout intervals since an accumulation of soot deposits will raise the flue gas temperature.
Tube cleaning is accomplished by opening the front and rear doors. Tubes may be brushed from either end. All
loose soot and accumulations should be removed. Any soot, or other deposits, should be removed from the fur-
nace and tube sheets.
8-2 750-91 (revised 2009)

8.3 — Water Level Controls
Refer to Section 8.17 for instructions on properly closing rear heads.
The flue gas outlet and stack should be inspected annually and cleaned as necessary. Commercial firms are available
to perform the work. The stack should be inspected for damage and repaired as required.
The fireside should be thoroughly cleaned prior to any extended lay-up of the boiler. Depending upon circum-
stances, a protective coating may be required. See Section 3.9 in Chapter 3.

The need to periodically check water level controls and the waterside of the pressure vessel cannot be overempha-
sized. Most instances of major boiler damage are the result of operating with low water, or the use of untreated (or
incorrectly treated) water.
Always be sure of the boiler water level. On steam boilers, the water column should be blown down daily. Check
samples of boiler water and condensate in accordance with procedures recommended by your local Cleaver-Brooks
authorized representative. Refer to Sections 3.7 and 3.8 in Chapter 3 for blowdown instructions and internal
inspection procedures.
Since low-water cutoff devices are generally set by the original manufacturer, no attempt should be made to adjust
these controls to alter the point of low-water cutoff or point of pump cut-in or cut-out. If a low-water device
should become erratic in operation, of if its setting changes from previously established levels, contact your local
FIGURE 8-1. Low-Water Plate
Figure 8-1 shows the low-water cutoff plate which is attached to a steam boiler. The instructions should be fol-
lowed on a definite schedule.
750-91 (revised 2009) 8-3

The low water cutoff controls normally function for long periods of time, which may lead to laxity in testing on the
assumption that normal operation will continue indefinitely.
FIGURE 8-2. Low Water Cutoff
On a steam boiler, the head mechanism of the low water cutoff device(s) should be removed from the bowl at least
semi-annually to check and clean the float ball, the internal moving parts, and the bowl or water column.
Remove the pipe plugs from the tees or crosses and make certain the cross-connecting piping is clean and free of
obstructions. Controls must be mounted in a plumb position for proper performance. Determine that piping is
vertically aligned after shipment and installation and throughout life of the equipment.
A blowdown of the water controls on a steam boiler should be performed daily.

It is impractical to blowdown the low water cutoff device(s) on a hot water boiler since the entire water content of
the system would become involved. Many hot water systems are fully closed and any loss of water will require
make-up and additional feedwater treatment that might not otherwise be necessary. Since the boiler and system
arrangement usually make it impractical to perform daily and monthly maintenance of the low water cutoff
device(s), it is essential to verify proper operation. Remove the operating mechanism from the bowl annually or
more frequently, if possible, to check and clean the float ball, internal moving parts, and the bowl housing. Also
check the cross-connecting piping to be certain that it is clean and free of obstruction.
8.4 — 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 pack-
ing, which could be forced below the glass and possibly plug the valve opening.
8-4 750-91 (revised 2009)

8.5 — Electrical Controls
1. Close the valves when replacing the glass.

2. Slip a packing nut, a 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.
3. Slide the packing nuts onto each valve and tighten.
4. It is recommended that the boiler is off and cool when the glass is replaced. However, if the glass is replaced
while the boiler is in service, open the blowdown and slowly bring the glass to operating temperature by opening
the gauge valves slightly.
5. After the glass is warmed up, close the blowdown valve and open the gauge valves completely.
! Warning
Do not attempt to change the gauge glass while the boiler is in service. Failure to follow these instructions could result
in serious injury or death.
6. Check try cocks and gauge cocks for freedom of operation and clean as required. It is imperative that the gauge
cocks are mounted in exact alignment. If they are not, the glass will be strained and may fail prematurely.

The operating controls should be inspected monthly. Examine tightness of electrical connections and keep the con-
trols clean. Remove any dust that accumulates in the interior of the control using a low pressure air. Take care not
to damage the mechanism.
Examine any mercury tube switches (if older device is being used) for damage or cracks. Dark scum over the nor-
mally bright surface of the mercury may lead to erratic switching action. Be certain that controls are correctly lev-
eled. The piping leading to the pressure control actuators should be cleaned, if necessary. Covers should be left on
controls at all times.
Dust and dirt can cause excessive wear and overheating of motor starter and relay contacts. Use a burnishing tool
or a hard surface paper to clean and polish contacts. Starter contacts are plated with silver and are not harmed by
discoloration and slight pitting. Replacement of the contacts is necessary only if the silver has worn thin.
! Caution
Do not use files or abrasive materials such as sandpaper on the contact points. Failure to follow these instructions
could result in equipment damage.
750-91 (revised 2009) 8-5

FIGURE 8-3. Recommended Maximum “Fusetron” Fuse Sizes
Thermal relay units (overloads) are of the melting-alloy type and, when tripped, the alloy must be given time to re-
solidify before relay can be reset. IF the overloads trip out repeatedly when the motor current is normal, replace
them with new overloads. If the condition continues after replacement, it will be necessary to determine the cause
of excessive current draw at the overloads.
Power supply to the boiler must be protected with dual element fuses (fusetrons) or circuit breakers. Similar fuses
should be used in branch circuits. Standard one-shot fuses are not recommended. Refer to the chart in Figure 8-2
for fuse requirement guidance.
8-6 750-91 (revised 2009)

8.6 — Flame Safety Control

The microprocessor based control requires minimal maintenance because the safety and logic timings are inaccessi-
ble. There also are not any accessible contacts. Check to see that the retaining screw is securely holding the chassis
to the mounting base. Also check to see that the amplifier and the program module are tightly inserted.
The relay’s self-diagnostic ability includes advising when it or its plug-in modules are at fault and require replace-
ment.
Your spare control should be stored in a dry atmosphere and wrapped in plastic. During an extended shutdown
(e.g., seasonal) the active control should be removed and stored. Moisture can cause problems with control opera-
tion.
It is recommended that service be rotated between the active and a spare control to assure a working replacement
is available.
! Warning
When replacing a control, be sure to lock out the main power supply switch since the control is “hot” even though the
burner switch is off. Failure to follow these instructions could result in serious injury or death.
Be sure the connecting contacts on the control and its base are not bent out of position.
The flame detector lens should be cleaned as often as operating conditions demand. Use a soft cloth moistened
with detergent to clean the lens.
A safety check procedure should be established to test the complete safeguard system at least once a month, or
more often. Tests should verify safety shutdown and a safety lockout upon failure to ignite the pilot, upon failure to
ignite the main flame, and upon loss of flame. Each of the conditions should be checked on a scheduled basis.
The following tests should be used to test the complete safeguard system. If the sequence of events is not as
described, then a problem may exist. Contact your local Cleaver-Brooks authorized representative for assistance.
8.6.1 — Checking Pilot Flame Failure

1. Close the gas pilot shutoff cock and shut off the main fuel supply.
2. Turn the burner switch “on.”
The pilot ignition circuit will be energized at the end of the pre-purge period. There should be an ignition spark,
but no flame. Since there is no flame to be detected, the program relay will signal the condition. The ignition cir-
cuit will de-energize and the control will lock out on a safety shutdown. The flame failure light (and optional
alarm) will be activated. The blower motor will run through the post-purge and stop.
3. Turn the burner switch “off.”
4. Reset the safety switch.
5. Re-open the gas pilot shutoff cock and re-establish main fuel supply.
750-91 (revised 2009) 8-7

8.6.2 — Checking Failure to Light Main Flame

1. Leave the gas pilot shutoff cock open.
2. Shut off the main burner fuel supply.
The pilot will light upon completion of the pre-purge period. The main fuel valve(s) will be energized, but there
should be no main flame.
The fuel valve(s) de-energize 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. The blower motor will run
6. Re-establish main fuel supply.
8.6.3 — Checking Loss of Flame

1. With the burner in normal operation, shut off the main burner fuel supply to extinguish main flame.
The fuel valve(s) will be de-energized and the relay will signal the condition within 4 seconds. The control will
then lock out on a safety shutdown. The flame failure light (and optional alarm) will be activated. The blower
motor will run through the post-purge and stop.
5. The flame detector lens should be cleaned as often as operating conditions demand. Use a soft cloth moistened
with detergent, if necessary.
8.7 — Oil Burner Maintenance

The burner should be inspected for evidence of damage due to improperly adjusted combustion. Any soot buildup
on the diffuser or the oil nozzle should be removed. The setting of the oil nozzle in relation to the diffuser and
other components is important for proper firing and should be checked.
8.7.1 — Oil Strainers

Oil strainers should be cleaned frequently to maintain a free and full flow of fuel.
8.7.2 — Light Oil Strainers

The fuel oil strainer screen must be removed and cleaned at regular intervals. It is advisable to remove the screen
each month and clean thoroughly by immersing it in solvent and blowing it dry with compressed air. To remove:
1. Loosen the cover cap screw, being careful not to lose the copper gasket. If necessary, tap the strainer cover gen-
tly to loosen.
2. Check the cover gasket for damage and replace if necessary.
3. Slip pliers into the cross on the top of the strainer and twist counterclockwise to remove the basket.
8-8 750-91 (revised 2009)

4. Reassemble in reverse order.
8.7.3 — Heavy Oil Strainers

Keep the cartridge of the oil strainer clear by regularly giving the exterior handle one complete turn in either direc-
tion. Do this often until experience indicates the frequency of cleaning necessary to maintain optimum condition of
flow. If the handle turns hard, rotate the handle back and forward until it can be turned through a complete revolu-
tion. Do not force it with a wrench or other tool.
Drain the sump as often until experience indicates the draining frequency necessary to maintain optimum condi-
tion. Remove the sump, or the head and cartridge assembly, for thorough cleaning and inspection at frequent inter-
vals. Exercise care not to damage the cartridge discs or the cleaner blades. Wash the cartridge in solvents. Do not
attempt to disassemble the cartridge.
8.7.4 — Cleaning the 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. A routine check and any necessary cleaning should be made during off peri-
ods or when the burner is firing on gas.
If at any time the burner flame appears “stringy” or “lazy,” it is possible that the nozzle tip or swirler has become
partially clogged or worn. Any blockage within the tip will cause the air pressure gauge to increase above its normal
value.
FIGURE 8-4. Standard Burner Nozzle Components
Disassemble with the power off:

1. Unlatch and withdraw the burner gun.
2. Insert the nozzle body into the hanger vise and use the spanner wrench to remove the tip.
3. Carefully remove the swirler and seating spring being careful not to drop or damage any parts.
750-91 (revised 2009) 8-9

4. Perform any necessary cleaning with a suitable solvent. Take the necessary precautions when working with sol-
vents. Use a soft fiber brush or pointed piece of soft wood for cleaning. Do not use wire or a sharp metallic
object, which could scratch or deform the orifices as well as the precision ground surfaces of the swirler and tip.
5. Inspect for scratches or signs of wear or erosion, which may make the nozzle unfit for further use.
The tip and swirler are a matched set, which are precision lapped at the time of assembly. The close fit of the
lapped surfaces must be maintained in order to provide optimum performance. Additional lapping may be
required to provide better atomization for more efficient combustion. Do not interchange parts if a spare is
kept.
6. In reassembling, be certain that the seating spring is in place and that it is holding the swirler tightly against the
tip. The swirler is stationary and does not rotate, but rather imparts a swirling motion to the oil.
7. See that the plugged hole is at the bottom of the nozzle body when the gun is installed.
8.7.5 — Cleaning Air Purge Nozzle (No. 6 Oil) and Back Pressure Orifice Nozzle (No. 2 Oil)
The air purge nozzle and its strainer should be inspected periodically and cleaned. The nozzle consists of a tip and
internal core.
1. Clean all internal surfaces of the tip and the slotted parts of the core using a wood splinter to avoid damage
from scratching.
2. Replace the core, setting it tightly but not excessively so.
3. Clean the strainer screen carefully to remove any foreign matter. Use suitable solvents for cleaning. Extremely
hot water at high velocity is also helpful in cleaning.
4. Replace strainer by screwing it into the nozzle body only finger tight. Do not use an orifice of a size other than
originally installed.
8.7.6 — Ignition System

For best results, maintain the proper gap and dimensions of the ignition electrode(s).
1. Inspect the electrode tip for signs of pitting or combustion deposits and dress as required with a fine file.
2. Inspect the porcelain insulator(s) for any cracks that might be present. If cracks are present, replace the elec-
trode since cracks in the insulator can cause grounding of the ignition voltage.
3. Wipe the insulating portion of the electrode(s) clean of any carbon, if present. Carbon is an electrical conductor.
Ammonia will aid in removing carbon and soot.
4. Check the ignition cables for cracks in the insulation.
5. Check to see that all connections between the transformer and the electrodes are tight.
6. Periodically remove the access plug from the gas pilot aspirator and clean out any accumulated lint or other for-
eign material.
8.8 — Gas Burner Maintenance

The gas burner components should be inspected for evidence of damage due to improperly adjusted combustion.
Combustion adjustments should be checked monthly.
8-10 750-91 (revised 2009)

8.9 — Motorized Gas Valve
Check periodically for a proper seal between the end of the burner housing and boiler refractory. Any deterioration
of the seal should be corrected, as an improper or poor seal allows air leaks, which can cause overheating or burn-
ing of the burner housing.
Whenever the burner is removed, the diffuser, gas housing and gas spuds (HTB model only) should be checked for
any deterioration. Verify that the diffuser skirt conforms to the bore of the burner housing so as to minimize the
amount of combustion air which bypasses the diffuser. If the burner is a high turndown burner (HTB) model,
check to see that the diffuser is properly located in reference to the gas spuds. There should be 1/4” between the
edge of the diffuser fins and the gas spuds when the burner is installed. Check to see that the diffuser fins don not
interfere with the gas ports or gas spuds in the burner housing.
Check the electrode setting for any cracks that might be present on the porcelain insulator. Replace the electrode if
cracking is evident, since cracking can cause grounding of the ignition voltage. Inspect the tip of the electrode for
signs of pitting, combustion deposits, and wear, and dress as required with a fine file.
Periodically remove the access plug from the gas pilot aspirator and clean out any accumulated lint or other foreign
material.
Check the ignition cables for cracks in the insulation. Verify that all connections between the transformer and the
electrode are tight.

The motorized gas valve (hydramotor) operating mechanism is completely immersed in oil and little maintenance is
required because of the sealed design. However, proper operation should be checked on a routine periodic basis.
Keep outer parts of the valve clean, especially the stem between the operator and the valve. A nicked, scored or
otherwise damaged valve stem can cause leakage. Do not remove dust covers if installed.
The packing gland is of the O-ring type. If oil is noticed around the operator base or if leakage occurs, repair by
replacing any leaking O-rings and refilling the actuator with oil.
If the actuator is sluggish or fails to operate, even after the oil level is checked, replace the entire operator portion.
8.10 — 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.
A low hum or buzzing will normally be audible when the coil is energized. If the valve develops a loud buzzing or
chattering noise, check for proper voltage and clean the plunger assembly and interior plunger tube thoroughly. Do
not use any oil. Be sure that the plunger tube and solenoid are tight when reassembled. Take care not to nick, dent,
or damage the plunger tube.
750-91 (revised 2009) 8-11

! Warning
Be sure to turn off power to the valve in order to avoid electrical shock. Failure to follow these instructions could result
Check coil position and make sure that any insulating washers or retaining springs are reinstalled in proper order.
8.11 — Air Control Damper, Linkage, and Cam Spring

The burner air control damper should be checked for free movement as a part of the monthly inspection. With the
burner off and the jackshaft damper control rod disconnected, the air control damper should rotate freely through
its entire range of movement. Any resistance to movement or excessive play in the support bearing should be inves-
tigated and corrected before the burner is put back in operation.
The overall tightness of the linkage assembly should be checked monthly. If necessary, tighten the setscrews and
the connections at the uniballs. Check the uniballs for wear and replace if necessary.
The linkage assembly should be tight but should not bind. If the linkage assembly is binding, determine the cause
of the binding and correct as necessary.
Linkage rod end attachment points should be marked on the variable displacement linkage arms as an aid in subse-
quent reassembly.
Inspection of the air damper and linkage bearings should be performed on a more frequent basis if the boiler is
operating in a dirty environment.
The fuel cam profile spring should be inspected monthly for wear, scoring or distortion. If any of the questionable
conditions are found, the spring must be replaced immediately to avoid the possibility of breakage in service. Use
care to avoid damaging the cam or spring during installation.
Lubricate occasionally with a non-gumming, dripless, high-temperature lubricant such as graphite or a silicone
derivative.
! Caution
Combustion should be checked and readjusted whenever the burner is removed or any control linkage is disturbed.
Failure to follow these instructions could result in equipment damage.
8-12 750-91 (revised 2009)

8.12 — Forced Draft Fan

The position of the fan housing and the clearance between it and the fan (impeller) is extremely important to the
output capacity of the fan.
To install and adjust:

4. Place external tooth lockwashers next to the spacers and install the fan housing on the studs.
5. Hold the fan housing in place with nuts and lockwashers. Tighten the nuts by hand.
6. Slide the impeller outward until its vanes contact the fan housing. The housing must be parallel to the impeller.
Adjust the spacers as necessary to align the housing with the impeller.
7. Slide the impeller toward the motor. Use a feeler gauge to obtain a .030” - .050” clearance between the impeller
and the housing.
8. Secure the key and then tighten the impeller hub setscrews.
9. Using a selected vane, rotate the impeller while checking to see that the clearance between the impeller and the
housing remains constant and within the specified .030” - .050” clearance.
10. Install the air duct assembly through the head opening. Tighten the screws securing the air duct to the fan hous-
ing only enough to create a seal between the neoprene gasket and the housing.
11. After connecting the motor leads, verify that the impeller rotation is counterclockwise when viewed from the
motor end.
NOTE: If the boiler is installed in a dusty location, check the vanes occasionally for deposits of dust or dirt. These
buildups can cause a decrease in air capacity, or lead to an unbalanced condition or cause damage to the equipment.
750-91 (revised 2009) 8-13

FIGURE 8-5. Forced Draft Fan Mounting
8-14 750-91 (revised 2009)

8.13 — 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. To remove the fan/motor:
! Warning
Disconnect and lock out electrical power to the boiler before removing the fan/motor cassette. Failure to follow these
2. Ensure the front door is securely bolted to the boiler.
! Warning
Do not remove the davit arm assembly without first ensuring that the front door is securely bolted to the boiler. Failure
to follow these instructions could result in serious injury or death.
3. Release the davit arm by removing the retaining bolt at the top center of the boiler.
! Warning
When suspending the fan/motor cassette from the davit arm, all equipment used must be of adequate strength to
safely support the complete cassette. Failure to follow these instructions could result in serious injury or death.
4. Connect the davit arm to the fan/motor cassette using the suspension system.
! Warning
Chains or other devices used to attach a lifting device to the fan/motor cassette must be arranged so the cassette does
not rotate or tilt when removed from the front head. Failure to follow these instructions could result in serious injury
or death.
5. Arrange the attaching chains so the lifting point is over the motor shaft centerline and the center of balance for
the fan/motor cassette. This point is approximately 4 inches from the motor backplate for 600 - 800 hp units,
and 3 inches for 250 - 500 hp units.
7. Swing the fan/motor cassette to the side and secure it to the boiler using high strength cord. Do not over
extend the motor wires.
! Caution
Be sure that the fan motor wiring and conduit are not stretched during the fan/motor cassette removal. Failure to fol-
low these instructions could result in equipment damage.
750-91 (revised 2009) 8-15

FIGURE 8-6. Fan/Motor Cassette Removal
8.14 — Inspection and Adjustment

NOx levels should be checked periodically to ensure compliance with all local and federal regulations, as well as to
ensure that the boiler is operating at maximum efficiency. Linkages should be inspected and free movement (no
binding) of the IFGR damper confirmed.
Increasing or decreasing NOx levels could indicate incorrect damper positioning, loose linkages, an improper air-
to-fuel ratio, or stack draft changes. If adjustment is required, or if problems persist, contact your local Cleaver-
Brooks authorized representative for further assistance.
As ash and products of combustion pass through the IFGR damper, there will be some accumulation on the
damper, windbox, and other parts of the IFGR system and burner.
To ensure proper operation of the IFGR system and burner, inspection and cleaning should be performed at regu-
lar intervals, depending on the load, type of fuel, and combustion temperatures.
1. With the IFGR damper exposed, inspect the internal linkages for secure connections, and check for free move-
ment of the linkage arms and the IFGR damper assembly. Check for free movement of the linkage by separat-
ing the external linkage from the jackshaft drive arm(s) and cycling the exterior linkage through its range of
movement.
8-16 750-91 (revised 2009)

8.15 — Airbox Gasket Installation
2. Check the clearance between the impeller and backplate (see Figure 8-6). Adjust, if necessary.
30 PPM
Standard 60 PPM 25 PPM 20 PPM
.040 + .010 .050 + .010/-.005 .060 + .005/-.000
FIGURE 8-7. Impeller Clearances
3. The impeller clearance is checked by inserting a long feeler gauge of the proper thickness between the impeller
and the impeller housing. Impeller clearances should be checked at the highest fin on the impeller (that fin
which is closest to the impeller housing), and must be checked at each point where the housing is attached to the
motor backplate.
4. If the impeller clearance is not correct at all points, adjust as necessary:
A. Loosen retaining nuts on both sides of the impeller housing.
B. Adjust retainers for the correct impeller clearance at two housing attachment points 180º apart.
C. Adjust retainers for correct clearance at the housing attachment points 90º from those initially adjusted.
D. Adjust for correct impeller clearance at the remaining attachment points.
5. Check and replace any gaskets that have been damaged. Gaskets that have been in use for one year or more
should be replaced. In particular, inspect the airbox gasket for damage and replace if necessary.

If the fan/motor cassette is opened for any reason after the unit has been in operation for one year, the airbox gas-
ket should be replaced.
! Caution
When replacing the airbox gasket, use only Cleaver-Brooks components. Failure to use components designed for this
application can result in improper combustion. Failure to follow these instructions could result in equipment damage.
Attach the airbox gasket to the inlet box with high-temperature silicone adhesive/sealant, using two beads of sili-
cone about 1/4” in from each side of the gasket (gasket surface is 2” wide).
1. Secure the gasket in position with clamps, using strips of wood on top of the gasket for a bearing surface.
2. After the silicone has dried (approximately 24 hours), remove the clamps and strips of wood.
750-91 (revised 2009) 8-17

FIGURE 8-8. Induced Flue Gas Recirculation System (IFGR)
8.16 — Fan/Motor Cassette Installation

To close the fan/motor cassette:
1. Check that all adjustment screws are tight, and check the linkage and IFGR damper for free movement before
closing the unit.
3. Slide the cassette into position until it begins to contact the inlet gasket, then measure the clearance between the
cassette flange and the front door mounting face. There must be clearance of at least 1/4” to provide adequate
gasket compression when the cassette is mounted tightly to the door.
! Warning
Do not remove the davit arm assembly from the motor/fan cassette without first verifying that the cassette is securely
bolted to the boiler. Failure to follow these instructions could result in serious injury or death.
5. After the cassette has been secured to the front head, reconnect the davit to the front door by screwing in the
retaining bolt at the top centerline.
8-18 750-91 (revised 2009)

8.17 — Safety Valves
6. Check occasionally that the fan is securely tightened to the motor shaft. Check the clearance between the fan
vanes and housing.

The safety valve is a very important safety device and deserves attention accordingly.
Follow the recommendations of your boiler inspector regarding valve inspection and testing. The frequency of test-
ing, either by the 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 in accordance with sections VI and VII of the ASME
Boiler and Pressure Vessel Code.
Avoid excessive operation of the safety valve — even one opening can provide a means of leakage. Safety valves
should be operated only often enough to assure that they ar in good working order. When a pop test is required,
raise the operating pressure to the set pressure of the safety valve, allowing it to open and reseat as it would in nor-
mal service.
Do not hand operate the valve with less than 75% of the stamped set pressure exerted on the underside of the disc.
When hand operating, be sure to hold the valve in an open position long enough to purge accumulated foreign
material from the seat area and then allow the valve to snap shut.
Frequent usage of the safety valve will cause the seat and disc to become wire drawn or steam cut. This will cause
the valve to leak and necessitate downtime of the boiler for valve repair or replacement. Repair of a valve must be
done only by the manufacturer or his authorized representative.
Avoid having the operating pressure too near the safety valve set pressure. A 10% differential is recommended. An
even greater differential is desirable and will assure better seat tightness and valve longevity.
8.18 — Fuel Oil Metering Valve, Adjusting, and Relief Valves

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. Excessive tightening of the packing nut prevents free movement of
the metering stem. Failure to follow these instructions could result in equipment damage.
750-91 (revised 2009) 8-19

If replacement of the metering valve packing is necessary, procure kit P/N 880-370 and install:
FIGURE 8-9. Metering Valve Packing Sequence
2. Match-mark the cam hub and drive shaft. Match-marking will enable replacement of the cam in its original posi-
tion and result in a minimum of cam adjustment when the burner is refired.
4. Loosen the setscrews in the cam hub and rotate, or move the cam to a position where it does not interfere with
stem removal.
5. Withdraw the metering valve stem and spring. Do not drop or mishandle. Check for nicks or scratches. Check
that the pin holding the metering portion is not protruding. Back off the packing gland.
6. Remove the capscrews holding the jackshaft support bracket so that the bracket can be moved. It may also be
necessary to loosen the supporting bracket on the far end of the shaft.
7. Remove the existing packing and guides. Do not reuse the packing and guides.
8. Lightly coat the stem with the lubricant provided with the packing kit. Place the new packing, O-rings and
guides onto the stem in the sequence shown in Figure 8-8. The beveled face of the guides and the teflon rings
must face upward, with the exception of the upper brass guide which is facing down. Be sure that the O-rings
are properly located.
9. Using the stem as a guide, insert the assembled packing into the cavity, then withdraw the stem.
10. In the event the packing is too high, remove one teflon packing from each side of the middle brass guide as
needed.
Under no circumstance eliminate the two teflon packings on only one side of the brass guide.
8-20 750-91 (revised 2009)

8.19 — Air Pump and Lubricating System
11. Replace the gasket, put the support in place, and secure all fastenings.
12. Replace the metering stem and spring. Lightly lubricate the stem to facilitate insertion and easy movement. Use
care when inserting so that the orifice and the stem are not damaged.
13. Snug the packing gland, but only sufficiently to place slight tension on the packing. The stem must move freely
from the force of the spring.
14. Work the stem up and down several times to ensure that it moves freely.
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.
17. Tighten the packing gland after a period of operation, if necessary, to maintain proper tension on the packing.
Do not over tighten.
If there are indications that the oil metering valve has become clogged at its orifice, it will be necessary to disassem-
ble the control to remove the obstruction. Clean the slotted stem of the oil metering valve with suitable solvent and
blow-dry with an air line. Follow the procedure outlined above when removing or reinstalling the metering valve
stem. Also check all fuel line strainers.
Should a pressure adjusting or relief valve become clogged, disassemble by releasing the locknut and backing off
the screw to relieve tension on the diaphragm. Remove the valve cover and the diaphragm to expose any dirt or for-
eign material which may have entered the valves. The diaphragms should be replaced annually.
8.19.1 — Air Compressor

The air pump requires little maintenance. However, the life of the pump is dependent upon a sufficient supply of
clean cool lubricating oil. The oil level in the air-oil tank must be observed closely. Lack of oil will damage the
pump making replacement necessary. Disassembly or field repairs to the pump are not recommended.
8.19.2 — Lubricating Oil

Lubricating oil must be visible in the gauge glass at all times. There is no specific level required as long as oil is vis-
ible. Do not operate if oil is not visible.
Oil with proper viscosity must be used. SAE 20 detergent is recommended, although SAE 10 detergent is also per-
missible.
When adding oil:

1. Remove the cover from the fill pipe and add oil through the conical strainer in the pipe with the unit running.
750-91 (revised 2009) 8-21

! Caution
Oil must NEVER be added unless the pump is in operation and the strainer screen is in place. Failure to follow these
instructions could result in equipment damage.
The oil and its container should be clean. Although there is a strainer in the lube oil line, its purpose is to remove
any unwanted materials rather than to act as a filter for unclean oil.
8.19.3 — Lubricating Oil Strainer and Cooling Coil

Air pressure from the pump forces lubricating oil from the tank through a cooling coil to the pump. The oil lubri-
cates 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. It is possible to visually verify oil flow dur-
ing operation by removing the filler cap and checking the flow. If necessary, the strainer may be cleaned during
operation.
In the event it is necessary to clean the strainer during operation, clean it an replace immediately. It can be cleaned
by immersing in solvent and blowing it dry with compressed air. Do not operate without the strainer any longer
than necessary, and never add new oil unless it is in place. A spare strainer basket can be obtained, if desired, and
used on a rotating basis while the other is serviced.
8.19.4 — Air Cleaner

Never operate the air pump without the air cleaner in place. The cleaner itself must be periodically checked and its
element flushed and cleaned semi-annually.
8.19.5 — Air-Oil Tank

Pads of steel wool are used in the air oil receiver tank as a filtering medium to separate the lube oil from the com-
pressed air.
The pads play a very important role and should be replaced semi-annually. It is also important that a proper grade
of steel wool be used. Only No. 3 coarse grade American steel wool or equivalent (CB919-124) should be used.
Three pads are required. When replacing the wool:
1. Insert two pads into the cylinder.
2. Alternate the grain of the pads.
3. Install the spacer with its stub end toward the opening and fit one pad over the stub. Be careful not to overly
compress the wool and be sure that it is fluffed out to fill all available space. Improper packing can cause high
oil consumption.
4. After the last pad is in place, slip the retainer screen onto the cylinder.
8-22 750-91 (revised 2009)

5. Be sure to fit an O-ring gasket under the cover so that a tight seal is obtained.
FIGURE 8-10. Air Oil Receiver Tank
8.19.6 — Lube Oil Cooling Coil

The fins on the tubing must be kept clean and free of any dust or dirt that would resist air flow and cause overheat-
ing. Use an air hose to blow away debris. Internal cleaning of the tubes is seldom required if a good quality lube oil
is used.
8.19.7 — Flexible Coupling Alignment

Alignment of the pump and motor through the flexible coupling is extremely important for trouble free operation.
Check the coupling alignment semi-annually and replace the coupling insert as required. Keep the coupling guard
in place.
The most commonly used tools for checking alignment are a small straightedge and a thickness gauge.
The coupling must be checked for both parallel (offset) alignment and angular (gap) alignment. Parallel misalign-
ment exists when shaft axes are parallel but not concentric. Angular misalignment is the reverse situation — shaft
axes 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. The check should be
done on the top of the coupling and at 90 degrees. A useful practice is to hold a flashlight behind the straightedge
so that any gap can readily be seen.
750-91 (revised 2009) 8-23

Shim stock of appropriate thickness and area is then used under either the feet of the pump or the motor to estab-
lish parallel alignment. A tolerance of .008” is a permissible limit.
FIGURE 8-11. Coupling Alignment
After parallel alignment is established, check for angular alignment, which is done by checking the gap between the
coupling halves. The coupling should have a minimum gap of 1/16” and a maximum of 3/32”.
Set the spacing between the halves at one point by using a thickness gauge and then rotate the coupling slowly to
be sure that clearance at that point remains the same through 360 degrees of rotation. Adjust to obtain proper gap
by loosening the hold-down bolts and shifting either the pump or the motor as required. Generally, a slight tapping
on either the front or rear legs is all that is needed to obtain lateral adjustment. Rear legs may require shimming for
vertical correction.
Tighten the hold-down bolts after adjustments are made and recheck alignment.
Calipers can also be used to check angular alignment. Measure the overall distance of the outer ends of the coupling
halves at 90º intervals. Shift the pump or motor, as required, so that the ends of the coupling are the same distance
apart at all points. The coupling will then have proper angular alignment.
Remember that alignment in one direction may alter alignment in another. Recheck both angular and parallel align-
ment procedures after making any alteration.
A properly aligned coupling will last longer and will provide trouble free mechanical operation.
8-24 750-91 (revised 2009)

8.19.8 — Air Compressor Replacement

Use the following procedures when replacing the pump. Be sure to tag the motor leads if disconnected to simplify
reconnection.
FIGURE 8-12. Air Compressor
8.19.8.1 — Dismantling
1. Lift out the two front cylinder pins that hold the screen and remove the screen.
2. Disconnect the flared nut on tubing (behind screen) and lift tubing high enough to prevent drainage of lubricat-
ing oil from the tank.
4. Remove the two sheet metal screws that hold the cylinder in place. One screw is located at the top rear of the
cylinder, the other is at the bottom front.
5. Remove the entire heat exchange assembly, consisting of the cylinder, the finned tubing, and the oil line.
8. Remove the coupling guard by pushing in on both sides until it clears the clamp.
9. Loosen the clamp at the rear of the tank and remove the tank with copper tubing attached.
10. Leave the rear pump bracket (coupling end) in place to aid in realignment of the replacement pump. Do this by
removing the two capscrews that extend through the bracket into the pump housing. Temporarily leave the
front bracket attached to the pump.
11. Remove the screws holding the front bracket to the base and lift off the pump with its attachments. Note the
location of the pipe fittings and brackets prior to removing for installation on the replacement pump. If piping
is dismantled, be sure that the check valve is reinstalled so the gate swings towards the pump.
8.19.8.2 — Reassembly
Reassemble in reverse order of disassembly. With the rear pump bracket left in place, realignment and spacing
between the pump shaft and the motor shaft is greatly simplified.
750-91 (revised 2009) 8-25

There should be approximately 7/8” space between the two shafts. Place the coupling insert between the coupling
halves prior to reassembly. Check that both shafts rotate freely.
If shims were used originally under either pump brackets or motor feet, be sure that they are correctly reinstalled.
When reinstalling the fan, slide the hub on the pump shaft so that it is bottomed. Tighten the setscrew and cap
screws. If the fan blades were removed from the hub, be sure that the side of the blade marked “Blower” faces the
hub when reassembling. When tightening the coupling halves or the fan hub, tighten the setscrews against the key
first, then tighten the setscrew against the shaft. Clean or remove any dust or grime from the blades prior to rein-
stalling.
When replacing the retainer screen, a slight force may be required to push the cooling coil into the air cylinder so
that the pins may be fitted into place.
If the motor was replaced or if motor leads were disconnected, be sure that pump rotation is proper before starting
operation. The air pump should rotate in a clockwise direction, as viewed from the drive shaft end.
NOTE: Keep the motor and other components free from dust and dirt to prevent overheating and damage. Motor
lubrication should follow manufacturer’s recommendations.
8.20 — Refractory
The boiler is shipped with completely installed refractory. The refractory consists of the rear head, the inner door,
and the furnace liner. Normal maintenance requires little time and expense, and prolongs the operating life of the
refractory.
Preventive maintenance through periodic inspection will keep the operator informed of the condition of the refrac-
tory, and will guard against unexpected and unwanted downtime and major repairs.
Frequent wash coating of the refractory surfaces is recommended. High-temperature bonding, air-dry type mortar,
diluted with water to the consistency of light cream, is used for wash coating. Re-coating intervals will vary with
operating loads and are best determined by the operator when the boiler is opened for inspection.
8-26 750-91 (revised 2009)

8.20 — Refractory
FIGURE 8-13. Refractory Liner Tile
8.20.1 — Furnace Liner

Maintenance consists of occasional wash coating of the entire liner. Face all joints or cracks by applying high tem-
perature bonding mortar with a trowel or fingertips. Wash coating should be done as soon as cracks are detected.
Should segments of the liner burn away or fall out, replace the entire refractory. Any refractory that may break out
should be removed as soon as detected so that it will not fuse to the bottom of the furnace and obstruct the flame.
If replacement is necessary, refer to Chapter 9 and order proper replacement materials. Remove existing refractory.
Thoroughly clean the furnace to remove all old refractory cement or other foreign material to ensure the new liner
seats firmly against the steel. Inspect the furnace metal.
Depending upon the design pressure of the boiler, the furnace may be of the corrugated type. It is necessary to fill
in the corrugation valleys under the furnace liner tile from 4 o’clock to 8 o’clock with insulating cement. The liner
tile should be fitted tightly against the crown of the corrugation.
NOTE: The area between the burner housing and the throat tile requires a good seal. An improper or poor seal allows
air leaks that can cause overheating and burning of the burner housing metal. The area should be inspected semi-annu-
ally. Contact your local Cleaver-Brooks representative for information and service.
750-91 (revised 2009) 8-27

FIGURE 8-14. Refractory Throat Tile
8.20.2 — Throat Tile and Liner Installation

The throat tile must be installed to maintain an approximately 12” inside diameter, and be centered in the furnace.
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.
The liner tile can be fitted tightly against the furnace, since the finished diameter is not critical.
FIGURE 8-15. Furnace Liner Refractory
8-28 750-91 (revised 2009)

8.20 — Refractory
It is recommended that the tile be dry-fitted, match-marked, removed, and then reinstalled with the proper amount
of refractory cement. Thin joints (less than 1/16”) are desirable. Generally, it will be necessary to shave a portion
from one or more tiles to obtain a fit. If a fill piece is required, cut it to fit and install the piece at the bottom of the
furnace. When installing the housing, or the tile against the housing, liberally coat the surface with refractory
cement. Remove any cement that is squeezed out.
Allow refractory to air dry as long as possible. If immediate use is required, fire intermittently at a low rate for sev-
eral hours to thoroughly dry the refractory.
For detailed information, request Bulletin C10-5921 from your local Cleaver-Brooks representative.
8.20.3 — Installation
The following procedure is typical for all standard diameter boilers with the exception of steps 6, 7, and 8 which are
not used for an 1.p. (plain furnace) boiler. Disregard these steps when working with 1.p. boilers.
FIGURE 8-16. Throat Tile and Furnace Liner
1. Install studs, bricking tool, creafelt, bottom and top arch bricks as shown on “Detail A” to check for correct fit
up. If interference is present at the arch brick, measure this distance and trim inside diameter (I.D.) of all bricks.
NOTE: The arch bricks must be trimmed to 12” on excessive pressures to maintain brick I.D.
2. Install the bottom half of arch bricks as shown on “Detail B.”
750-91 (revised 2009) 8-29

3. Mix the vee block to a mortar-like consistency (per manufacturer’s instructions) and pack the front valleys of the
furnace corrugations with the mixture, flush with the furnace I.D. up to 3 o’clock and 9 o’clock from the center-
line of the furnace. Install both pieces of cerafelt to insulate the tile from the corrugation and begin bottom half
of first row of tiles as shown on “Detail C.”
4. To begin top half of arch bricks and tiles, measure off upper half of furnace arch bricks and tiles with templates,
mark with chalk, and determine if a cut brick or cut tile is needed (see “Detail B”). If a cut brick is required,
locate it below the 2 o’clock and 10 o’clock positions. If the brick is cut, the angle of the cut surface should be
the same as the original brick. If cut brick or tile measures less than 1/2 full width, cut two pieces.
5. Install bricking tool as shown on “Detail A” and continue installing upper half by alternating one arch brick and
one corresponding tile.
6. For the last two rows of tiles, pack all remaining valleys of furnace corrugations (measure 36” from inside sur-
face of arch bricks) with vee block mixture flush with furnace I.D. up to the 3 o’clock and 9 o’clock centerline of
the furnace.
7. After joint cement hardens (approximately 2 hours), remove bricking tool, wooden tile supports, and discard
cerafelt shims.
INSTALLATION NOTES:
1. No cerafelt, cut bricks, or cut tiles to be installed in the upper 120º section of the furnace. See “Detail A” and
“Detail B.”
2. Pack all bricks and tiles tightly with mallet and remove excess cement: 1/16” typical joint, 1/8” maximum.
3. No cement applied between cerafelt and bricks, tiles, or furnace. Only applied between bricks and tiles.
4. Do not cover furnace weld seam with cerafelt. cut and space to suit as shown on “Detail B” and “Detail C.”
5. Support upper tiles with wooden boards to suit assembly. Two boards per tile as shown on “Detail C.” (For 96”
diameter, use 3/4” x 1-1/2” x 38”. For 78” diameter, use 3/4” x 1-1/2” x 28”.)
6. To insure tight fit and maximum I.S. of arch bricks, cut a 3” square piece of scrap cerafelt and use as a shim between
bricking tool O.D. and I.D. of upper half of bricks.
7. Stagger cemented joints (seams) between all arch bricks and tiles.
8. After each half course of bricks or tiles installed, clean up excessive cement and fill open joint areas where neces-
sary.
9. For 78” diameter boilers, use bricking tool #98-d-280 and fasten with two 1/2”-13 nuts. For 96” boilers, use brick-
ing tool #98-d-279 and fasten with two 5/8”-11 nuts.
8.20.4 — Rear Door

The rear door is a steel shell lined with insulation material and castable refractory.
Burned or discolored paint on the outer surface of the door does not necessarily indicate refractory trouble, but
may be an indication of other conditions such as:
• Leaking gaskets.
• Improper seal.
• Door retaining bolts insufficiently or unevenly tightened.
• The air line to the rear sight tube may be blocked or loose.
• Door was repainted with other than heat resistant paint.
Therefore, before assuming that the refractory requires reworking:
8-30 750-91 (revised 2009)

8.20 — Refractory
• Check the condition of the tadpole gasket and rope seal.

• Check for cracks in the castable refractory.
• Check the tightness of the door bolts.
• See that the air line to the sight tube is clear, and that the connections are tight. If necessary, blow the line clear
with an air hose.
FIGURE 8-17. Rear Door Sealing
It is normal for refractories exposed to hot gasses to develop thin “hairline” cracks. This is not an indication of
improper design or workmanship. Since refractory materials expand and contract with changes in temperature, they
should be expected to show minor cracks due to contraction when examined at low temperatures. Cracks to
approximately 1/8” across may be expected to close at high temperature. If there are any cracks that are relatively
large (1/8” to 1/4” in width), clean and fill them with high-temperature bonding mortar. Any gap that may show
between the castable refractory and the baffle tile should be filled in a similar manner.
After opening the rear door, clean the flange with a scraper or wire brush. Clean the surface of the refractory care-
fully with a fiber brush to avoid damaging the surface. Clean the mating surfaces of the baffle tile and the boiler
shell. Remove all dried seating material. Wash-coat the lower half of the rear door refractory prior to closing.
750-91 (revised 2009) 8-31

The upper half of the door contains a lightweight insulating material, similar to that used in the inner door. A thin
wash-coat mixture, applied gently with a brush, is helpful in maintaining a hard surface.
If the baffle tile or the refractory require replacement, contact your local Cleaver-Brooks authorized representative.
8.20.5 — Front Inner Door

The front inner door is lined with a lightweight castable insulation material. Thin “hairline” cracks may develop
after a period of time. However, the cracks will generally close die to expansion when the boiler is fired.
A thin wash-coat mixture, applied gently with a brush, is helpful in maintaining a hard surface.
Minor repairs can be accomplished by enlarging or cutting out affected areas, being certain that they are clean, and
then patching as required. Should the entire insulation require replacement, remove existing material and clean to
bare metal. Inspect the retaining pins and replace if necessary. Reinforcing wire, suitably attached may also be used.
The recommended insulation is “Vee Block Mix” and is available in 50 lb. bags (Cleaver-Brooks P/N 872-162).
Mix the material with water to a troweling consistency. Mixing should be completely uniform with no portion
either wetter or drier than another. Trowel the mixture into any areas that are being patched. If replacing complete
insulation, begin at the bottom of the door and apply the mixture to a thickness equal to the protecting shroud.
With a trowel, apply horizontally back and forth across the door in layers until the required thickness is reached.
Allow to air-dry as long as possible. If immediate use of the boiler is required, fire as slowly as possible to avoid
rapid drying of the material.
8.21 — Opening and Closing Rear Door

A good seal between the rear door and the pressure vessel is necessary to prevent leakage of combustion gasses,
loss of heat, and to aid in obtaining operating efficiency. Leaks can also cause hot spots that can lead to premature
refractory failure and/or damage to the door metal.
When opening the door, either for routine maintenance of for an annual inspection, do not do so when the boiler
or the door is hot. The refractory will hold its temperature for some time and exposure to ambient temperature or
rapid cooling may cause refractory cracking and/or harm to the boiler and door metal.
! Warning
Be certain that the davit arm is under tension before opening. Failure to follow these instructions could result in seri-
Before loosening the door bolts, tighten the nut on the davit stud to ensure tension on the davit arm. Putting the
davit arm under tension will help eliminate sagging, and will facilitate opening and closing.
The opened door should be supported by blocking or jacking to eliminate possible deformation of the door.
8-32 750-91 (revised 2009)

8.22 — Lubrication
Prior to closing, check all gaskets and sealing surfaces. If the door gasket is hard or brittle, it should be replaced.
The fiberglass ropes used for the baffle seal and for the door gasket seal should not be reused. The door flange and
the tube sheet area of the baffle seal should be clean and free of old sealing material, scale, etc. Be sure that all of
the gasket retaining fasteners are in place.
Remove the old rope and insulating cement from the baffle tile or refractory. Be careful not to chip or crack the
refractory. The rope is placed in the groove of the monolithic design and on top of the lip of the tile baffle type
construction.
Attach a new length of 1-1/4” diameter fiberglass rope (P/N 853-982) to the baffle. Be certain that it is properly
positioned and use a rapid setting adhesive (P/N 872-481) to hold it in place.
NOTE: A boiler built for high pressure design, such as 150 psi or higher steam or for 60 psi or higher hot water, is
constructed with a flanged tube sheet that fits inside the boiler shell and door flange.
The area between the curved portion of the sheet and the flange is packed with fiberglass rope and covered with
cement to fill the void and to provide a smooth sealing area.
Replacement is not normally necessary, but, if it is, completely remove the old material. Firmly caulk a layer of 1/2”
diameter rope (P/N 853-996) into the area. Tamp a second layer of 1” diameter rope (P/N 853-999) over the first
layer. Apply a coating of insulating cement pulp (P/N 872-26) over the ropes to form a smooth surface. Allow the
cement pulp to harden before closing the door.
8.21.1 — Closing and Sealing

Coat the door gasket with an oil and graphite mixture. Apply a small amount of a pulp mixture, consisting of P/N
872-26 cement and water around the inner circumference of the gasket. Press rope into this area. Use 1/2” diame-
ter rope (P/N 853-996) for a boiler of low pressure design. Use 1” diameter rope (P/N 853-999) for a high pres-
sure boiler.
After the rope is installed, the entire rope and gasket area, and the baffle area, should be liberally coated with the
pulp mixture. When the door is closed, the pulp will compress to protect the tadpole gasket and form a seal
between the refractory surface and the tube sheet.
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 over tighten.
Tighten alternate bolts until the door is secured and gas tight. After the boiler is back in operation, retighten the
bolts to compensate for any expansion. Loosen the nut on the davit stud to release tension from the davit arm.
8.22.1 — Electric Motors

Manufacturers of electric motors vary in their specifications for lubrication and care of motor bearings, however,
their specific recommendations should be followed.
750-91 (revised 2009) 8-33

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 con-
ditions, humidity, and ambient temperatures.
Complete renewal of grease, when necessary, can be accomplished by forcing out the old grease with the new
grease:
1. Thoroughly wipe those portions of the housing around the filler and drain plugs (above and below bearings).
2. Remove the drain plug (bottom) and free the drain hole of any hardened grease which may have accumulated.
3. With the motor not running, add new grease through the filler hole until clear grease starts to come out of the
drain hole.
4. Before replacing the drain plug, run the motor for 10 to 20 minutes to expel any excess grease.
5. The filler and drain plugs should be thoroughly cleaned before they are replaced.
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 - Precision Grease No. 2
• Humble Oil - Andok B
• Texaco - Multifak No. 2
• Phillips - 1B + RB No. 2
• Fiske Bros. - Ball Bearing Lubricant
• Standard/Mobil - Mobilux No. 2
NOTE: Siemens TEFC motors use a different and incompatible grease to those listed above.
For Siemens Motors: Contains re-greasable bearings. The shaft end (impeller end) requires the use of CB’s high tem-
perature auto grease system (PN 884-133) for proper lubrication.
The opposite shaft end (end opposite impeller) can be greased by the auto grease system or by hand pump, using two
or three pumps every three months with a grease compatible with a high temperature aluminum complex grease.
Daily • Check visually for free movement of IFGR linkage.

Quarterly • Manually check for free movement of IFGR linkage.
• Inspect and clean IFGR damper (oil-fueled system).
• Inspect and clean fan and burner (oil-fueled system).
Semi-Annually • Inspect and clean IFGR damper (gas-fueled system).
• Inspect and clean fan and burner (gas-fueled system).
• Open motor/fan cassette to check for free movement of IFGR linkage and damper
assembly.
Annually • Inspect fan impeller.
8-34 750-91 (revised 2009)

8.23 — Oil Heater: Electric, Steam, Hot Water
8.22.2 — Control Linkage

Apply a non-gumming, dripless, high-temperature lubricant, such as graphite or a silicone derivative to all pivot
points and moving parts. Work lubricant in well and wipe away excess. Repeat application at regular intervals to
maintain freedom of motion of parts.
8.22.3 — Solenoid and Motorized Valves

8.22.4 — IFGR Lubrication

Motors should be lightly lubricated at startup.
! Warning
Disconnect and lock out electrical power to the boiler before lubricating the fan motor. Failure to follow these instruc-
tions could result in serious injury or death.
4. Free the drain hole of any hard grease (if necessary, use a piece of wire).
NOTE: The amount and type of grease is very important. Only enough grease should be added to replace the grease
used by the bearing. Either too much or too little grease can be harmful. The grease cavity should be filled 1/3 to 1/2
full, using Chevron SRI 2 grease or equivalent. Shell Dolium R is a suitable substitute lubricant.
6. With the fill and drain plugs still removed, apply electric power to the boiler, start the motor, and let it run for
approximately 30 minutes.
7. Turn the boiler off.
! Warning
Disconnect and lock out electrical power to the boiler before lubricating the fan motor. Failure to follow these instruc-
9. Wipe excess grease from the motor, and install the fill and drain plugs. The motor is ready for operation.
10. Reconnect electrical power.

An annual maintenance of the heaters consists primarily of removing the heating element from the shell and scrap-
ing any accumulation of carbonized oil or sludge deposits that may have collected on the heat exchanging surfaces.
750-91 (revised 2009) 8-35

Before breaking any of the electrical connections to the electric heating elements, mark all wires and terminals to
assure rapid and correct replacement of wires.
Finish the cleaning process with a cleaning solvent to cut all hardened deposits from the heater element. Because of
the insulating effect of carbon and sludge, periodic cleaning is necessary to prevent overheating of the elements. If
operation of the heater becomes sluggish, examine the elements at once and clean as required.
Inspect the shell or tank each time the heater is removed. Flush all accumulated sludge and sediment from the tank
before reinstalling the heater.
The condensate from steam oil heaters must be safely discharged to waste. The waste should be checked periodi-
cally for any traces of oil that would indicate leaking tubes within the heater.
The hot water oil heater contains a heat transfer solution. Oil flows through an inner tube while boiler water sur-
rounds the outer tube. The space between the two tubes is filled with the heat transfer solution and is connected to
an expansion chamber on the rear of the heater. A visual indicator on the chamber reveals the presence of any oil if
an oil leak occurs.
A 50/50 solution of permanent antifreeze and water is generally used as the heat transfer solution. If there is no
danger of freezing, plain water may be used as a replenishment if necessary to refill.
Evidence of oil in either the steam heater condensate or in the water heater indicator demands prompt repairs.
8.24 — 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 pro-
duce visible flame change. Any time maintenance is performed on the burner linkage, the air-fuel ratio should be
checked. Readjustment of the burner may be required due to variations in fuel composition. A combustion analyzer
should be used to adjust air-fuel ratio for maximum operating efficiency. If your burner requires adjustments, con-
tact your local Cleaver-Brooks authorized representative for assistance.
8.25 — Air Pump Belt

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.
On a combination fired unit it is an acceptable practice to remove the belt when gas is being used for extended
periods. It is not absolutely necessary to do this, however, pump and belt life will be extended if the belt is
removed.
8-36 750-91 (revised 2009)

8.26 — Recommended Boiler Inspection Schedule
Daily Monthly Semi-Annually Annually

• Check water level • Inspect burner • Clean low water cutoff • Clean fireside surfaces
• Check combustion • Inspect for flue gas leak • Clean oil pump • Clean breeching
visually • Inspect for hot spots strainer, filter • Inspect waterside sur-
• Blow down boiler • Check cams • Clean air cleaner and faces
• Blow down water col- air/oil separator • Check operation of
• Check for tight closing
umn of fuel valve • Inspect refractory safety valves
• Record feedwater pres- • Check fuel and air link- • Remove and clean oil
sure/temperature age preheater
• Record flue gas tem- • Check indicating lights • Check air pump cou-
perature and alarms pling alignment
• Record oil pressure and • Check operating and • Inspect/repair burner
temperature limit controls housing to refractory
• Record gas pressure seal
• Check safety and inter-
• Treat water according lock controls
to the established pro- • Check for leaks, noise,
gram vibration, unusual con-
• Record atomizing air ditions, etc.
pressure • Check low water cut-
off operation
750-91 (revised 2009) 8-37

8-38 750-91 (revised 2009)

CHAPTER 9 Parts
9.1 — Ordering Parts

Furnish complete information when ordering parts by giving the item number, description, and the quantity of
parts desired, together with the complete nameplate data, including all electrical requirements.
Repair and replacement parts should be ordered from your local Cleaver-Brooks authorized representative.
CB Boiler Horsepower Shell Diameter

400 - 800 96”
250 - 350 78”
125 - 200 60”
50 - 100 48”
15 - 100 36”
750-91 (revised 2009) 9-1

Parts
9.2 — Parts Lists and Drawings

9.2.1 — Air Compressor and Piping
FOR BLOWER MOTOR
23 24 25
8 ITEM QTY PART NO. DESCRIPTION USED ON
FUELS 100, 101,

10 1 530-B-97 AIR INLET ASSEMBLY
1 200, 400, & 600
9 1 530-B-96 AIR INLET ASSEMBLY FUEL 700 ONLY
5 2 1 333-A-20 STRAINER ASSEMBLY -
3 1 923-79 AIR CLEANER 3/4" -
7 4 1 538-B-135 AIR-OIL TANK ASSEMBLY -
FROM STRAINER 5 1 SEE TABLE AIR COMPRESSOR BRACKET (NOTE 4) SEE TABLE
TO AIR/OIL TANK 19 20 21 22
6 1 450-B-13 BELT GUARD ASSEMBLY -
FROM AIR FILTER 7 1 505-B-100 AIR PUMP ASSEMBLY -
DETAIL "A-A" 8 1 SEE TABLE SHEAVE SEE TABLE
1 921-451 SHEAVE 60 HZ.
9
1 921-452 SHEAVE 50 HZ.
16 17
10 1 809-144 V-BELT -
15
31 11 1 507-B-1010 TUBING, AIR-OIL TANK TO MANIFOLD -
"A" 5 12 1 507-B-1011 TUBING, AIR-OIL TANK TO COMPRESSOR -
13 1 507-B-1013 TUBING, AIR-OIL TANK TO FINNED TUBING -
14 18
14 1 507-B-2647 TUBING, STRAINER TO FINNED TUBING -
13 6 15 1 507-A-2648 TUBING, STRAINER TO COMPRESSOR -
16 2 928-39 PIPE STRAP 3/8" -
"A" 17 4 860-7 SCREW, MACH, RD HD 1/4-20 X 1/2" LG. -
11
3 18 3 860-229 SCREW, MACH, FLAT HD 1/4-20 X 3/8" LG. -
30 19 3 868-157 CAPSCREW, HEX HD 3/8-16 X 1-1/4" LG. -
16 20 5 952-93 LOCKWASHER, 3/8" -
12 17 21 2 952-106 WASHER, 3/8" -
22 5 869-30 HEX NUT, 3/8-16" -
4 868-158 CAPSCREW, HEX HD 3/8-16 X 1-1/2" LG. 250 H.P.
4 23
4 868-176 CAPSCREW, HEX HD 1/2-13 X 2" LG. 300-350 H.P.
4 952-93 LOCKWASHER, 3/8" 250 H.P.
24
4 952-94 LOCKWASHER, 1/2" 300-350 H.P.
4 869-30 HEX NUT 3/8-16 250 H.P.
29 25
28 4 869-15 HEX NUT, 1/2-13 300-350 H.P.
26 3 77-28 SPACER -
1
27 1 928-49 PIPE STRAP, 2" -
28 6 952-92 LOCKWASHER, 1/4" -
2 29 6 868-136 CAPSCREW, HEX HD 1/4-20 X 3/4" LG. -
30 1 845-39 FLARED ADAPTER, 3/4" NPT X 3/4" ODC -
19 31 1 845-8 FLARED NUT, 45 X 1/4" ODC -
27
TABLE ITEMS 5 & 8

60 HZ. 50 HZ.
20
H.P. ITEM 5 ITEM 8 ITEM 5 ITEM 8
22
26 CB 250 8-C-2323 921-595 8-C-2326 921-461
& 300 8-C-2326 921-584 8-C-2326 921-461
CBW 350 8-C-2326 921-584 8-C-2327 921-461
9-2 750-91 (revised 2009)

9.2.2 — Side Mounted Air Compressor Piping

BOLT HEAD
ON TOP
6
1
8 7
3 5
4
SIDE ELEVATION 78 "
BILL OF MATERIAL FOR 60" & 78" DIA.
ITEM QTY PART NO. DESCRIPTION USED ON
1 1 505-113 COMPRESSOR ASSEMBLY -

2 2 008-01159 BRACKET -
3 4 868-00431 CAPSCREW, HEX. HD. 5/16"-18 X 2-1/4" LG. -
4 4 952-114 LOCKWASHER, 5/16" -
5 4 952-133 WASHER, 5/16" -
6 1 847-469 BUSHING, RED. 1" X 3/4" 78"
7 1 SEE TABLE MOTOR -
8 1 SEE TABLE COUPLING, HALF -
TABLE ITEMS 7 & 8
ITEM 200-460V (60 HZ) 600V (60 HZ) 200-380V (50 HZ)
7 894-3431 894-3432 894-2291 3/4" 3/4"
8 819-158 819-158 819-150
C
L
BOILER
NOTES:
1. UNLESS OTHERWISE NOTED, ALL PIPE TO BE
SCH. 40 ASTM A120 WELDED BLACK STL. AND ALL
FITTINGS TO BE 150# M.I..
2. ALL DIMENSIONS ARE APPROXIMATE.
FRONT ELEVATION 78 "
750-91 (revised 2009) 9-3

Parts
9.2.3 — Air Line Piping

1 1 827-8 BULK CONDUIT, 1/2" THINWALL EMT. X "B" LG. APPROX.

2 1 827-8 BULK CONDUIT, 1/2" THINWALL EMT. X "A" LG. APPROX.
3 1 8-A-2833 BRACKET
4 1 928-33 PIPE STRAP, 1/2" CONDUIT
5 1 868-136 CAPSREW, HEX HD. 1/4"-20 X 3/4" LG.
6 1 859-118 ELBOW, STREET, 1/2" X 45 (SEE NOTE 3)
7 1 848-141 COUPLING, 1/2" CONDUIT
8 2 848-325 CONNECTOR, STRAIGHT, 1/2" EMT. CONDUIT
9 1 848-398 COUPLING, UNION, 1/2" EMT. CONDUIT
3 5
VIEW "A-A "
SIGHT PORT & PIPING
REAR HEAD
7 8
9 6
A
8
A 3
1 2
REAR VIEW
9-4 750-91 (revised 2009)

9.2.4 — Burner Housing Support & Front Head Plt

LFURNACE
C C
LFURNACE
5
29
24 28 24 19
28 19
18 18
23 23
17 29 17
15 13 15 13
16 14 16 14
11,12 1112
10 10 78
8 7
FRONT HEAD 6 9 6
9
5" DIA. HOLE
2 3
4 FRONT HEAD
5"
1 OIL ONLY
GAS AND COMBINATION
26 TUBE SHEET
27
25 BAFFLE SEAL 22
BAFFLE
STUD
INNER DOOR
20 21
BAFFLE ATTACHMENT
78" "LE" BOILER TABLE ITEM 28

FUEL 100 101-200 400-600 700
H.P.
250 -- -- 429-1389 429-1387
300 -- -- 429-1389 429-1387

STANDARD 78" CB BOILER TABLE ITEM 28
FUEL 250 & 300 429-1356 429-1358 -- --
100 101-200 400-600 700
H.P. 60 PPM ONLY
250 429-D-1266 429-D-1270 429-819 429-D-1273
350 -- -- 429-1390 429-1388
300 429-D-1266 429-1271 429-819 429-D-1273
350 60 PPM
350 250-350 429-1357 429-1359 -- --
429-1268 429-1272 429-820 429-1274
30,25,20 PPM
750-91 (revised 2009) 9-5

Parts
Burner Housing Support & Front Head Plt

BILL OF MATERIAL
FOR 78" CB, CBW, & "LE" BOILERS
ITEM QTY PART No. DESCRIPTION HP FUEL USED ON OPTION

CODE
1 1 57-1125 BULK PIPE - 4" x 19-1/4" T.B.E. - GAS/COMB - A8
2 1 853-348 BULK PACKING - 1/4" DIA. x 12" - GAS/COMB - A8
3 1 65-B-177 RETAINER - GASKET - GAS/COMB - A8
4 3 860-15 SET SCREW - SOCKET HEAD - GAS/COMB -
5 1 146-334 SPUD KIT AND PATTERN
6 1 656-7967 INSTALLATION-GASKET (656D7965) - - -
7 20 952-286 WASHER - 1/2" - - -
8 20 869-29 NUT HEX. - 1/2-13 - - -
1 465-B-635 INSULATED FRONT HEAD PLATE, LH SWING - - STD. CB ONLY CR
9 1 - - STD. CB ONLY CR
465-B-138 INSULATED FRONT HEAD PLATE, RH SWING
1 15-B-121 FLANGE RING - - ALL EXCEPT 78"LE A2
10
8 296-A-19 CLAMPS - - 78" LE A2
11 8 952-106 WASHER - 3/8" BRASS - - -
12 8 869-37 NUT HEX. - 3/8-16 BRASS - - -
13 2 32-A-928 GASKET - BURNER HOUSING SUPPORT - - - A2
14 1 85-C-444 SUPPORT - BURNER HOUSING - - - A2
15 8 869-29 NUT HEX. - 1/2-13 BRASS - - -
16 1 853-3 SET-PACKING - 3/8" x 71-1/2" LG. - - - A2
17 1 15-B-39 FLANGE RING - - - A2

18 8 869-15 NUT HEX. - 1/2-13 - - -
19 10# 872-390 CEMENT - REFRACTORY - - - A3
20 3 869-37 NUT HEX. - 3/8" BRASS - - ALL EXCEPT "LE"
21 6 952-326 WASHER - 3/8" FLAT BRASS - - ALL EXCEPT "LE"
22 5oz. 872-558 THERMO SILICATE CEMENT - - -
1 32-A-927 GASKET - BURNER PLATE - - STANDARD
23
2 32-A-927 GASKET - BURNER PLATE - - HIGH TURN A8
24 853-1017 GASKET-1/8" x 1" x 42-13/16" SILICON - - DOWN ONLY
1*
25 1* 853-394 GASKET 2" x 78" - - ALL EXCEPT "LE" A2
26 6.5FT 971-291 STRIP - PERFORATED - - ALL EXCEPT "LE" A2
27 24 841-A-551 RIVET - - ALL EXCEPT "LE"
28 1 SEE TABLE BURNER DRAWER - - - A5
1 40-C-402 HOUSING - BURNER 250-350 NATURAL STANDARD, GAS, A8,B6
& COMBINATION
1 40-C-446 HOUSING - BURNER 250-350 PROPANE PG
STANDARD &
29 1 40-C-396 HOUSING - BURNER 250-350 OIL HIGH TURN A8
DOWN, OIL
HIGH TURN
1 40-C-565 HOUSING - BURNER - - DOWN, GAS, & A8,PG
COMBINATION ,BG
* SOLD BY THE FOOT
9-6 750-91 (revised 2009)

9.2.5 — Control Panel
750-91 (revised 2009) 9-7

Parts
Control Panel
9-8 750-91 (revised 2009)

9.2.6 — Entrance Box
750-91 (revised 2009) 9-9

Parts
9.2.7 — Front Head (Electrical)
9-10 750-91 (revised 2009)

9.2.8 — Front Davit
750-91 (revised 2009) 9-11

Parts
9.2.9 — Front Head Insulation
9-12 750-91 (revised 2009)

9.2.10 — Front Head Linkage
750-91 (revised 2009) 9-13

Parts
9.2.11 — Gas Train

MAIN GAS TRAIN
14 4
5 15
3 5
ITEM QTY P/N DESCRIPTION USED ON

1 TABLE 1
M1
* 940-4541 VALVE (STD) 3" GTS 250-350 HP
3" 10" 10"
2 945-139 ACTUATOR (STD) 2",2-1/2",3" GTS 50-350 HP TYP
TYP
3 940-4546 VALVE (POC) 3" GTS 250-800 HP
TYP 4 7
4 945-143 ACTUATOR (POC) 2",2-1/2",3" GTS 6 3 TYP
5 2 941-130 LUBRICATED PLUG VALVE 3" GTS TYP
1 507-6785 GAS PRESS. SENSOR 200-350 HP (HAWK) 8 8
7
1 817-752 HIGH GAS PRESS. SWITCH 300-350 HP (STD) M2
8 - ** HIGH GAS PRESS. SWITCH ALL HP (HAWK)
2 4
2 157-1039 S.O. NIPPLE 1/2" 3" GTS (STD) 1 3
TABLE 1
** S.O. NIPPLE ALL HP (HAWK)
9 948-2 MAIN VENT VALVE 3/4" VVS
948-54 MAIN VENT VALVE 1-1/4" VVS
TABLE 1 M3
11 157-1040 S.O. NIPPLE 3" GTS, 3/4" VVS 10"
157-1041 S.O. NIPPLE 3" GTS, 1-1/4" VVS
2 8-1002 BRACKET 2", 2-1/2", 3" GTS 9 2
12 2
2 8-1159 BRACKET MAXON 2", 2-1/2", 3" GTS
1 1
13 NOT USED NOT USED
14 1 919-99 CAPLUG 3" GTS
15 1 858-171 UNION 3" GTS
16 TABLE 1 948-197 PILOT VALVE -
M4
17 TABLE 1 948-2 PILOT VENT VALVE - 11
18 1 918-356 PILOT REGULATOR -
2 9 4
19 1 507-1015 PILOT TUBING 250-350 HP
A
20 1 850-109 PILOT GAUGE -
21 SCHEM. 825-30 PILOT GAS COCKS -
22 1 845-194 ELBOW 125-800 HP
M5
23 1 940-134 BUTERFLY VALVE 3" 150-350 HP A
1 11 3 37 38 TYP
39 40 4 PLACES
4 9 4
A
* THE ACTUATORS ARE INCLUDED W/ ITEMS #1 & 3 GAS VALVES.

**FOR ALL HAWK, ITEM #7 IS NOT USED AND
M6
REPLACE ITEM #8 WITH STANDARD PIPE NIPPLE.
A TYP
3 11 37 38
3 39 40 4 PLACES
OVERALL LENGTH
SEE TABLE 1
9-14 750-91 (revised 2009)

Gas Train
ITEM QTY P/N DESCRIPTION USED ON OPTION
24 1 157-81 ELBOW 3" W/ TEST CONN. 150-350 HP B3
25
1 859-87 ELBOW 3" 250-350 HP
26 1 858-336 FLANGED UNION 3" 250-350 HP B3
27 1 847-562 ELBOW 4" X 3" 250-350 HP
2 7-77 U-BOLT 3" GTS
29 4 952-114 LOCKWASHER QTY 6 ON 4" GTS
30 4 952-133 WASHER QTY 6 ON 4" GTS
31 4 869-36 HEX NUT QTY 6 ON 4" GTS
32 2 928-44 STRAP QTY 3 ON 4" GTS
33 2 952-92 LOCKWASHER QTY 3 ON 4" GTS
34 2 952-145 WASHER QTY 3 ON 4" GTS
35 2 869-21 HEX NUT QTY 3 ON 4" GTS
36 2 868-404 CAPSCREW QTY 3 ON 4" GTS
41 2 8A15 GAS PILOT BRACKET FUEL 101, 600 B3
42 2 868-135 CAPSCREW FUEL 101, 600
PILOT GAS TRAIN

STARTER GAS TRAIN ( SEE NOTES 5 ) 1/2" X 1/2"
X 1/4" TYP.
TYP TYP TYP
F 27 21 18 20 TYP 19 TYP
S1 27 S2 1/2" TYP. 16
26 24
C P1 22 TYP
24
D 21
A
23
E
B 25 23
25 S3
P2
24
17
16 21
25 23 P3
TABLE 1
BOILER MAIN GAS TRAIN STARTER TRAIN PILOT TRAIN OVERALL LENGTH
HORSEPOWER TRAIN VENT VALVE SIZE SCHEMATIC SCHEMATIC SCHEMATIC MAIN GAS TRAIN
SIZE M1,M2, M3,M4,M5
STD & FM IRI STD FM IRI ALL INS. STD & FM IRI
M6
250 3" - 1-1/4" M3 M3 M5 S1 P1 P2 - 80"
300-350 3" 3/4" 1-1/4" M5 M6 M5 S1 P1 P2 - 80"
750-91 (revised 2009) 9-15

Parts
9.2.12 — Light Oil/Air Piping
9-16 750-91 (revised 2009)

Light Oil/Air Piping
750-91 (revised 2009) 9-17

Parts
9.2.13 — Heavy Oil/Air Piping
9-18 750-91 (revised 2009)

Heavy Oil/Air Piping
750-91 (revised 2009) 9-19

Parts
9.2.14 — Heavy OIl Alstrom Heater
9-20 750-91 (revised 2009)

Heavy OIl Alstrom Heater
750-91 (revised 2009) 9-21

Parts
9.2.15 — CB-LE IFGR

ITEM #4 P/N
BOILER BOILER SHELL AND BASEFRAME

PRESS. H.P. WELDMENT & ASSEMBLY
PRESS. ASSY SKID DETAIL

ITEM #1 P/N 30# 250 270 02244 (270D02241)
H.W. 300 270 02245
PPM STD. HOI 350 270 02246
125# 250 270 02250 (270D02247)
132D1688(RH) 132D2093(RH) H.W. 300 270 02251
60 PPM 350 270 02252
132-1720(LH) 132-2094(LH) 150#
250 270 02256 (270D02253)
300 270 02257
132-1721(RH) 132-2095(RH) HTHW.
350 270 02258
30,25 PPM 250 270 02220 (270D02217)
132-1722(LH) 132-2096(LH) 15# 300 270 02221
ST.
350 270 02222 146 333
132-1723(RH) 132-2097(RH)
250 270 02226 (270D02223)
20 PPM 150#
132-1724(LH) 132-2098(LH) 300 270 02227
ST. 350 270 02228
200# 250 270 02232 (270D02229)
ST. 300 270 02233
350 270 02234
250# 250 --
ST. 300 --
350 --
300# 250 --
300 --
ST.
350 --
16
13
1
2
9-22 750-91 (revised 2009)

ITEM QTY PART NO. DESCRIPTION OPTION

CODE
1 1 SEE TABLE FRONT HEAD ASSEMBLY (STD.132-D-1688) (HOI.132-D-2093) A2
2 1 146-D-13 BLOWER ASSEMBLY
3 1 146-D-120 BURNER HSG SUPP., FRT HD PLATE, & BURNER DRAWER
4 1 SEE TABLE PRESSURE VESSEL ASSEMBLY (SEE NOTE #1) A1
5 1 465-D-625 REAR HEAD ASSEMBLY (NOT SHOWN) 43
6 1 146-D-102 FURNACE LINER AND BRICKING ( SEE PAGE 9-45 & 9-46)
7 1 461-C-576 AIR HOOD, CENTER A2
8 1 32-C-2532 GASKET, BLOWER ASSEMBLY A2
9 33 841-507 SPRING CLIPS, GASKET (656-B-7882) A2
10 1 32-C-2543 GASKET-BLOWER CARTRIDGE (146-C-28)
1 476-C-237 LINKAGE ASSEMBLY,IFGR (GAS ONLY) A4
1 476-262 LINKAGE ASSEMBLY,IFGR (LIGHT OIL ONLY) A4
11
1 476-C-238 LINKAGE ASSEMBLY,IFGR 20-30 PPM (COMB. L.O. & GAS) A4
1 476-C-299 LINKAGE ASSEMBLY,IFGR 60 PPM (COMB. L.O. & GAS) A4
1 146-D-208 INSTALLATION HEAVY OIL ISOLATION SYSTEM
12 1 146-C-136 AIR COMPRESSOR ASSEMBLY (NOT SHOWN)
13 1 656-C-7726 AIR HOOD ASSEMBLY A2
14 2 32-B-899 GASKET, FRONT AND REAR HEAD 78" (656-B-7882)
15 1 465-C-1634 FRONT HEAD INSULATION A2
16 1 146-C-38 DAVIT ASSEMBLY, FRONT HEAD 78"
17 1 146-C-261 INSULATION & LAGGING (THOMASVILLE)
18 1 146-D-15 SAFETY VALVES
1 18
4 17
8
10
15
2
11
9 14
750-91 (revised 2009) 9-23

Parts
9.2.16 — IFGR Impeller
9-24 750-91 (revised 2009)

9.2.17 — Pressure Controls
750-91 (revised 2009) 9-25

Parts
9.2.18 — Temperature Controls
9-26 750-91 (revised 2009)

9.2.19 — W.C. - Main & Aux.
750-91 (revised 2009) 9-27

Parts
W.C. - Main & Aux.
9-28 750-91 (revised 2009)

9.2.20 — Vessel Handholes & Manways
PRESSURE VESSEL, 78" DIA. 15# ST, HW,30# ,125# HW. Std. & LE
ITM REQ PART-NO. DESCRIPTION
1 2 953-00050 YOKE, MANHOLE, PRESSED STEEL
2 2 869-00065 NUT, HEX,HEAVY 3/4-10 UNC-2B ASTM-A3
3 2 952-00124 WASHER, FLAT, PLAIN, #10GA, SAE TYPE
4 1 853-00939 GASKET, MANHOLE, 12" X 16"
5 1 821-00207 COVER, MANHOLE, SA-285 GR.C PVQ
6 6 104-00449 YOKE, HANDHOLE, CAST IRON
7 6 869-00017 NUT, HEX, FINISHED, PLAIN, 5/8-11 UNC-2
8 6 952-00101 WASHER,FLAT,PLAIN,#13GA,SAE TYPE
9 6 853-00935 GASKET, HANDHOLE, 3-1/4" X 4-1/2"
10 6 317-60 COVER, HANDHOLE,
PRESSURE VESSEL, 78" DIA. 150# ST,150#HTHW. Std & LE.

1 2 953-00050 YOKE, MANHOLE, PRESSED STEEL,
2 2 869-00065 NUT,HEX,HEAVY,3/4-10 UNC-2B,ASTM-A3
4 1 853-00939 GASKET, MANHOLE, 12" X 16"
5 1 821-00207 COVER,MANHOLE,SA-285 GR.C PVQ
6 6 953-00048 YOKE, HANDHOLE, 2 PRONG FORGED
7 6 869-00017 NUT,HEX,FINISHED,PLAIN,5/8-11 UNC-2
9 6 853-00935 GASKET,HANDHOLE, 3-1/4" X 4-1/2"
10 6 317-60 HANDHOLE COVER ASSY., 78 & 96"
PRESSURE VESSEL LE 78" 200#,250# ST. Std & LE

1 2 953-00050 YOKE, MANHOLE, PRESSED STEEL,
2 2 869-00065 NUT,HEX,HEAVY,3/4-10 UNC-2B,ASTM-A3
4 1 853-01044 GASKET, MANHOLE, 12" X 16"
5 1 821-00207 COVER,MANHOLE,SA-285 GR.C PVQ
6 6 953-00048 YOKE, HANDHOLE, 2 PRONG FORGED
7 6 869-00017 NUT,HEX,FINISHED,PLAIN,5/8-11 UNC-2
9 6 853-01042 GASKET, HANDHOLE, 3-1/4" X 4-1/2"
10 6 317-60 HANDHOLE COVER ASSY., 78 & 96"
750-91 (revised 2009) 9-29

Parts
9.2.21 — Rear Head Sealing - Davit
9-30 750-91 (revised 2009)

9.2.22 — Throat Tile and Furnace Liner

2
5
5 12" (1/8") FOR 78" DIA.
CL FURNACE
4
2
AREA OF BRICKS 2
TO BE TRIMMED IF 36" APPROX.
INTERFERENCE EXISTS. FURNACE
""
DETAIL A
(INSIDE VIEW) 1
5 3 6 1
8
4 7 FURNACE
FRONT TUBE SHEET
120∞
SEE NOTE #1 BOILER SHELL
60∞ POWER
10 O'CLOCK 2 O'CLOCK (OPTIONAL CORRUGATED FURNACE)
CHALK MARKS
4
3
2 STARTER BRICK
SEAM OF ITEM #4
DETAIL " B " (2 PIECES-
12" (1/8") FOR 78" DIA.
END TO END)
(FRONT VIEW)
C
L FURNACE
120∞
2
60∞
36" APPROX.
10 O'CLOCK 2 O'CLOCK
5 1 1
3
4 FURNACE
STARTER TILE 1 FRONT TUBE SHEET BOILER SHELL
LOW PRESSURE
SEAM OF ITEM #7
(2 PIECES- DETAIL "C " (STANDARD PLAIN FURNACE)
END TO END) (INSIDE VIEW)
750-91 (revised 2009) 9-31

Parts
Throat Tile and Furnace Liner

BASIC BILL OF MATERIAL
FURNACE LINER & BRICKING - 78"
ITEM QTY PART No. DESCRIPTION USED ON
36 94-A-204 TILE - 34" O.D. FURNACE (CORRUGATED) 250-350 H.P. (POWER ONLY)
1
39 94-A-204 TILE - 34" 0.D. FURNACE (PLAIN) 250-350 H.P. (L.P. ONLY)
2 24 94-B-343 REFRACTORY - ARCH BRICK 250-350 H.P. (ALL)
3 10 LBS. 872-390 CEMENT - JOINT MORTAR 250-350 H.P. (ALL)
4 2 872-655 SIZED INSUL. 1/4" X 6-3/4" X 48" LG. 250-800 H.P. (ALL)
5 12 841-01736 STUD, 1/2"-13 UNC X 2" LG. 250-350 H.P. (ALL)
6 15 LBS. 872-162 REFRACTORY - VEE BLOCK MIX 250-350 H.P. (POWER ONLY)
7 2 872-657 SIZED INSUL. 1/4" X 21" X 48" LG. 250-350 H.P. (POWER ONLY)
8 2 872-656 SIZED INSUL. 1/4" X 16" X 48" LG. 250-350 H.P. (POWER ONLY)
BASIC BILL OF MATERIAL

OPTIONAL CORRUGATED FURNACE LINER & BRICKING - CB & LE 78"
USED ON
ITEM QTY PART No. DESCRIPTION
H.P. PRESSURE
1 36 094-A-00204 TILE - 34" O.D. FURNACE (CORRUGATED) CB & LE 250-350 125#-250#
2 24 094-B-00343 REFRACTORY - ARCH BRICK CB & LE 250-350 125#-250#

3 10 LBS. 872-00390 CEMENT - JOINT MORTAR CB & LE 250-350 125#-250#
4 2 872-00655 SIZED INSUL. 1/4" X 6-3/4" X 48" LG. CB & LE 250-350 125#-250#
5 12 841-01736 STUD, 1/2"-13 UNC X 2" LG. CB & LE 250-350 125#-250#
6 15 LBS. 872-00162 REFRACTORY - VEE BLOCK MIX CB & LE 250-350 125#-250#
7 2 872-00657 SIZED INSUL. 1/4" X 21" X 48" LG. CB & LE 250-350 125#-250#
8 2 872-00656 SIZED INSUL. 1/4" X 16" X 48" LG. CB & LE 250-350 125#-250#
9-32 750-91 (revised 2009)

CLEAVER-BROOKS
Model CB, CB-LE Packaged Boiler
400 - 800 HP, Light Oil, Heavy Oil, Gas, or Combination
Operation and Maintenance Manual
Manual Number: 750-94
Release Date: December 2009

Copyright © 2009 by Cleaver-Brooks
All rights reserved. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means without the prior writ-
ten consent of Cleaver-Brooks.
Cleaver-Brooks
11950 West Lake Park Drive
Milwaukee, WI 53224
414-359-0600
Model CB, CB-LE Packaged Boiler
750-94
Table of Contents
CHAPTER 1 Basics of Firetube Operation 1-1

1.1 — Introduction 1-1
1.2 — The Boiler 1-4
1.3 — Construction 1-5
1.4 — Steam Controls (All Fuels) 1-6

1.4.1 — Operating Limit Pressure Control 1-6
1.4.2 — High Limit Pressure Control 1-7
1.4.3 — Modulating Pressure Control 1-7
1.4.4 — Low Water Cutoff and Pump Control 1-7
1.4.5 — Water Column Assembly 1-8
1.4.6 — Water Column Drain Valve 1-8
1.4.7 — Water Gauge Glass Drain Valve 1-9
1.4.8 — Vent Valve 1-9
1.4.9 — Steam Pressure Gauge 1-9
1.4.10 — Auxiliary Low-Water Cutoff 1-9
1.5 — Hot Water Controls (All Fuels) 1-11

1.5.1 — Water Pressure and Temperature Gauge 1-11
1.5.2 — Operating Limit Temperature Control 1-11
1.5.3 — High Limit Temperature Control 1-11
1.5.4 — Modulating Temperature Control 1-12
1.5.5 — Low-Water Cutoff 1-12
1.5.6 — Auxiliary Low-Water Cutoff (optional) 1-12
750-94 (revised 2009) i

Model CB, CB-LE Packaged Boiler Manual
1.6 — IFGR Components 1-12
1.6.1 — Flue Gas Transfer Port, IFGR Damper, & Flange Collar 1-12
1.6.2 — IFGR Damper Linkage 1-13
1.6.3 — Over-Travel Mechanism 1-13
1.6.4 — Fuel Change-Over Linkage 1-13
1.6.5 — Fan/Motor Cassette 1-15
1.6.6 — Burner Drawer 1-15
1.6.7 — Combustion Air Inlet 1-15
1.6.8 — Front Door Insulation 1-16
CHAPTER 2 Burner Operation and Control 2-1

2.1 — The Burner 2-1
2.2 — Control and Component Function 2-2
2.3 — Components Common to All Boilers 2-3
2.4 — Controls for Gas Firing 2-7
2.5 — Controls Common to Oil-Fired Boilers 2-10
2.6 — Additional Controls for Heavy Oil 2-14
2.7 — Controls for Combination Burners Only 2-18
2.8 — Combustion Air 2-18
2.9 — Automatic Ignition 2-19
2.11 — Oil Fuel Flow: Light Oil 2-20
ii 750-94 (revised 2009)

2.12 — Oil Fuel Flow: Heavy Oil 2-22
2.13 — Gas Fuel Flow 2-24
2.14 — Modulating Firing 2-24
CHAPTER 3 Waterside Care and Requirements 3-1

3.2 — Water Requirements: Hot Water Boiler 3-2

3.2.1 — Air Removal 3-2
3.2.1.1 — Minimum Water Temperature 3-2
3.2.1.2 — Rapid Replacement of Boiler Water 3-3
3.2.1.3 — Continuous Flow Through the Boiler 3-3
3.2.2 — Water Circulation 3-3
3.2.2.1 — Multiple Boiler Installations 3-4
3.2.2.2 — Pump Location 3-5
3.2.2.3 — Pump Operation 3-5
3.2.3 — Pressure 3-5
3.3 — Water Requirements: Steam Boiler 3-7

3.3.1 — Feed Pump Operation 3-7
3.3.2 — Water Feeder (optional) Operation 3-8
3.4 — Water Treatment 3-8
3.5 — Cleaning 3-9

3.5.1 — Hot Water and Steam Piping 3-9
3.5.2 — Pressure Vessel 3-9
3.6 — Boil-Out of a New Unit 3-10
750-94 (revised 2009) iii

3.7 — Washing Out 3-13
3.7.3 — Flushing of Pressure Vessel Interior 3-13
3.8 — Blowdown: Steam Boiler 3-14

3.8.1 — Intermittent Manual Blowdown 3-15
3.8.2 — Continuous Blowdown 3-15
3.8.3 — Frequency of Manual Blowdown 3-15
3.8.4 — Manual Blowdown Procedure 3-16
3.9 — Periodic Inspection 3-17
3.10 — Preparation for Extended Lay-Up 3-19
CHAPTER 4 Sequence of Operation 4-1

4.2 — Circuit and Interlock Controls 4-2
4.3 — Sequence of Operation: Oil or Gas 4-4

4.3.1 — Pre-Purge Cycle 4-4
4.3.2 — Ignition Cycle 4-5
4.3.3 — Run Cycle 4-6
4.3.4 — Burner Shutdown: Post Purge 4-7
4.4 — Flame Loss Sequence 4-7

4.4.1 — No Pilot Flame 4-8
4.4.2 — Pilot But No Main Flame 4-8
4.4.3 — Loss of Flame 4-8
iv 750-94 (revised 2009)

CHAPTER 5 Starting and Operating Instructions 5-1
5.2 — Control Settings: Steam and Hot Water 5-3

5.2.1 — Operating Limit Control 5-3
5.2.2 — High Limit Control 5-3
5.2.3 — Modulating Control 5-3
5.2.4 — Low-Water Cutoff and Pump Control 5-4
5.2.5 — Additional Considerations 5-4
5.3 — Gas Pilot 5-4
5.5 — Firing Preparations for No. 2 Oil (Series 100 - 200) 5-7
5.5.1 — Oil Flow 5-7
5.6 — Firing Preparation for No. 6 Oil (Series 400 - 600) 5-9
5.6.1 — Oil Flow 5-10
5.6.3 — Oil Temperature 5-11
5.6.4 — Starting 5-12
5.7 — Firing Preparations for Gas (Series 200-400-700) 5-13
5.8 — IFGR Setup 5-15
5.9 — Startup, Operating and Shutdown: All Fuels 5-17

5.9.1 — Operating 5-19
5.9.2 — Shutdown 5-20
5.10 — Control Operational Test and Checks 5-20
750-94 (revised 2009) v

CHAPTER 6 Adjustment Procedures 6-1
6.1.1 — High Turndown Burner 6-1
6.2 — Linkage: Modulating Motor and Air Damper 6-2
6.3 — Modulating Motor 6-5
6.4 — Modulating Motor Switches: Low-Fire and High-Fire 6-6
6.5 — Burner Operating Controls: General 6-6
6.6 — Modulating Pressure Control: Steam 6-10
6.7 — Operating Limit Pressure Control: Steam 6-10
6.8 — High Limit Pressure Control: Steam 6-10
6.9 — Modulating Temperature Control: Hot Water 6-11
6.10 — Operating Limit Temperature Control: Hot Water 6-12
6.11 — High Limit Temperature Control: Hot Water 6-12
6.12 — Low Water Cutoff Devices: Steam & Hot Water 6-12
6.13 — Combustion Air Proving Switch 6-12
6.14 — Atomizing Air Proving Switch 6-13
6.15 — Gas Pilot Flame Adjustment 6-14

6.15.1 — Measure and Adjust Pilot 6-14
vi 750-94 (revised 2009)

6.16 — Gas Pressure and Flow Information 6-16
6.16.1 — Pressure 6-16
6.16.2 — Gas Flow 6-19
6.16.3 — Pressure Correction 6-19
6.16.4 — Checking Gas Flow 6-21
6.17 — Gas Fuel Combustion Adjustment 6-21

6.17.1 — Standard Burner Low-Fire Adjustment 6-25
6.17.2 — High Turndown Burner Low-Fire Adjustment 6-26
6.18 — Low-Gas Pressure Switch 6-26
6.19 — High-Gas Pressure Switch 6-27
6.20 — Fuel Oil Pressure and Temperature: General 6-27
6.21 — Fuel Oil Combustion Adjustment 6-29

6.21.1 — Standard Burner Low-Fire Adjustment: Heavy Oil 6-30
6.21.2 — High Turndown Burner Low-Fire Adjustment: Light Oil 6-31
6.22 — Burner Drawer Adjustment 6-31
6.23 — Oil Drawer Switch 6-33
6.24 — Low Oil Temperature Switch 6-33
6.25 — High Oil Temperature Switch (Optional) 6-34
6.26 — Low Oil Pressure Switch (Optional) 6-34
6.27 — Electric Oil Heater Thermostat (400 and 600 Series: Steam) 6-34
6.28 — Steam Oil Heater Thermostat: No. 6 Oil 6-35
6.29 — Hot Water Oil Heater Thermostat (400 and 600 Series) 6-35
750-94 (revised 2009) vii

6.30 — Steam Heater Pressure Regulator (400 and 600 Series: Steam) 6-35
CHAPTER 7 Troubleshooting 7-1

CHAPTER 8 Inspection and Maintenance 8-1

8.1.1 — Periodic Inspection 8-2
8.2 — Fireside Cleaning 8-3
8.3 — Water Level Controls 8-4

8.4 — Water Gauge Glass 8-5
8.5 — Electrical Controls 8-6
8.6 — Flame Safety Control 8-8

8.6.1 — Checking Pilot Flame Failure 8-9
8.6.2 — Checking Failure to Light Main Flame 8-9
8.6.3 — Checking Loss of Flame 8-10
8.7 — Oil Burner Maintenance 8-10

8.7.1 — Oil Strainers 8-10
8.7.2 — Light Oil Strainers 8-10
8.7.3 — Heavy Oil Strainers 8-11
8.7.4 — Cleaning the Oil Nozzle 8-11
8.7.5 — Cleaning Air Purge Nozzle (No. 6 Oil) and Back Pressure Orifice Nozzle
(No. 2 Oil) 8-12
viii 750-94 (revised 2009)

8.7.6 — Ignition System 8-12
8.8 — Gas Burner Maintenance 8-13
8.9 — Motorized Gas Valve 8-14
8.10 — Solenoid Valves 8-14
8.11 — Air Control Damper, Linkage, and Cam Spring 8-15
8.12 — Forced Draft Fan 8-16
8.13 — Fan/Motor Cassette Removal 8-18
8.14 — Inspection and Adjustment 8-20
8.15 — Airbox Gasket Installation 8-21
8.16 — Fan/Motor Cassette Installation 8-22
8.17 — Safety Valves 8-23
8.18 — Fuel Oil Metering Valve, Adjusting, Relief Valves 8-23
8.19 — Air Pump and Lubricating System 8-26

8.19.2 — Lubricating Oil 8-26
8.19.3 — Lubricating Oil Strainer and Cooling Coil 8-27
8.19.4 — Air Cleaner 8-27
8.19.5 — Air-Oil Tank 8-27
8.19.6 — Lube Oil Cooling Coil 8-28
8.19.7 — Flexible Coupling Alignment 8-28
8.19.8 — Air Compressor Replacement 8-30
8.19.8.1 — Dismantling 8-30
8.19.8.2 — Reassembly 8-31
750-94 (revised 2009) ix

8.20 — Refractory 8-32
8.20.1 — Furnace Liner 8-33
8.20.2 — Throat Tile and Liner Installation 8-34
8.20.3 — Installation 8-35
8.20.4 — Rear Door 8-37
8.20.5 — Front Inner Door 8-39
8.21 — Opening and Closing Rear Door 8-40

8.21.1 — Closing and Sealing 8-41
8.22 — Lubrication 8-41

8.22.1 — Electric Motors 8-41
8.22.2 — Control Linkage 8-43
8.22.3 — Solenoid and Motorized Valves 8-43
8.22.4 — IFGR Lubrication 8-43
8.23 — Oil Heater: Electric, Steam, Hot Water 8-44
8.24 — Combustion 8-45
8.25 — Recommended Boiler Inspection Schedule 8-46
CHAPTER 9 Parts Lists and Drawings 9-1

9.1 — Ordering Parts 9-1
9.2 — Parts 9-2

9.2.1 — Air Compressor and Piping 9-2
9.2.3 — Air Line Piping 9-4
9.2.4 — Alstrom Heater 9-5
9.2.5 — Burner Housing Support 9-7
9.2.6 — Control Panel 9-9
9.2.7 — Entrance Box 9-11
9.2.8 — Front Davit 9-12
9.2.9 — Front Head Linkage 9-13
9.2.10 — Heavy Oil Piping 9-14
x 750-94 (revised 2009)

9.2.11 — Standard Impeller 9-16
9.2.12 — Front Head (Electrical) 9-17
9.2.13 — Pressure Controls 9-19
9.2.14 — Oil/Air Piping, Front Head (Light Oil) 9-20
9.2.15 — Rear Head Sealing-Davit 9-22
9.2.16 — Furnace Liner/Bricking 9-23
9.2.17 — Throat Tile and Furnace Liner 9-25
9.2.18 — Blower Assembly 9-27
9.2.19 — Temperature Controls 9-30
CHAPTER 10 Gas Train Parts Lists 10-1

10.1 — Standard Main Gas Train 10-1
10.2 — Starter Gas Train Butterfly Valve: All Boilers 10-1
10.3 — Pilot Gas Trains: All Boilers 10-2

10.3.1 — Standard & CSD-1 Pilot Gas Train 10-2
10.3.2 — NFPA85 Pilot Gas Train 10-2
10.4 — Standard Main Gas Trains 10-3

10.4.1 — 60, 30, &20 PPM Standard Main Gas Train 10-3
10.4.2 — 60, 30, & 20 PPM W/NFPA-85 10-5
10.4.3 — 60, 30, & 20 PPM, 600 HP Standard Main Gas Train 10-6
10.4.4 — 60, 30, & 20 PPM, 600 HP W/NFPA-85 10-7
10.4.5 — 60, 30, & 20* PPM, 700 & 800 HP Standard Main Gas Train 10-8
60, 30, & 20* PPM, 700 & 800 HP W/FM 10-8
10.4.6 — 60, 30, & 20* PPM, 700 & 800 HP Standard Main Gas Train W/NFPA-
85 10-9
750-94 (revised 2009) xi

xii 750-94 (revised 2009)
PREFACE
Safety Precautions
It is essential to read and understand the following safety precautions before attempting to operate the
equipment. Failure to follow these precautions may result in damage to equipment, serious injury, or
death. A complete understanding of this manual is required before attempting to startup, operate, or
maintain the equipment. The equipment should be operated only by personnel who have a working
knowledge and understanding of the equipment.
! Important
The following symbols are used throughout this manual:
! Warning
750-94 (revised 2009) xiii

! Caution
could result in damage to the equipment.
NOTE: This symbol indicates information that is vital to the operation of the equipment.
! Warning
• 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 injury or death.

This operating manual presents information that will help to properly operate and care for the equip-
ment. Study its contents carefully. The unit will provide good service and continued operation if
proper operating and maintenance instructions are followed. No attempt should be made to operate
the unit until the principles of operation and all of the components are thoroughly understood. Failure
to follow all applicable instructions and warnings may result in severe injury or death.
It is the responsibility of the owner to train and advise, in all aspects of safety, not only his or her per-
sonnel, but the contractors’ personnel who are servicing, repairing, or operating the equipment.
Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the
job. The electrical and mechanical devices supplied as part of the unit were chosen because of their
xiv 750-94 (revised 2009)

known ability to perform, however, proper operating techniques and maintenance procedures must be
followed at all times. Although these components afford a high degree of protection and safety, oper-
ation of equipment is not to be considered free from all dangers and hazards inherent in handling and
firing of fuel.
Any “automatic” features included in the design do not relieve the attendant of any responsibility.
Such features merely free him of certain repetitive chores and give him more time to devote to the
proper upkeep of equipment.
It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount
of written instructions can replace intelligent thinking and reasoning and this manual is not intended
to relieve the operating personnel of the responsibility for proper operation. On the other hand, a
thorough understanding of this manual is required before attempting to operate, maintain, service, or
repair this equipment.
Because of state, local, or other applicable codes, there are a variety of electric controls and safety
devices which vary considerably from one boiler to another. This manual contains information
designed to show how a basic burner operates.
Operating controls will normally function for long periods of time and we have found that some oper-
ators become lax in their daily or monthly testing, assuming that normal operation will continue indef-
initely. Malfunctions of controls lead to uneconomical operation and damage and, in most cases, these
conditions can be traced directly to carelessness and deficiencies in testing and maintenance.
It is recommended that a boiler room log or record be maintained. Recording of daily, weekly,
monthly, and yearly maintenance activities and recording of any unusual operation will serve as a valu-
able guide to any necessary investigation.
Most instances of major boiler damage are the result of operation with low water. We cannot empha-
size too strongly the need for the operator to periodically check his low water controls and to follow
good maintenance and testing practices. Cross-connecting piping to low water devices must be inter-
nally inspected periodically to guard against any stoppages which could obstruct the free flow of water
to the low water devices. Float bowls of these controls must be inspected frequently to check for the
presence of foreign substances that would impede float ball movement.
The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be
inspected frequently to check for the presence of any mud, sludge, scale, or corrosion.
750-94 (revised 2009) xv

The services of a qualified water treating company or a water consultant to recommend the proper
boiler water treating practices are essential.
The operation of this equipment by the owner and his or her operating personnel must comply with
all requirements or regulations of the owner’s insurance company and/or other authority having juris-
diction. In the event of any conflict or inconsistency between such requirements and the warnings or
instructions contained herein, please contact Cleaver-Brooks before proceeding.
xvi 750-94 (revised 2009)

CHAPTER 1 Basics of Firetube Operation
1.1 — Introduction
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. The vessel contains the water and absorbs the energy generated
from the flame. The front door and rear door provide the seal to contain the hot combustion gasses. Baffles designed into
the doors serve to redirect the combustion gasses through the various firetube passages. The flame originates in the fur-
nace. As the combustion gasses travel down the furnace and through the various firetube channels, heat from the flame and
combustion gasses is transferred to the water. Transferred energy develops into the required steam or hot water. The pri-
mary purpose of the boiler is to supply energy to the facility’s operations — for heat, manufacturing processes, laundry,
kitchen, etc. The nature of the facility’s operation will dictate whether aa steam or hot water boiler should be used.
The general information in this manual applies directly to Cleaver-Brooks Model CB Boilers in sizes ranging from 400
through 800 boiler horsepower for the following fuels:
Series 100 Light Oil (No. 2) only
Series 200 Light Oil (No. 2) or Gas
Series 400 Heavy Oil (No. 6) or Gas
Series 600 Heavy Oil (No. 6) only
Series 700 Gas only
NOTE: Although the Series 400 or 600 burner is designed and designated to burn No. 6 oil, the burner will handle grades 4
and 5 equally well, with some possible modifications. While the manual contains pertinent information on No. 6 fuel oil, all ref-
erences to No. 6 fuel should be considered applicable to all grades of heavy oil.
750-94 (revised 2009) 1-1

FIGURE 1-1. Firetube Boiler (cutaway view)
Rated Capacity 400 through 800 hp

Operating Pressure Steam: 15 - 250 psig, or higher if specified
Hot Water: 30 - 250 psig, or higher if specified
Ignition Automatic
Firing Full Modulation Through Operating Ranges
Burner (Gas) Non-premix, Orificed Type
Air Damper Rotary Type (Electrically Modulated)
The LE option, available on Cleaver-Brooks firetube boilers, reduces nitrogen oxide (NOX) emissions, a major precursor to
ozone pollution (smog). Carbon monoxide (CO) emissions also tend to be lower, die to increased turbulence caused by the
addition of the flue gasses into the combustion air stream, thereby improving combustion.
1-2 750-94 (revised 2009)

1.2 — The Boiler
The LE Option is used on Cleaver-Brooks Model CB firetube boilers firing either natural gas and/or light oil, and is com-
patible with both hot water and steam systems.
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. In this approach, the combus-
tion air fan handles both the combustion air and the recirculated flue gasses. Accordingly, this method is called Induced
Flue Gas Recirculation (IFGR) because the flue gas is “induced” into the fan inlet.
The LE Option, with its various levels of IFGR systems, can affect the selection of the combustion air fan, motor, burner,
and other components. Several different system configurations are available, depending on the requirements for NOX emis-
sions and the fuels used. All systems use similar primary components, but may have different linkage controls, IFGR
damper, fan, and motor sizes.
Always order genuine Cleaver-Brooks parts from your local Cleaver-Brooks authorized representative.
The boiler and related equipment installation are to be in compliance with the standards of the National Board of Fire
Underwriters. Installation should also conform to state and local codes governing such equipment. Prior to installation, the
proper authorities having jurisdiction are to be consulted, permits obtained, etc. All boilers in the above series comply, when
equipped with optional equipment, to Industrial Risk Insurers (IRI), Factory Mutual (FM), or other insuring underwriters
requirements.
1.2 — The Boiler

The Model CB boiler is a packaged firetube boiler of welded steel construction and consists of a pressure vessel, burner,
burner controls, forced draft fan, damper, air pump, refractory, and appropriate boiler trim.
The horsepower rating of the boiler is indicated by the numbers following the fuel series. Thus, CB700-600 identifies a gas-
fired 600 hp boiler.
The firetube construction provides some characteristics that differentiate it from other boiler types. Because of its vessel
size, the firetube contains a large amount of water, allowing it to respond to load changes with minimum variation in steam
pressure.
Firetube boilers are rated in boiler horsepower (BHP), which should not be confused with other horsepower measurements.
Hot water is commonly used in heating applications with the boiler supplying water to the system at 180º F to 220º F. The
operating pressure for hot water heating systems usually in 30 psig to 125 psig.
Steam boilers are designed for low pressure or high pressure applications. Low pressure boilers are limited to 15 psig design,
and are typically used for heating applications. High pressure boilers are typically used for process loads and can have a
design pressure of 75 to 350 psig.
Steam and hot water boilers are defined according to design pressure and operating pressure. Design pressure is the maxi-
mum 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. Typically, the safety valves are set at or below design pressure. Oper-
ating pressure is the pressure of the boiler at which it normally operates. The operating pressure usually is maintained at a
suitable level below the setting of the pressure relieving valve(s) to prevent their frequent opening during normal operation.
750-94 (revised 2009) 1-3

The type of service that your boiler is required to provide has an important bearing on the amount of waterside care it will
require.
! Caution
Waterside care is of prime importance. For specific information or assistance with your water treatment requirements, con-
tact your Cleaver-Brooks service and parts representative. Failure to follow these instructions could result in equipment
damage.
Feedwater equipment should be checked and ready for use. Be sure that all valves, piping, boiler feed pumps, and receivers
are installed in accordance with prevailing codes and practices.
Water requirements for both steam and hot water boilers are essential to boiler life and length of service. Constant attention
to water requirements will pay dividends in the form of longer life, less downtime, and prevention of costly repairs. Care
taken in placing the pressure vessel into initial service is vital. The waterside of new boilers and new or remodeled steam or
hot water systems may contain oil, grease, or other foreign matter. A method of boiling out the vessel to remove accumula-
tions is described in Chapter 3.
The operator should be familiar with Chapter 3 before attempting to place the unit into operation.
1.3 — Construction
Steam boilers designed for 15 psig and hot water boilers designed for 250º F at 125 psi or less are constructed in accordance
with Section IV, Power Boilers, of ASME Code.
Steam boilers designed for operating pressures exceeding 15 psig are constructed in accordance with Section 1, Power Boil-
ers, of the ASME Code. hot water boilers designed for operating temperatures above 250º F or 125 psi are likewise built to
ASME Code.
1-4 750-94 (revised 2009)

FIGURE 1-2. Steam Boiler: Light Oil or Gas Fired
1.4.1 — Operating Limit Pressure Control

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.
1.4.2 — High Limit Pressure Control

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. The high limit pressure control is normally equipped with a
manual reset.
750-94 (revised 2009) 1-5

1.4.3 — Modulating Pressure Control

Senses changing boiler pressures and transmits the information to the modulating motor to change the burner firing rate
when the manual-automatic switch is set on “automatic.”
FIGURE 1-3. Boiler Controls
1.4.4 — Low Water Cutoff and Pump Control

Float-operated control responds to the water level in the boiler. It performs two distinct functions:
• Stops firing of the burner if water level lowers below the safe operating point. Energizes the low-water light in the con-
trol panel, and it also causes the low-water alarm bell (optional equipment) to ring. Code requirements of some models
require a manual reset type of low-water cutoff.
• Starts and stops the feedwater pump (if used) to maintain water at the proper operating level.
FIGURE 1-4. Low Water Cutoff Pump Control.
1-6 750-94 (revised 2009)

! Caution
Determine that the main and auxiliary low water cutoffs and pump control are level after installation and throughout the equip-
ment’s operating life. Failure to follow these instructions could result in equipment damage.
1.4.5 — Water Column Assembly

Houses the low-water cutoff and pump control and includes the water gauge glass and gauge glass shutoff cock.
1.4.6 — Water Column Drain Valve

Provided so that the water column and its piping can be flushed regularly to assist in maintaining cross-connecting piping
and in keeping the float bowl clean and free of sediment. A similar drain valve is furnished with auxiliary low-water cutoff
for the same purpose.
1.4.7 — Water Gauge Glass Drain Valve

Provided to flush the gauge glass.
FIGURE 1-5. Water Column Assembly & LWCO
1.4.8 — Vent Valve

Allows the boiler to be vented during filling, and facilitates routine boiler inspection as required by ASME Code.
1.4.9 — Steam Pressure Gauge

Indicates boiler internal pressure.
750-94 (revised 2009) 1-7

1.4.10 — Auxiliary Low-Water Cutoff

Breaks the circuit to stop burner operation in the event boiler water drops below the master low-water cutoff point. Manual
reset type requires manual resetting in order to start the burner after a low-water condition.

Prevents buildup over the design pressure of the pressure vessel. The size, rating, and number of valves on a boiler is deter-
mined by the ASME Boiler Code. The safety valve and the discharge piping are to be installed to conform to the ASME
Code requirements. The installation of a valve is of primary importance to its service life. A valve must be mounted in a ver-
tical position so that discharge piping and code required drains can be properly piped to prevent buildup of back pressure
and accumulation of foreign material around the valve seat area. Apply only a moderate amount of pipe compound to male
threads and avoid overtightening, which can distort the seats. Use only flat-jawed wrenches on the flats provided. When
installing a flange-connected valve, use a new gasket and draw the mounting bolts down evenly. Do not install or remove
side outlet valves by using a pipe or wrench in the outlet.
FIGURE 1-6. Safety Valve
! Warning
Only properly qualified personnel such as the safety valve manufacturer’s certified representative can adjust or repair the
boiler safety valves. Failure to follow these instructions could result in serious injury or death.
1-8 750-94 (revised 2009)

1.5.1 — Water Pressure and Temperature Gauge

Indicates the internal water pressure and the boiler water temperature.
FIGURE 1-7. Water Pressure and Temperature Gauge & Limit Controls (configurations will vary)
1.5.2 — Operating Limit Temperature Control

Breaks a circuit to stop burner operation on a rise of boiler temperature at a selected setting. It is adjusted to stop or start
the burner at a preselected operating temperature.
1.5.3 — High Limit Temperature Control

Breaks a circuit to stop burner operation on a rise of temperature at a selected setting. It is adjusted to stop burner at a pre-
selected temperature above the operating control setting. The high limit temperature control normally is equipped with a
manual reset.
1.5.4 — Modulating Temperature Control

Senses changing boiler water temperature and transmits the information to the modulating motor to change the burner fir-
ing rate when the manual-automatic switch is set on “automatic.”
1.5.5 — Low-Water Cutoff

Breaks the circuit to stop burner operation if the water level in the boiler drops below a safe operating point, activating a
low-water light and optional alarm bell if burner is so equipped.
1.5.6 — 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.
750-94 (revised 2009) 1-9


Relieves the boiler of pressure higher than the design pressure or a lower pressure, if designated. Relief valves and their dis-
charge piping are to be installed to conform to ASME Code requirements.
! Warning
Only properly qualified personnel such as the safety valve manufacturer’s certified representative can adjust or repair the
boiler safety valves. Failure to follow these instructions could result in serious injury or death.
1.6.1 — Flue Gas Transfer Port, IFGR Damper, & Flange Collar
The flue gas transfer port is a tube that allows the flue gasses to travel from the exit of the fourth-pass tubes to the entrance
of the combustion air fan.
The IFGR damper controls the volume of flue gas induced into the combustion air stream. The damper is located in the
flue gas transfer port and is positioned by the control linkage.
1.6.2 — IFGR Damper Linkage

The IFGR damper is positioned by the control linkage. The linkage could consist of a single arm, or it could consist of sev-
eral arms driven from the jackshaft to provide modulating control.
FIGURE 1-8. Induced Flue Gas Recirculation System
1-10 750-94 (revised 2009)

1.6.3 — Over-Travel Mechanism

The over-travel mechanism has two functions. It allows the linkage to pass through the front door, and it allows jackshaft
rotation to exceed (over-travel) IFGR linkage movement. A set of springs allows the linkage to stay in a fixed position while
the jackshaft rotates.
1.6.4 — Fuel Change-Over Linkage

When a boiler is equipped to fire either gas or oil (dual fuel boilers), and the required NOX levels are below 60 ppm on nat-
ural gas, a dual linkage arrangement is used to provide the different recirculation rates required for each fuel. Two jackshaft
drive arms are provided, one for oil and one for gas. The linkage is manually connected to the appropriate arm, based on the
fuel being used.
On dual fuel boilers with two jackshaft drive arms, as defined above, a proximity switch is used to prove that the correct
linkage connection is made. (Refer to the wiring diagram provided with the boiler.)
FIGURE 1-9. Damper Linkage
750-94 (revised 2009) 1-11

1.6.5 — Fan/Motor Cassette

The fan and motor assemblies are designed as a cassette so that they can be removed from the front of the boiler without
opening the front door. The front door davit arm can be used to remove the assembly.
FIGURE 1-10. Fan/Motor Cassette
1.6.6 — Burner Drawer

The as spudding pattern for the IFGR system may be different than that of a non-IFGR, High-Turndown CB Burner of
the same horsepower (HP) model designation.
1.6.7 — Combustion Air Inlet

The combustion air inlets are located at the top of the front door. Air enters from the rear of the air inlet shrouds, which
reduces the sound level and captures heat from the boiler and stack flue outlet.
1.6.8 — Front Door Insulation

If NOX emissions are below 60 ppm, the front door is insulated inside to control temperature build up. The insulation is
held in place with wire mesh.
1-12 750-94 (revised 2009)

CHAPTER 2 Burner Operation and Control
2.1 — The Burner

The oil burner is of the low pressure, air atomizing (nozzle) type. The gas burner is of the non-premix orifice type. The
burners are ignited by a spark ignited gas pilot. The pilot is of the interrupted type and is extinguished after main flame is
established.
NOTE: A Series 100 boiler is usually equipped with a light oil pilot, although a gas pilot is also available.
Burners equipped to burn oil and gas (combination burners) include equipment for each distinct fuel. Since the burner uses
only one type of fuel at a time, a gas/oil selector switch is incorporated.
Regardless of which fuel is used, the burner operates with full modulation (within its rated operating range). The burner
returns to minimum firing position for ignition. High-pressure boilers (above 15 psi) can be wired for both low-pressure
and high-pressure modulation, which enables the boiler to operate at lower pressure during off-load hours, but at a some-
what reduced steam output, dependent upon lower steam pressure and steam nozzle sizing.
The flame safeguard and program relay include a flame detector to supervise both oil and gas flames, and to shut the burner
down in the event of loss of flame. The programming portion of the control provides a pre-purging period, proving of the
pilot and main flame, and a period of continued blower operation to post-purge the boiler of all unburned fuel vapor. Other
safety controls shut down the burner under low-water conditions, excess steam pressure, or water temperature.
Safety interlock controls include combustion and atomizing air proving switches and, depending upon the fuel and insur-
ance carrier requirements, controls that prove the presence of adequate fuel pressure, plus temperature proving controls
when heated fuel oil is used.
The sequence of burner operation from startup through shutdown is governed by the program relay in conjunction with
the operating, limit, and interlock devices. The devices are wired into the circuitry to provide safe operation and protect
against incorrect operating techniques.
All CB boilers have the burner assembly attached to the front head. The entire head may be swung open for inspection and
maintenance.
Combustion air is provided by a centrifugal blower located in the front head. Combustion air delivery to the burner is under
the control of the damper motor. The motor also regulates the flow of fuel through a linkage system connected to the gas
750-94 (revised 2009) 2-1

butterfly valve and/or oil through a cam operated metering valve. Fuel input and air are thus properly proportioned for
most efficient combustion.
Filtered primary air for atomizing fuel oil is furnished independently of combustion air by an air compressor. 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.
Indicator lights signaling load demand, fuel valve, low water, and flame failure conditions are standard equipment.
In addition to the standard basic controls supplied, other devices may be required to meet specific requirements of an insur-
ance carrier or local code. Refer to the Wiring Diagram (WD) prepared by Cleaver-Brooks for your specific installation to
determine the specific controls in the burner and limit control circuits. The function of individual components is outlined in
this chapter and the electrical sequence is covered in Chapter 3.

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.
The actual controls furnished with any given boiler will depend upon the type of fuel for which it is equipped, and whether
it is a hot water or steam boiler. Refer to the applicable group or groups within this chapter that apply to the particular
boiler.
NOTE: Boilers with optional features may have control components not listed here.
2-2 750-94 (revised 2009)

FIGURE 2-1. Boiler Components
Forced Draft Fan Motor Drives forced draft fan directly to provide combustion air.
Also referred to as a blower motor.
Forced Draft Fan Provides all air, under pressure, for combustion of pilot fuel
and main fuel, and for purging.
Modulating Motor Operates the rotary air damper and fuel metering valves
through a cam and linkage system to provide proper air/
fuel ratios under all boiler load conditions.
Modulating Motor Transformer (located Reduces control circuit voltage (115 Vac) to required volt-
in the modulating motor) age (24 Vac) for operation of the modulating motor.
Forced Draft Fan Motor Starter Energizes forced draft fan (blower) motor.
Ignition Transformer Provides high voltage spark for ignition of gas pilot or light
oil pilot.
Low Fire Switch An internal auxiliary switch, cam actuated by the motor
shaft, which must be closed to indicate that the air damper
and fuel metering valve are in the low fire position before
an ignition cycle can occur.
750-94 (revised 2009) 2-3

Atomizing Air Proving Switch A pressure sensitive switch actuated by air pressure from
the air pump. Its contacts close to prove presence of atom-
izing air. The fuel valves cannot be energized unless this
switch is satisfied.
Manual-Automatic Switch When set at “automatic,” subsequent operation is at the
command of the modulating control, which governs the
position of the modulating motor in accordance with load
demand. When set at “manual,” the modulating motor,
through the manual flame control, can be positioned at a
desired burner firing rate. The primary purpose of the man-
ual position is for testing and setting the air/fuel ratio
Manual Flame Control A manually operated potentiometer that permits the posi-
tioning of the modulating motor to a desired burner firing
rate when the manual-automatic switch is set on “manual.”
It is used primarily for initial or 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.”
Burner Switch A manually operated start-stop switch for directly starting
and stopping burner operation.
Flame Detector Monitors gas or oil pilot and energizes the programmer
flame relay in response to a flame signal. It continues to
monitor main flame (oil or gas) after expiration of pilot
providing period. a standardly equipped boiler has a lead
sulfide (infrared sensitive) detector.
Combustion Air Proving Switch A pressure sensitive switch actuated by air pressure from
the forced draft fan. Its contacts close to prove presence of
combustion air. The fuel valves cannot be energized unless
this switch is satisfied.
Alarm Sounds to notify the operator of a condition requiring
attention. The alarm is available as optional equipment.
Stack Thermometer Indicates temperature of vented flue gasses.
Diffuser A circular plate, located at the furnace end of the burner
drawer, that imparts a rotary swirling motion to combus-
tion air immediately prior to its entering the flame, thus
providing a thorough and efficient mixture with the fuel.
Rotary Air Damper Provides accurate control of combustion air in proportion
to fuel input for various load demands. It consists of two
concentric cylinders with openings. The outer is stationary.
The inner is rotated, under control of the modulating
motor, to vary the effective size of the openings where they
overlap.
2-4 750-94 (revised 2009)

Indicator Lights Provide visual information of boiler operation as follows:
• Flame Failure
• Load Demand
• Low Water
Program Relay and Flame Safeguard Automatically programs each starting, operating, and shut-
Control down period in conjunction with operating limit and inter-
lock devices. Includes, in a timed an proper sequence, the
operation of the blower motor, ignition system, fuel
valve(s), and the damper motor. The sequence includes air
purge periods prior to ignition and upon burner shutdown.
The flame detector portion of the control monitors both oil
and gas flames and provides protection in the event of loss
of a flame signal.
The control recycles automatically during normal opera-
tion, or following a power interruption. It must be manually
reset following a safety shutdown caused by a loss of flame.
An internal checking circuit, effective on every start, pre-
vents burner operation in the event anything causes the
flame relay to hold in during this period.

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 items listed below.
Gas Pilot Valve A solenoid valve that opens during the ignition period to
admit fuel to the pilot. It closes after main flame is estab-
lished. The sequence of energizing and de-energizing is
controlled by the programming relay. A second gas pilot
valve may be required by insurance regulations.
Gas Pilot Vent Valve When a second gas pilot valve is required, a normally open
vent valve (optional equipment) is installed between them.
Its purpose is to vent gas to the atmosphere, should any be
present in the pilot line when the pilot valves are closed.
The valve closes when the pilot valves are energized.
Gas Pilot Shutoff Cock For manually opening or closing the gas supply to the gas
pilot valve.
Gas Pressure Gauge Indicates gas pressure to pilot.
Gas Pressure Regulating Valve Reduces incoming gas pressure to suit the pilot.
Gas Pilot Aspirator Provides complete mixing of gas and air to the pilot.
Gas Pilot Adjusting Cock Regulates the size of the gas pilot flame.
750-94 (revised 2009) 2-5

Gas Modulating Cam An assembly, consisting of a quadrant, a series of adjustable
allen-head screws, and a contour spring, provided for
adjustment of gas input at any point in the modulating
range.
Main Gas Cock For manually opening and closing the main fuel gas supply
downstream of the main gas line pressure regulator. A sec-
ond shutoff cock, downstream of the main gas valve(s), is
installed to provide a means of shutting off the gas line
whenever a test is made for leakage across the main gas
valve.
Butterfly Gas Valve The pivoted disc in the valve is actuated by connecting link-
age from the gas modulating cam to regulate the rate of gas
flow to the burner.
Main Gas Valves Electrically actuated shutoff valves that open simultane-
ously to admit gas to the burner. The downstream valve is
equipped with a “proof of closure” switch that is connected
into the pre-ignition interlock circuit.
Main Gas Vent Valve A normally open solenoid valve installed between the two
main gas valves to vent gas to the atmosphere should any
be present in the main gas line when the gas valves are de-
energized. The vent valve closes when the gas valves are
energized.
Low Gas Pressure Switch A pressure actuated switch that is closed whenever main
gas line pressure is above a preselected pressure. Should the
pressure drop below the setting, the switch contacts open a
circuit causing the main gas valve(s) to close, or prevent the
burner from starting. The switch is usually equipped with a
device that must be manually reset after being tripped.
High Gas Pressure Switch A pressure actuated switch that is closed whenever main
gas line pressure is below a preselected pressure. Should the
pressure rise above the setting, the switch contacts will
open a circuit causing the main gas valve(s) to close, or pre-
vent the burner from starting. The switch is usually
equipped with a device that must be manually reset after
being tripped.
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.
2-6 750-94 (revised 2009)

FIGURE 2-2. Gas Train (configurations may vary)
FIGURE 2-3. Gas Modulating Cam
750-94 (revised 2009) 2-7


The following items are applicable to all oil-fired or gas and oil-fired boilers. Additional controls for No. 6 oil are listed in
section 2.9 — Automatic Ignition.
FIGURE 2-4. Front of Burner Drawer.
Oil Drawer Switch Opens the limit circuit if oil drawer burner gun is not
latched in the forward position required for burning oil.
Atomizing Air Proving Switch Pressure actuated switch whose contacts are closed when
sufficient atomizing air pressure from the air pump is pres-
ent for oil firing. Oil valve(s) will not open, or will not
remain open, unless switch contacts are closed.
Atomizing Air Pressure Gauge Indicates the atomizing air pressure at the burner gun.
Oil Solenoid Valve Opens when energized through contacts in the program-
mer and allows fuel oil flow from the oil metering valve to
the burner nozzle. A light oil fired burner uses two valves
operating simultaneously.
2-8 750-94 (revised 2009)

Fuel Oil Controller An assembly combining into a single unit the gauges, regu-
lators, and valves required for regulating the flow of fuel oil.
All controllers have the following integral parts. In addition
to these, the controller used on a No. 6 oil fired burner has
additional components described in section 2.1.
• Oil Metering Valve: Valve metering stem moves to
increase or decrease the orifice area to regulate the sup-
ply of fuel oil to the burner nozzle in accordance with
boiler load variances. Stem movement is controlled by
the modulating motor through linkage and the oil
metering cam.
• Oil Modulating Cam: Assembly consisting of a quad-
rant, a series of adjustable allen-head screws and a con-
tour spring provided for adjustment of oil input at any
point in the modulating range.
• Oil Burner Pressure Gauge: Indicates pressure of the
fuel oil at the metering valve.
• Oil Pressure Regulator: For adjustment of the pressure
of oil at the metering valve.
Oil Relief Valve Maintains a constant oil supply pressure to the fuel oil con-
troller by bypassing excess fuel oil.
Terminal Block
Fuel Oil Strainer Prevents foreign matter from entering the burner system.
Gas Pilot See section 2.4 for description of the various components.
Light Oil Pilot Valve: When a light oil pilot is furnished, a solenoid valve is pro-
vided to control flow of fuel to the pilot nozzle. It is ener-
gized through programmer contacts. It is de-energized to
shut off pilot fuel flow after main flame is ignited and
established.
Back Pressure Orifice A restriction located in the oil return line immediately
downstream of the fuel oil controller to create back pres-
sure (100 and 200 series only).
750-94 (revised 2009) 2-9

Air Pump Module Assembly Provides the compressed air required to atomize the fuel oil
for proper combustion. It is started automatically by the
programmer’s sequence. Components include:
• Air Pump Motor: Drives the air pump and an air cool-
ing fan. The motor is started and stopped simultane-
ously with the forced draft fan motor.
• Air Pump: Provides air for atomization of the fuel oil.
• Air Filter: The filter cleans the air supply prior to enter-
ing the air pump.
• Check Valve: Prevents lubricating oil and compressed
air from surging back through the pump and air filter
when the pump stops.
• Air-Oil Receiver Tank: Holds a supply of oil for lubri-
cating the air pump. The receiver tank also separates
lube oil from the atomizing air before delivery to the
nozzle.
• Lube Oil Level Sight Glass: Indicates the level of lubri-
cating oil in the air-oil receiver tank.
• 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.
• Lube Oil Fill Pipe and Strainer: Used when adding oil to
the air-oil receiver tank.
Low Oil Pressure Switch (optional) Switch contacts open when the fuel oil pressure drops
below selected pressure. Switch will interrupt the limit cir-
cuit upon loss of sufficient fuel oil pressure for correct
combustion.
Fuel Oil Pump Transfers fuel oil from the storage tank and delivers it
under pressure to the burner system.
2-10 750-94 (revised 2009)

FIGURE 2-5. Oil Control Valve Assembly - Light Oil
FIGURE 2-6. Oil Control Valve Assembly - Heavy Oil
750-94 (revised 2009) 2-11

FIGURE 2-7. Air Pump Components

The oil heater is provided to heat heavy oil to the point where it can be effectively atomized and burned. Most heavy oil
heaters utilize an electric heater to reduce the viscosity of the heavy oil until steam or hot water is available to the oil heater
shell.
Heavy oil heaters, operating with hot water, will have additional controls.
Heater Switch Manually provides power to the oil heater system.
Oil Heater (electric) Used for heating sufficient fuel oil for low-fire flow during
cold starts before steam or hot water is available for heat-
ing. The heater must be turned off during extended boiler
lay-up, or at any time the fuel oil transfer pump is stopped.
Electric Oil Heater Thermostat Senses fuel oil temperature and energizes or de-energizes
the electric oil heater to maintain required temperature of
the fuel oil.
Steam Oil Heater Thermostat Senses fuel oil temperature and controls the opening and
closing of the steam heater valve to maintain the required
temperature of the fuel oil.
2-12 750-94 (revised 2009)

Oil Heater Shell (steam/hot water) Heats fuel oil through medium of steam or hot water. Elec-
tric heater is housed in the steam heater, but is housed sep-
arately on a hot water heater. Steam oil heaters on 15 psi
boilers operate at boiler pressure. Steam oil heaters fur-
nished on high pressure boilers are to be operated at less
than 15 psi. Operation is accomplished with a steam pres-
sure regulator valve.
Oil Return Excess oil returned to the heavy oil supply tank.
Oil Inlet From Supply Tank Heavy oil inlet from the supply tank.
Steam Heater Check Valve Prevents oil contamination of the waterside of pressure ves-
sel should any leakage occur in the oil heater.
Steam Trap Drains condensate and prevents loss of steam from the
steam oil heater. Condensate must be piped to a safe point
of discharge.
Check Valve (steam heater discharge) Prevents air entry during shutdown periods when cooling
action may create vacuum within steam heater.
Steam Heater Pressure Regulator Adjust to provide reduced (usually less than 15 psi) steam
pressure to the heater to properly maintain the required fuel
oil temperature. The regulator and the pressure gauge are
not furnished on 15 psi units.
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.
Steam Pressure Gauge Indicates steam pressure entering the heater.
Oil Relief Valve allows release of excessive pressure to the return side of the
oil line piped to the tank.
Low Oil Temperature Switch Thermostatic switch that prevents burner from starting, or
stops burner firing if fuel oil temperature is lower than
required for oil burner operation.
Oil Supply Pressure Gauge Indicates fuel oil pressure in the oil heater and supply pres-
sure to the fuel oil controller’s pressure regulator.
750-94 (revised 2009) 2-13

FIGURE 2-8. Oil Heating Assembly (Steam)
In addition to the components of the fuel oil controller identified in section 2.5, the following are used with a heavy oil fired
burner.
High Oil Temperature Switch (optional) Switch contacts open when fuel oil temperature raises
above a selected temperature. Switch will interrupt the limit
circuit in the event fuel oil temperature rises above the
selected point.
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.
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.
Fuel Oil Thermometer Indicates temperature of fuel oil being supplied to the fuel
oil controller.
Back Pressure Valve For adjustment of oil pressure on the downstream side of
the metering valve. Also regulates rate and return oil flow.
Oil Return Pressure Gauge Indicates oil pressure on the return side of the fuel oil con-
troller.
Manual Bypass Valve Provided as a timer saver in establishing oil flow. When
open, it permits circulation of oil through the supply and
return lines. The valve MUST be closed prior to initial light
off.
2-14 750-94 (revised 2009)

Orifice Oil Control Valve Valve may be opened prior to startup to aid in establishing
fuel oil flow through the controller. The valve MUST be
closed prior to initial light off. Its disc has an orifice to per-
mit a continuous circulation of hot fuel oil through the con-
troller.
Air Purge Valve Solenoid valve opens simultaneously with closing of oil
solenoid valve at burner shutdown, allowing compressed air
to purge oil from the burner nozzle and adjacent piping.
The oil is burned by the diminishing flame, which continues
burning for approximately 4 seconds after the oil solenoid
valve closes.
Air Purge Orifice Nozzle Limits purging air to proper quantity for expelling
unburned oil at normal delivery rate.
Air Purge Orifice Nozzle Filter Filters the purging air of any particles that might plug the
air purge orifice nozzle.
Air Purge Check Valve Valve check prevents fuel oil from entering the atomizing
air line.
Air Purge Relay When energized, control operation of air purge valve.

Burners equipped to burn either oil or gas include equipment for each fuel. The Gas-Oil Selector Switch engages the appro-
priate interlocks and controls for gas or oil operation. Chapter 4 details the required mechanical functions of each fuel sys-
tem.
2.8 — Combustion Air

Air for combustion of fuel (referred to as “secondary” air) is furnished by the
forced draft fan mounted in the boiler head. In operation, air pressure is built up in
the entire head and is forced through a diffuser plate for a thorough mixture with
the fuel for proper combustion. The supply of secondary air to the burner is gov-
erned by automatically throttling the output of the fan by regulating the rotary air
damper. The damper provides the proper amount of air for correct ratio of air to
fuel for efficient combustion at all firing rates.
FIGURE 2-9. Secondary Air Flow Diagram
750-94 (revised 2009) 2-15

2.9 — 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. All other burners are equipped with a gas
burning pilot. In the case of a combination burner, the gas pilot is used to ignite either the main gas flame or the oil flame.
Either pilot serves the same function. (The term “pilot” is used interchangeably.)
At the beginning of the ignition cycle, and governed by the program relay, the pilot solenoid valve and ignition transformer
are simultaneously energized.
The ignition transformer supplies high voltage current for the igniting spark. A gas pilot has a single electrode and a spark
arcs between the tip of the electrode and the wall of the tube surrounding it. A light oil pilot has two electrodes and the arc
is between their tips. The pilot solenoid valve and the transformer are de-energized after main flame is ignited and estab-
lished.
Fuel for the gas pilot is supplied from the utility’s main, or from a tank (bottle) supply. Secondary air flows into and mixes
with the pilot gas stream to provide an adequate flame.
Insurance regulations may require two gas pilot solenoid valves with a normally open vent valve between them. The vent
valve closes when the gas pilot valves open, and opens when the gas pilot valves shut to vent gas, should any be present in
the pilot line during the de-energized period of the gas pilot valves.
Fuel for a light-oil pilot is provided from the line that supplies oil under pressure for the main flame. A solenoid actuated
valve controls flow of oil to the pilot nozzle. The valve is energized simultaneously with the ignition transformer at the
beginning of the ignition cycle and is de-energized after main flame is ignited and established.

Air for atomizing the fuel oil (referred to as “primary” air) is pumped by the air pump into the air-oil receiver tank and deliv-
ered under pressure through a manifold block to the oil burner nozzle.
The atomizing air mixes with the fuel oil just prior to the oil leaving the nozzle.
Atomizing air pressure is indicated by the air pressure gauge on the burner gun.
Air pressure from the pump also forces sufficient oil from the tank to the pump bearings to lubricate them and also to pro-
vide a seal and lubrication for the pump vanes. As a result, the air delivered to the tank contains some lube oil, however,
most of it is recovered 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. Further explanation is given
in chapter 5.
2-16 750-94 (revised 2009)


Fuel oil is delivered into the system by a supply pump which delivers part of its discharge to the oil burner. Excess oil is
returned to the oil storage tank through the fuel oil relief valve and oil return line. Normally the pump operates only while
the burner is in operation, although a positioning switch is often provided so that either continuous or automatic pump
operation can be obtained (See Figure 2-10).
The oil flows through a fuel oil strainer to prevent any foreign material from flowing through the control valves and nozzle.
The fuel oil controller contains in a single unit, a metering valve, a regulator, and a gauge required to regulate the pressure
and flow of oil to the burner. The adjustable regulator controls the pressure. To assist in the regulation, back pressure is cre-
ated by an orifice nozzle located in the oil return line immediately downstream of the fuel oil controller.
The programming relay energizes or de-energizes the solenoid oil valves to permit or cut off oil flow to the burner. Two
valves, operating simultaneously, are used. The valves are closed when de-energized. They cannot be opened (energized)
unless the combustion air proving switch and the atomizing air proving switch are closed. The two switches are satisfied,
respectively, by sufficient combustion air pressure from the forced draft fan and pressurized air from the air pump.
The oil flow to the burner is controlled by the movement of the metering stem in the oil metering valve, which varies the
flow to meet load demands. The metering valve and the air damper are controlled simultaneously at all times by the modu-
lating motor to proportion combustion air and fuel for changes in load demand.
750-94 (revised 2009) 2-17

FIGURE 2-10. Light Oil Flow Diagram

Fuel oil is delivered into the system by the fuel oil supply pump which delivers part of its discharge to the oil heater. The
remainder of the fuel oil returns to the oil storage tank through a fuel oil relief valve and oil return line (see Figure 2-11).
The combination electric and steam oil preheater is controlled by thermostats. The electric oil heater thermostat energizes
the electric heater, which is provided to supply heated oil on cold starts. The steam heater thermostat controls operation of
the steam solenoid valve to permit a flow of steam to the heater when steam is available.
2-18 750-94 (revised 2009)

A hot water boiler is equipped to heat the oil with hot water from the boiler, unless other preheating equipment is utilized.
The electric heater, which is housed separately, is sized to provide heated oil on a cold start. The hot water thermostat con-
trols the operation of a pump that supplies hot water to the oil heater when hot water is available.
The heated oil flows through a fuel oil strainer to prevent any foreign matter from entering the control valves and nozzle.
The fuel oil controller contains, in a single unit, the necessary valves, regulators and gauges to regulate the pressure and flow
of oil to the burner.
The program relay energizes or de-energizes the solenoid oil valve to permit or cut off oil flow to the burner. The oil sole-
noid is closed when de-energized. It cannot be opened (energized) unless the combustion air proving switch, the atomizing
air proving switch, and the low oil temperature and any pressure switches are closed. They are satisfied, respectively, by suf-
ficient combustion air pressure from the forced draft fan, pressurized air from the air pump, and sufficient oil temperature
and pressure.
Oil flow to the burner is controlled by the movement of the metering stem of the oil metering valve, which varies the flow
to meet load demands. The metering valve and the air damper are controlled simultaneously at all times by the modulating
motor to proportion combustion air and fuel for changes in load demand.
Oil is purged from the burner gun upon each burner shutdown. The air purge solenoid valve opens as the fuel valve closes,
diverting atomizing air through the oil line. The air assures a clean nozzle and line for subsequent restart.
750-94 (revised 2009) 2-19

FIGURE 2-11. No. 6 Heavy Oil Flow Diagram (Steam-Electric Heater)

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.
The main gas valve is of the normally closed type, and is opened (energized) in proper sequence by the programming relay.
2-20 750-94 (revised 2009)

The butterfly gas valve modulates the flow of gas from low through high fire settings. The position of the butterfly valve
disc is governed by the gas modulating cam. The butterfly gas valve, and the air control damper are controlled simultane-
ously by the modulating motor to proportion combustion air and fuel for changes in load demand.
The gas flow rate required for rated burner input depends upon the heating value (Btu/cubic foot) of the gas supplied. The
gas pressure regulator adjusts the gas pressure (flow rate) to the entrance of the gas train. The regulator is not always sup-
plied with the burner, but may be provided by others.
The main gas valves cannot be energized (opened) unless the combustion air proving switch is closed to indicate a sufficient
supply of combustion air. The low gas pressure and high gas pressure switches must be closed to prove sufficient, but not
excessive, gas fuel pressure.

The modulating motor, through a linkage arrangement, controls the air damper and the butterfly gas valve, or the oil meter-
ing valve, to maintain a constant air/fuel ratio throughout the firing range.
During burner operation, the motor is controlled by a modulating pressure control on a steam boiler, or by a modulating
temperature control on a hot water boiler. A manually operated potentiometer is provided to permit positioning of the
motor at the desired burner firing rate. The potentiometer is used primarily for initial or subsequent checking and setting of
fuel input. Normal operation should be with the manual-automatic switch in the “automatic” position and under the con-
trol of the modulating control.
The modulating motor (commonly called a damper motor) is reversible. It has an internal limit switch that restricts shaft
rotation to 90º. During normal operation the motor will move in either direction or stop at any position within the range.
The motor potentiometer is electrically connected to a matching potentiometer in the modulating control. Changing steam
pressure or water temperature alters the electrical resistance of the modulating controller potentiometer. The change in
resistance compels an integral balancing relay to start, stop, or reverse the motor rotation. Rotation in either direction con-
tinues until the resistance ratio of the two potentiometers is equal.
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. A low-fire switch, integral to the motor, is actuated by the rotation of the motor.
The switch must be closed to establish that the damper and fuel metering valves are in the low-fire position before the pro-
grammer commences into the ignition period. During this time, neither the manual flame control nor the modulating con-
trol have any control over the damper motor, regardless of their setting.
An optionally equipped boiler uses a second integral switch to establish that the motor has driven the damper to an open
position during the pre-purge period. The second integral switch closes, as high fire position is approached, to complete an
internal circuit in the programmer to allow continuation of the programming cycle.
750-94 (revised 2009) 2-21

2-22 750-94 (revised 2009)

CHAPTER 3 Waterside Care and
Requirements
3.1 — Overview
The operator should be familiar with this chapter 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.
Feedwater equipment should be checked and ready for use. Be sure that all valves, piping, boiler feed pumps, and receivers
are installed in accordance with prevailing codes and practices.
Water requirements for both steam and hot water boilers are essential to boiler life and length of service. It is vital care be
taken in placing the pressure vessel into initial service. The waterside of new boilers and new or remodeled steam or hot
water systems may contain oil, grease, or other foreign matter. A method of boiling out the vessels to remove the accumula-
tions is described later in this chapter.
Boilers, as a part of a hot water system, require proper water circulation. The system must be operated as intended by its
designer in order to avoid thermal shock or severe, possibly damaging, stresses from occurring to the pressure vessel.
NOTE: This manual only covers boilers using water. Glycol solutions have different operating requirements, circulation rates,
temperatures, etc.
3.2.1 — Air Removal

The hot water outlet includes a dip tube which extends 2 to 3 inches into the boiler. The dip tube reduces the possibility of
air, which may be trapped at the top of the shell, from entering into the system. Oxygen or air released in the boiler will col-
lect or be trapped at the top of the boiler shell.
The air vent tapping on the top center line of the boiler should be piped into the expansion or compression tank. Air
trapped at the top of the boiler will find its way out of the boiler through the tapping.
750-94 (revised 2009) 3-1

3.2.1.1 — Minimum Water Temperature

The minimum recommended boiler water temperature is 170º F. When water temperatures lower than 170º F are used, the
combustion gasses are reduced in temperature to a point where water vapor condenses, causing corrosion in the boiler and
possible breeching.
Condensation is more severe on a unit that operates intermittently and which is greatly oversized for the actual load. Con-
densation can be minimized by maintaining the boiler water temperatures above 170º F.
A temperature of 170º 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. (The electric preheater on
the boiler must provide additional heat to the oil if boiler water temperature is not maintained above 200º F.
NOTE: If the operating water temperature going to the system must be lower than 170º F, the operating boiler water tem-
perature should be a minimum of 170º F (200º F if used to preheat No. 6 oil) and mixing valves should be used to avoid
damage to the equipment.
3.2.1.2 — Rapid Replacement of Boiler Water

The system layout and controls should be arranged to prevent the possibility of pumping large quantities of cold water into
a hot boiler, which will cause shock or thermal stresses. Water temperature in a boiler of 200º F or 240º F cannot be com-
pletely replaced with 80º F water in a few minutes time without causing thermal stress. The same fact applies to periods of
normal operation, as well as during initial startup.
NOTE: The circulating pumps should be interlocked with the burner so that the burner cannot operate unless the circulat-
ing pump is running in order to avoid damage to the equipment.
When individual zone circulating pumps are used, it is recommended that they be kept running, even though the hear users
do not require hot water. The relief device or bypass valve will thus allow continuous circulation through the boiler and can
help prevent rapid replacement of boiler water with cold zone water.
3.2.1.3 — Continuous Flow Through the Boiler

The system should be piped and the controls arranged to allow water circulation through the boiler under all operating con-
ditions. The operation of three-way valves and system controls should be checked to be sure that the boiler will not be
bypassed. Constant circulation through the boiler eliminates the possibility of stratification within the unit and results in
more even water temperatures to the system.
A rule of thumb of 3/4 to 1 gpm per boiler horsepower can be used to determine the minimum continuous flow rate
through the boiler under all operating conditions. The operator should determine that a flow of water exists through the
boiler before initial firing or refiring after the boiler has been drained.
3.2.2 — Water Circulation

The following chart shows the maximum gpm circulation rate of boiler water in relation to full boiler output and system
temperature drop.
3-2 750-94 (revised 2009)


SIZE PUT (1000)
10 20 30 40 50 60 70 80 90 100
(BHP) BTU/HR
15 500 100 50 33 25 20 17 14 12 11 10
20 670 134 67 45 33 27 22 19 17 15 13
30 1,005 200 100 67 50 40 33 29 25 22 20
40 1,340 268 134 89 67 54 45 38 33 30 27
50 1,675 335 168 112 84 67 56 48 42 37 33
60 2,010 402 201 134 101 80 67 58 50 45 40
70 2,345 470 235 157 118 94 78 67 59 52 47
80 2,680 536 268 179 134 107 90 77 67 60 54
100 3,350 670 335 223 168 134 112 96 84 75 67
125 4,185 836 418 279 209 168 140 120 105 93 84
150 5,025 1,005 503 335 251 201 168 144 126 112 100
200 6,695 1,340 670 447 335 268 224 192 168 149 134
250 8,370 1,675 838 558 419 335 280 240 210 186 167
300 10,045 2,010 1,005 670 503 402 335 287 251 223 201
350 11,720 2,350 1,175 784 587 470 392 336 294 261 235
400 13,400 2,680 1,340 895 670 535 447 383 335 298 268
500 16,740 3,350 1,675 1,120 838 670 558 479 419 372 335
600 20,080 4,020 2,010 1,340 1,005 805 670 575 502 448 402
700 23,430 4,690 2,345 1,565 1,175 940 785 670 585 520 470
800 26,780 5,360 2,680 1,785 1,340 1,075 895 765 670 595 535
FIGURE 3-1. Maximum Circulating Rate Chart
3.2.2.1 — Multiple Boiler Installations

When multiple boilers are used, care must be taken to ensure adequate or proportional flow through the boilers. Propor-
tional flow can best be accomplished by use of balancing valves and gauges in the supply line from each boiler. If balancing
valves or orifice plates are used, a significant pressure drop (3 to 5 psi) must be taken across the balancing device to accom-
plish the purpose.
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. The net
result would be that the common header water temperature to the system would not be up to the desired point.
3.2.2.2 — Pump Location

It is recommended that the system circulating pumps take suction from the outlet connection on the boiler, and that they
discharge to the system load in order to put the boiler and the expansion tank on the suction side of the pump. The suction
side is preferred because it decreases air entry into the system and does not impose the system head on the boiler.
750-94 (revised 2009) 3-3

It is common practice to install a standby system circulating pump. The main circulating pumps are usually located adjacent
to the boilers in the boiler room.
3.2.2.3 — Pump Operation

Pumps are normally started and stopped by manual switches. It is also desirable to interlock the pump with the burner so
that the burner cannot operate unless the circulating pump is running.
3.2.3 — Pressure
The design of the system and usage requirements often dictate the pressure exerted upon the boiler. Some systems are pres-
surized with air, or with an inert gas such as nitrogen. Caution must be exercised to ensure that the proper relationship of
pressure-to-temperature exists within the boiler so that all of the boiler’s internal surfaces are fully wetted at all times. For
this reason, the internal boiler pressure, as indicated on the water pressure gauge, must be held to the level identified on Fig-
ure 3-2.
When initially firing a newly installed boiler, or when cutting an existing boiler into an operating system, the boiler or boilers
to be cut into operation MUST be pressurized equal to the system and/or other boilers prior to opening the header valves.
It is advisable to have a thermometer installed in the return line to indicate return water temperature. Knowing the supply
water temperature, the boiler system differential can be established. With knowledge of the pumping rate, the operator can
easily detect any excessive load condition and take appropriate corrective action.
FIGURE 3-2. Internal Boiler Pressure
Special caution must be taken to guard against any condition, or combination of conditions, that might lead to the transfer
of cold water to a hot boiler or hot water to a cold boiler. It cannot be over emphasized that rapid changes in temperature
within the boiler can, and sometimes do, cause damage.
3-4 750-94 (revised 2009)

3.3.1 — 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. After opening the valves, momentarily energize the feed pump motor to establish correct
pump rotation. With the correct rotation established, close the boiler feed pump entrance switch. The pump should shut
down when the water level reaches the proper level (see Figure 3-3).
FIGURE 3-3. Low Water Cutoff Sight Gauge
Feedwater pumps must have adequate capacity to maintain required water level under all operating conditions. Check the
feedwater pumps periodically and maintain as necessary to prevent unexpected breakdowns.
NOTE: Prior to operating the pump, carefully check the alignment of the flexible coupling, if one is used. A properly aligned
coupling will last a long time and provide trouble-free mechanical operation.
3.3.2 — 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. If the valves are installed, it is illegal to operate the boiler with closed or unsealed
open valves.
! Warning
The isolation valves and the water column piping must be locked open during operation. Failure to do so may result in a low
water condition. Failure to follow these instructions could result in serious injury or death.
750-94 (revised 2009) 3-5

3.4 — Water Treatment

Properly treated boiler feed water, coupled with good engineering and operating practices, lead to maximum effectiveness
and long trouble-free life of pressure vessels, at the lowest operating cost. Contact your local Cleaver-Brooks authorized
representative for information on how to prevent the presence of unwanted solids and corrosive gasses.

• Prevent hard scale deposits or soft sludge deposits, which reduce heat transfer and can lead to overheated metal and
costly downtime and repairs.
• eliminate corrosive gasses in the supply or boiler water.
• Prevent intercrystalline cracking or caustic embrittlement of boiler metal.
• Prevent carryover and foaming.
Accomplishment of the above objectives generally requires proper feedwater treatment before and after introduction of the
water into the boiler. The selection of pre-treatment processes depends upon the water source, its chemical characteristics,
amount of makeup water needed, plant operating practices, etc. Treating methods include filtering, softening de-mineraliz-
ing, deaerating, and preheating. After-treatment involves chemical treatment of the boiler water.
Because of the variables involved, no single boiler compound can be considered a “cure-all” nor is it advisable to experi-
ment with homemade treating methods. Sound recommendations and their employment should be augmented by a peri-
odic analysis of the feedwater, boiler water, and condensate.
The internal or waterside surfaces of the pressure vessel should be inspected with enough frequency to determine the pres-
ence of any contamination, accumulations of foreign matter, corrosion, and/or pitting. If any of the conditions are
detected, contact your local Cleaver-Brooks authorized representative for advice on corrective action.
A properly sized water meter should be installed in the raw water make-up line in order to accurately determine the amount
of raw water admitted to the boiler (steam or hot water) and to aid in maintaining proper waterside conditions.
3.5 — Cleaning
3.5.1 — Hot Water and Steam Piping

Steam and water piping systems connected to the boiler may contain oil, grease, or foreign matter. The impurities must be
removed in order to prevent damage to pressure vessel heating surfaces. On a steam system, the condensate should be
wasted until tests show the elimination of undesirable impurities. During the periods 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 corro-
sion does not occur. For more information, contact your local Cleaver-Brooks authorized representative.
On a hot water system, chemical cleaning is generally necessary and the entire system should be drained after treatment.
Consult your local Cleaver-Brooks authorized representative for recommendations, cleaning compounds, and application
procedures.
3-6 750-94 (revised 2009)

3.5.2 — Pressure Vessel

The waterside of the pressure vessel must be kept clean from grease, sludge, and foreign material. Such deposits, if present,
will shorten the life of the pressure vessel, will interfere with efficient operation and functioning of control of safety devices,
and quite possibly cause unnecessary and expensive re-work, repairs, and downtime.
The installation and operating conditions that the boiler will be subjected to should be considered and cleaning of the water-
side of the pressure vessel should be provided during the course of initial start-up.
The pressure vessel and the steam and return lines or hot water piping represent, in effect, a closed system. Although the
steam and return (condensate) lines or the hot water piping system may have been previously cleaned, it is possible that:
• Cleaning has been inadequate.
• Partial or total old system is involved.
• Conditions may prevent adequate cleaning of piping.
The pressure vessel waterside should be inspected on a periodic basis. An inspection will reveal true internal conditions and
serve as a check against conditions indicated by chemical analysis of the boiler water. Inspection should be made three
months after initial starting and at regular 6-, 9-, or 12-month intervals thereafter. The frequency of further periodic inspec-
tions will depend upon the internal conditions found.
If any unwanted conditions are observed, contact you local Cleaver-Brooks authorized representative for recommendations.
Any sludge, mud, or sediment found will need to be flushed out. If excessive mud or sludge is noticed during the blow-
down, the scheduling or frequency of blowdown may need to be revised. The need for periodic draining or washout will
also be indicated.
Any oil or grease present on the heating surfaces should be removed promptly by a boil-out with an alkaline detergent solu-
tion.
NOTE: Temperature of initial fill of water for hydrostatic tests, boil-out, or for normal operation should be as stated in the
ASME Boiler Code.

The internal surfaces of a newly installed boiler may have oil, grease, or other protective coatings used in manufacturing.
Such coatings must be removed because they lower the heat transfer rate and could cause over-heating of a tube. Before
boiling out procedures 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 is strongly recommended when handling or mixing
caustic chemicals. Do not permit the dry material or the concentrated solution to come in contact with skin or clothing. Failure
to follow these instructions could result in serious injury or death.
750-94 (revised 2009) 3-7

Your local Cleaver-Brooks authorized representative will be able to recommend a cleaning or boil-out procedure. In the
event such service is unavailable or is yet unscheduled, the following information may be of assistance.
Several chemicals are suitable for boil-out. One combination often used is soda ash (sodium carbonate) and caustic soda
(sodium hydroxide) at the rate of 3 to 5 pounds each per 1,000 pounds of water, along with a small amount of laundry
detergent added as a wetting agent.
The suggested general procedure for cleaning a boiler is (refer to Figure 3-4 to determine water capacity):
1. Have sufficient cleaning material on hand to complete the job.
2. When dissolving chemicals:
a) warm water should be put into a suitable container
b) slowly introduce the dry chemical into the water, stirring at all times until completely dissolved
c) add the chemical slowly and in small amounts to prevent excessive heat and turbulence
3. An overflow pipe should be attached to one of the top boiler openings and routed to a safe point of discharge. A relief
or safety valve tapping is usually used.
4. Water relief valves and steam safety valves must be removed before adding the boil-out solution so that neither it nor the
grease which it may carry will contaminate the valves. Use care in removing and reinstalling the valves. (Refer to Chapter
8, section 8.-13 for valve installation instructions.)
5. All valves in the piping leading to or from the system must be closed to prevent the cleaning solution form getting into
the system.
6. Fill the pressure vessel with clean water until the top of the tubes is 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.
7. The boiler should then be fired intermittently at a low rate sufficient to hold solution just at the boiling point. Boil the
water for at least five hours. Do not produce steam pressure.
Water - Gallons Water - Weight

Generator Sizes Normal Flooded Normal Flooded
CB-LE 400 HP 1777 2402 14810 20015
CB-LE 500 HP 1914 2796 15950 23300
CB-LE 600 HP 2312 3391 19270 28260
CB-LE 700 HP 2760 4003 23000 33360
CB-LE 800 HP 2760 4003 23000 33360
FIGURE 3-4. Water Capacity and Weights
8. Allow a small amount of fresh water to enter the boiler to create a slight overflow that will carry off surface impurities.
9. Continue the boil and overflow process until the water clears. shut the burner down.
10. Let the boiler cool to 120º F or less.
! Warning
Be sure to drain the hot water to a safe point of discharge to avoid scalding. Failure to follow these instructions could result
11. Remove handhole plates and wash the waterside surfaces thoroughly using a high pressure water stream.
3-8 750-94 (revised 2009)

3.7 — Washing Out
12. Inspect the surfaces. If they are not clean, repeat the boil-out.
13. After closing the handholes and reinstalling the safety or relief valves, fill the boiler and fire it until the water is heated to
at least 180º F to drive off any dissolved gasses, which might otherwise corrode the metal.
The above procedure may be omitted in the case of a unit previously used or known to be internally clean. However, con-
sideration must be given to the possibility of contaminating materials entering the boiler from the system.
On a steam system, the condensate should be wasted until tests show the elimination of undesirable impurities. During the
period that condensate is wasted, be sure make-up water is treated to prevent an accumulation of unwanted materials or cor-
rosion.
On a hot water system, chemical cleaning is generally necessary and the entire system should be drained after treatment.
Consult your local Cleaver-Brooks authorized representative for recommendations, cleaning compounds, and application
procedures.
3.7 — Washing Out

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 of sludge, sediment, scale, etc. on the pressure vessel waterside.
If the operator is absolutely certain that the system is tight, then an annual waterside inspection may be sufficient. However,
if there is any doubt, the pressure vessel waterside should be inspected no later than three months after initially placing the
boiler into operation, and periodically thereafter as indicated by conditions observed during inspections.

No later than three months after initially placing the boiler into operation and starting service, and thereafter as conditions
warrant, the pressure vessel should be drained after being properly cooled to near ambient temperature. Handhole covers
should be removed and waterside surfaces should be inspected for corrosion, pitting, or formation of deposits.
3.7.3 — Flushing of Pressure Vessel Interior

Upon completion of the inspection, the pressure vessel interior should be flushed out, as required, with a high pressure
hose. If deposits are not fully removed by flushing, a consultation may be required with your local Cleaver-Brooks autho-
rized representative. In extreme cases, it may be necessary to resort to acid cleaning. Professional advice is recommended if
acid cleaning is required.
The inspections will indicate the effectiveness of the feedwater treatment. The effectiveness of treatment, the water condi-
tions, and the amount of fresh water make-up required are all factors to be considered in establishing frequency of future
pressure vessel washouts. Contact your local Cleaver-Brooks authorized representative for more information.
750-94 (revised 2009) 3-9


Boiler water blowdown is the removal of some of the concentrated water from the pressure vessel and its replacement with
feedwater so that the lowering of the concentration of solids in the boiler water occurs.
Solids are brought in by the feedwater even though the water is treated prior to use through external processes that are
designed to remove unwanted substances which contribute to scale and deposit formations. However, none of the pro-
cesses can remove all 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. There-
fore, blowdown and internal chemical treatment are required to prevent the solids from forming harmful scale and sludge.
Scale has a low heat transfer value and acts as an insulation barrier. Scale retards heat transfer, which not only results in
lower operating efficiency, and consequently higher fuel consumption, but more importantly, can cause overheating of
boiler metal. Overheating of boiler metal can result in tube failures or other pressure vessel metal damage and lead to boiler
down-time and costly repairs.
Scale is caused primarily be calcium and magnesium salts, silica, and oil. Any calcium and magnesium salts in the boiler
water are generally precipitated by the use of sodium phosphate, along with organic materials, to maintain the precipitates
or “sludge” in a fluid form. The solids such as sodium salts and suspended dirt don not readily form scale. But as the boiler
water boils off as relatively pure steam, the remaining water is thickened with the solids. If the concentration is permitted to
accumulate, foaming and priming will occur and the sludge can cause harmful deposits that bring about overheating of the
metal.
The lowering or removal of the concentration requires the use of boiler water blowdown. The two principal types of blow-
down are intermittent manual blowdown and continuous blowdown.
3.8.1 — Intermittent Manual Blowdown

Manual or sludge blowdown is necessary for the operation of the boiler regardless of whether or not continuous blowdown
is employed.
The blowdown tappings are located at the bottom or lowest part of the boiler in order to lower the dissolved solids in the
pressure vessel water, and to remove a portion of the sludge that accumulates in the lower part of the vessel.
Equipment generally consists of a quick opening valve and a shutoff valve. The valves and necessary piping are not nor-
mally furnished with the boiler, but supplied by others. All piping must be to a safe point of discharge. Piping must be prop-
erly supported and free to expand.
3.8.2 — Continuous Blowdown

Continuous blowdown is used in conjunction with a surface blow-off tapping (furnished on 60” diameter and larger units)
and is the continuous removal of concentrated water.
The surface blow-off opening, when furnished, is on the top center line of the pressure vessel. It is provided with an inter-
nal collecting pipe terminating slightly below the working water level for the 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.
3-10 750-94 (revised 2009)

Periodic adjustments are made to the valve setting to increase or decrease the amount of blowdown in accordance with the
test analysis.
The flow control valve and piping are generally provided by others. All piping must be to a safe point of discharge.
3.8.3 — Frequency of Manual Blowdown

When continuous blowdown is utilized, manual blowdown is primarily used to remove suspended solids or sludge. The con-
tinuous blowdown removes sediment and oil from the surface of the water along with a prescribed amount of dissolved sol-
ids.
When surface or continuous blowdown is not utilized, manual blowdown is used to control the dissolved or suspended sol-
ids in addition to the sludge.
In practice, the valve(s) of the bottom blowdown are opened periodically in accordance with an operating schedule and/or
chemical control tests. From the standpoint of control, economy and results, frequent short blows are preferred to infre-
quent lengthy blows. The length and frequency of the blowdown is particularly important when the suspended solids con-
tent of the water is high. With the use of frequent short blows a more uniform concentration of the pressure vessel water is
maintained.
In cases where the feedwater is exceptionally pure, or where there is a high percentage of return condensate, blowdown may
be employed less frequently since less sludge accumulates in the pressure vessel. When dissolved and/or suspended solids
approach or exceed predetermined limits, manual blowdown to lower the concentrations is required.
It is generally recommended that a steam boiler be blown down at least once in every eight-hour period, but frequency may
vary depending upon water and operating conditions. The blowdown amounts and schedule should be recommended by
your local Cleaver-Brooks authorized representative.
A hot water boiler does not normally include openings for surface blowdown and bottom blowdown since blowdowns are
seldom practiced. The need remains to be alert to system water losses and corresponding amount of raw water make-up. A
water meter is recommended for water make-up lines.
3.8.4 — Manual Blowdown Procedure

Blowdown is most effective at a point when the generation of steam is at the lowest rate and feedwater input is also low,
thus providing a minimum dilution of the boiler water with low concentration feedwater.
1. 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 slow opening
globe type valve downstream. Valves will vary depending upon pressure involved and make or manufacturer. If seatless
valves are installed, follow the manufacturer’s recommendations.
If a quick opening valve and globe type of slow opening valve are in combination, the former is normally opened first
and closed last with blow down accomplished with the globe or slow opening valve.
750-94 (revised 2009) 3-11

2. When opening the second or downstream valve, crack it slightly to allow the lines to warm, then continue opening
slowly.
! Caution
Do not pump the lever action valve open and closed, as water hammer is apt to break the valve bodies or pipe fittings. Fail-
ure to follow these instructions could cause damage to the equipment.
The length of each blow should be determined by actual water analysis. Lowering the water in the gauge glass approxi-
mately 1/2” is often acceptable as a guide to adequate blow. However, lowering the water 1/2” should not be interpreted
as a rule since water analysis procedures should prevail. If the glass cannot be viewed by the party operating the valve,
another operator should watch the glass and direct the valve operator.
3. Close the downstream (slow opening) valve first and as fast as possible.
4. Close the valve next to the boiler.
5. Slightly crack the downstream valve and then close it tightly.
Under not circumstances should a blow-off valve be left open and the operator should never leave until the blowdown
operation is completed and the valves are closed.

Insurance regulations or local laws will require a periodic inspection of the pressure vessel by an authorized inspector. Suf-
ficient notice is generally given to permit removal of the boiler from service and preparation for inspection.
! Warning
To avoid the hazard of electrical shock, we recommend the use of a low voltage flashlight during an internal inspection.
Preferably, inspectors should work in pairs. Failure to follow these instructions could result in serious injury or death.
When shutting down the boiler, the load should be reduced gradually and the pressure vessel cooled at a rate that avoids
damaging temperature differential that can cause harmful stresses. Vessels should not normally be drained until all pressure
is relieved - 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. Some heat, however, may be
desirable to dry out the interior of the boiler.
If the internal inspection is being made at the request of an authorized inspector, it is well to ask the inspector observe the
conditions prior to cleaning or flushing of waterside surfaces.
Be certain that a supply of manhole and handhole gaskets is available, along with any other gaskets or items needed to place
the unit back into operation after inspection.
Have available information on the boiler design, dimensions, generating capacity, operating pressure or temperature, time in
service, defects found previously, and any repairs or modifications. Also have available for reference records of previous
inspections.
Be prepared to perform any testing required by the inspector including a hydrostatic test.
3-12 750-94 (revised 2009)

After proper cooling and draining of the vessel, flush out the waterside with a high pressure water hose. Remove any scale
or deposits from the waterside surfaces and check for internal or external corrosion and leakage.
The fireside surface should also be thoroughly cleaned so that metal surfaces, welds, joints, tube ends, fittings and any previ-
ous repairs can be readily checked.
Be sure that steam valves, and valves to expansion tank (hot water), feedwater valves, blow-off valves, all fuel valves, and
electrical switches are shut off prior to opening handholes, manhole, and front or rear doors. Adequately vent the pressure
vessel prior to entry.
Clean out the low-water cutoff piping, the water level controls and cross-connecting pipes. Replace the water gauge glass
and clean out the water cocks. Also check and clean the drain and the blowdown valves and piping.
Check all water and steam piping and valves for leaks, wear, corrosion, and other damage. Replace or repair as required.

Many boilers used for heating or seasonal loads or for standby service may have extended periods of non-use. Special atten-
tion must be given to idle boilers so that neither waterside nor fireside surfaces are allowed to deteriorate from corrosion.
Too many conditions exist to lay down definite rules. There are two methods of storage: wet or dry. Your local Cleaver-
Brooks authorized representative can recommend the better method depending upon circumstances in the particular instal-
lation.
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.
Although pollution control regulations may continue to limit the permissible sulphur content of fuel oils, care must be taken
to avoid corrosion problems that sulphur can cause, especially in a boiler that is seasonally shut down. Dormant periods,
and even frequent shutdowns, expose the fireside surfaces to condensation below the dew point during cooling. Moisture
and any sulphur residue can form an acid solution. Under certain conditions, and especially in areas with high humidity, the
corrosive effect of the acid will be serious enough to eat through or severely damage boiler tubes or other metal heating sur-
faces during the time that a boiler is out of service.
The condition does not generally occur during normal firing operation, because the high temperature of operation vapor-
izes any condensation. However, proper boiler operation must be maintained, especially with a hot water boiler, to prevent
the flue gasses from falling below the dew point.
At the start of lay-up, thoroughly clean the fireside by removing any soot or other products of combustion from the tubes,
tube sheets, and other fireside surfaces. Brushing will generally suffice. Sweep away or vacuum any accumulation. The fire-
side surfaces may be flushed with water. However, all moisture must be eliminated after flushing and the surface dried by
blowing air or applying some form of heat. It is good practice to protect the cleaned surfaces by coating them with an anti-
corrosive material to prevent rust.
750-94 (revised 2009) 3-13

T prevent condensation from forming in the control cabinet, keep the control circuit energized. For extended lay-up peri-
ods, especially where high humidity or large swings in ambient temperature occur, the control should be removed and
stored in a dry atmosphere.
Dry storage is generally employed when the boiler will be out of service for a significant period of time, or where freezing
temperatures may exist. In the dry storage method the boiler must be thoroughly dried because any moisture would cause
corrosion. Both fireside and waterside surfaces must be cleaned of all scale, deposits, soot, etc. Steps must be taken to elim-
inate moisture by placing moisture-absorbing materials such as quick lime (at 2 pounds for 3 cubic feet of volume) or silica
gel (at 5 pounds for 30 cubic feet of volume) on trays inside the vessel. Fireside surfaces may be coated with an anti-corro-
sive material, or grease or tar paint. Refractories should be brushed clean and wash-coated. All openings to the pressure ves-
sel, such as manhole and handholes, should be shut tightly. Feedwater and steam valves should be closed. Damper and vents
should be closed to prevent air from reaching fireside surfaces. Periodic inspection should be made and absorption materi-
als renewed.
Wet storage is generally used for a boiler held in stand-by condition or in cases where dry storage is not practical. The pos-
sibility of freezing temperatures must be considered. Care must again be taken to protect metal surfaces. Variables preclude
definite recommendations. However, it is suggested that the pressure vessel be drained, thoroughly cleaned internally, and
re-filled to overflowing with treated water. If deaerated water is not available, the unit should be fired to boil the water for a
short period of time. Additional chemicals may be suggested by your local Cleaver-Brooks authorized representative to
minimize corrosion. Internal water pressure should be maintained at greater than atmospheric pressure. Nitrogen is often
used to pressurize the vessel. Fireside surfaces must be thoroughly cleaned and the refractory should be wash-coated.
3-14 750-94 (revised 2009)

CHAPTER 4 Sequence of Operation
4.1 — Overview
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.
sequence applies regardless of the make or model. Please refer to the Wiring Diagram (WD) prepared by Cleaver-Brooks for
your specific installation.
A. The burner and control system are in starting condition when the following conditions exist:
• The operating limit pressure control (steam boiler) or the operating limit temperature control (hot water boiler) and high
limit pressure or temperature control are below their cutoff setting.
B. All entrance switches are closed and power is present at the line terminals of:
• Oil pump motor starter (if provided)
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 program relay. Chapters 6 and 7 contain operating instructions and specific
information on setting and adjusting the controls.
750-94 (revised 2009) 4-1

4.2 — Circuit and Interlock Controls

The burner control circuit is a two-wire system designed for 115 Vac, 60 Hz, single-phase power.
The electrical portion of the boiler is made up of individual circuits with controls that are wired in a manner designed to
provide a safe workable system. The program relay provides connection points for the interconnection of the various cir-
cuits.
The controls used vary depending upon the fuel oil or gas and the specific requirement of applicable regulatory bodies.
Refer to the boiler wiring diagram to determine the actual controls provided. The circuits and controls normally used in the
circuits are identified in the following table and are referred to in Section 4.3.
Circuit Components
Limit Circuit • Burner switch (BS)
• Gas-oil selector switch (GOS) - combination burner only
• Oil drawer switch (ODS) - oil burner
• Low oil temperature switch (LOTS) - nos. 5 and 6 oil only
• Low gas pressure switch (LGPS)
• LE proximity switch interlock
Blower Motor Starter Circuit • Blower motor starter (BMS)
• Air compressor motor starter (ACMS) - if provided
• Air purge valve (APV) - nos. 5 and 6 oil only
Running Interlock Circuit • Blower motor starter interlock (BMSI)
• Atomizing air proving switch (AAPS) - if provided
Low Fire Proving Circuit • Low fire switch (LFS)
Pilot Ignition Circuit • Gas pilot valve (GPV)
• Gas pilot vent valve (GPVV) - if provided
Flame Detector Circuit • Flame detector (FD)
• Main gas vent valve (MGVV) - if provided
• Oil valve (OV)
4-2 750-94 (revised 2009)

Circuit Components
Firing Rate Circuit • Damper motor transformer (DMT)
High Fire Proving Circuit • High fire switch (HFS)
Running Interlock and Limit Circuit • Low oil pressure switch (LOPS)
To comply with requirements of insurance underwriters such as Factory Mutual (FM), Industrial Risk Insurers (IRI), or oth-
ers, additional interlock devices may be used.

The following sequence occurs with power present at the program relay (PR) input terminals and with all other operating
conditions satisfied.
4.3.1 — Pre-Purge Cycle

When the burner switch (BS) is turned “on,” and controls wired in the “limit” and “fuel valve interlock” circuits are closed
and no flame signal is present, the “blower motor start circuit” is powered energizing the blower motor starter (BMS). The
load demand light (LDL) turns on. When firing oil, the air compressor motor starter (ACMS - if provided) is also powered.
the air purge valve (APV - nos. 5 and 6 oil only) remains de-energized.
At the same time, the program relay signals the modulating damper motor (MDM) to open the air damper. The damper
begins to open and drives to its full open or high fire position. Opening the damper motor allows a flow of purging air
through the boiler prior to the ignition cycle.
On certain boilers the circuitry will include a high fire switch (HFS). The purpose of the switch is to prove that the modu-
lating damper motor (MDM) has driven the damper to the open position during the pre-purge cycle. In this instance, the
“high fire proving circuit” is utilized.
The controls wired into the “running interlock circuit” must be closed within 10 seconds after the start sequence. In the
event any of the controls are not 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.
To assure that the system is in low fire position prior to ignition, the low fire switch (LFS) must be closed to complete the
“low fire proving circuit.” The sequence will stop and hold until the modulating damper motor (MDM) has returned to the
750-94 (revised 2009) 4-3

low fire position and the contacts of the low fire switch (LFS) are closed. Once the low fire switch is closed, the sequence is
allowed to continue.
NOTE: The ignition trial cannot be started if flame or a flame simulating condition is sensed during the pre-purge period.
A safety shutdown will occur if flame is sensed at this time.
4.3.2 — Ignition Cycle

The ignition transformer (IT) and gas pilot valve (GPV) are energized from the appropriate pilot ignition terminal.
NOTE: An oil-fired burner may be equipped with an oil pilot rather than a gas pilot. The ignition sequence of both is
identical.
The pilot flame must be established and proven by the flame detector (FD) within a 10 second period in order for the igni-
tion cycle to continue. If for any reason this does not happen, the system will shut down and safety lockout will occur.
NOTE: Depending upon the requirements of the regulatory body, insurer, or fuel being burned, either the 10 or 15 sec-
ond pilot ignition terminal may be used. Both provide the same function but differ in time interval allowed for proving
main flame ignition. Refer to the boiler wiring diagram.
With a proven pilot, the main fuel valve(s) (OV or MGV) is energized and the main fuel valve light (FVL) in the panel is
lighted. The main flame is ignited and the trial period for proving the main flame begins. It lasts 10 seconds for light oil and
natural gas, and 15 seconds for heavy oil. At the end of the proving period, if the flame detector still detects main flame, the
ignition transformer and pilot valve are de-energized and pilot flame is extinguished.
NOTE: If the main flame does not light, or stay lit, the fuel valve will close. The safety switch will trip to lock out the con-
trol. Refer to flame loss sequence (see Section 4.4) for description of action.
! Warning
The cause for loss of flame or any other unusual condition should be investigated and corrected before attempting to
restart. Failure to follow these instructions could result in serious injury or death.
4.3.3 — 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). This allows operation in ranges above low fire.
With the manual-automatic switch (MAS) set at automatic, subsequent modulated firing will be at the command of the
modulating control (MC), which governs the position of the modulating damper motor (MDM). The air damper and fuel
valves are actuated by the motor through a linkage and cam assembly to provide modulated firing rates.
4-4 750-94 (revised 2009)

NOTE: Normal operation of the burner should be with the switch in the manual-automatic position and under the direction
of the modulating control. The manual position is provided for initial 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 posi-
tion, thus allowing more air than desired to flow through the boiler. Excess air flow subjects the pressure vessel metal and
refractory to undesirable conditions. The effectiveness of nozzle purging is lost on a No. 6 oil burner.
The burner starting cycle is now complete. The LDL and FVL lights on the panel remain lit. Demand firing continues as
required by load conditions.
4.3.4 — Burner Shutdown: Post Purge

The burner will fire until steam pressure or water temperature in excess of demand is generated. With modulated firing, the
modulating damper motor (MDM) should return to the low fire position before the operating limit control (OLC) opens.
When the limit control circuit is opened, the following sequence occurs:
1. The main fuel valve circuit is de-energized, causing the main fuel valve (MGV or OV) to close.
2. The flame is extinguished.
3. The control panel lights (LDL and FVL) are turned off.
4. The blower motor continues to run to force air through the boiler for the post purge period.
5. On a No. 6 oil burner, the air purge valve (APV) is powered from the blower motor start circuit via the contacts of the
air purge relay (APR) to provide an air purge of the oil nozzle. The damper motor returns to the low fire position if it is
not already in that position.
6. The blower motor start circuit is de-energized at the end of the post purge cycle and the shutdown cycle is complete.
The program relay is now ready for subsequent recycling, and when steam pressure or water temperature drops to close the
contacts of the operating control, the burner again goes through its normal starting and operating cycle.

The program relay will recycle automatically each time the operating control closes, or after a power failure. It will lockout
following a safety shutdown 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 pre-purge period.
The control will prevent startup or ignition if limit circuit controls or fuel valve interlocks are open. The control will lock
out upon any abnormal condition affecting air supervisory controls wired in the running interlock circuit.
! Caution
The lockout switch must be manually reset following a safety shutdown. The cause for loss of flame or any unusual condition
should be investigated and corrected before attempting to restart. Failure to follow these instructions could cause damage to
the equipment.
4.4.1 — No Pilot Flame

The pilot flame must be ignited and proven within a 10-second period after the ignition cycle begins. If not proven within
this period, the main fuel valve circuit will not be powered and the fuel valve(s) will not be energized. The ignition circuit is
immediately de-energized and the pilot valve closes, the reset switch lights and lockout occurs immediately.
750-94 (revised 2009) 4-5

The blower motor will continue to operate. The flame failure light and the alarm bell (optional) are energized 10 seconds
later.
The blower motor will be de-energized. The lockout switch must be manually reset before operation can be resumed. (Refer
to the previous caution notice.)
4.4.2 — Pilot But No Main Flame

When the pilot flame is proven, the main fuel valve circuit is energized. Depending upon the length of the trial-for-ignition
period, the pilot flame will be extinguished 10 or 15 seconds later. The flame detecting circuit will respond to de-energize
the main fuel valve circuit within 2 to 4 seconds to stop the flow of fuel. The reset switch lights and lockout occurs immedi-
ately. The blower motor will continue to operate.
The flame failure light and alarm bell (optional) are energized 10 seconds later.
4.4.3 — Loss of Flame

If a flame outage occurs during normal operation and/or the flame is no longer sensed by the detector, the flame relay will
trip within 2 to 4 seconds to de-energize the fuel valve circuit and shut off the fuel flow. The reset switch lights and lockout
occurs immediately. The blower motor continues operation. The flame failure light and alarm bell (optional) are energized
10 seconds later.
If the burner will not start, or upon a safety lockout, the troubleshooting section in the operating manual and the technical
bulletin should be referred to for assistance in pinpointing problems that may not be readily apparent.
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 bulletin.
Knowledge of the system and its controls will make troubleshooting much easier. Costly down time or delays can be pre-
vented by systematic checks of the actual operation against the normal sequence to determine the stage at which perfor-
mance deviates from normal. Following a routine may possibly eliminate overlooking an obvious condition, often one that
is relatively simple to correct.
Remember, a safety device, for the most part, is doing its job when it shuts down or refuses to operate. NEVER attempt to
circumvent any of the safety features.
Preventive maintenance and scheduled inspection of all components should be followed. Periodic checking of the relay is
recommended to see that a safety lockout will occur under conditions of failure to ignite either pilot or main flame, or from
loss of flame.
4-6 750-94 (revised 2009)

CHAPTER 5 Starting and Operating
Instructions
5.1 — Overview
The instructions in Chapter 5 are all based upon installation being complete and all electrical, fuel, water, and vent stack
connections are made.
The operator should be familiar with the burner, boiler, and all controls and components. To quickly locate and identify the
various controls and components mentioned the following paragraphs, refer to the illustrations and the contents of Chap-
ters 1, 2, and 3. Instructions for adjusting major components are given in Chapter 6 — Chapter 6 should be reviewed prior
to firing. The wiring diagram should also be thoroughly reviewed, along with the firing sequence outlined in Chapter 4.
! Warning
It is recommended that the starting instructions be read completely until they are thoroughly understood, before attempting to
operate the boiler, rather than performing each operation as it is read for the first time. Failure to follow these instructions could
Verify supply of fuel and proper voltage. Check for blown fuses, open circuit breakers, dropped out overloads, etc. Check
reset of all starters and controls having manual reset features. Check the lockout switch on the programmer and reset if nec-
essary.
The boiler should be filled with water to the proper operating level using water of ambient temperature. Be sure that treated
feedwater is available and use. In heating applications, the entire system should be filled and vented. Refer to Chapter 3 for
water requirements. On a steam boiler, open the test valve to vent air displaced during filling. Leave the test valve open until
the escape of steam is noted after the burner is operating.
! Warning
Prior to firing a boiler, be sure that discharge piping from safety valves or relief valves, and discharge piping from all blowdown
and drain valves, is piped to a SAFE point of discharge, so that emission of hot water or steam cannot possibly cause injury. Fail-
ure to do so could result in serious injury or death.
750-94 (revised 2009) 5-1

Check all linkage for full and free movement of the damper and metering valves and cams. The check can be done by loos-
ening the linkage at the damper motor connecting arm and manipulating the linkage by hand.
Check for rotation of all motors by momentarily closing the motor starter or relay. The blower impeller rotation is counter-
clockwise when viewed from the front of the boiler. The air pump rotation is clockwise when viewed from its drive end.
Before operating the boiler feed pump or oil supply pump, be sure all valves in the line are open or properly positioned.
For safety reasons, perform a final pre-startup inspection, especially checking for any loose or incomplete piping or wiring
or any other situations that might present a hazard.
NOTE: The pressure vessel support legs are welded to mounting skids in front and secured by bolts at the rear of the pres-
sure vessel. The bolts are tightened for shipment. When the boiler is installed, and prior to initial firing, the bolts securing
the rear legs to the skid must be loosened to allow for expansion and contraction caused by differences in temperature
between pressure vessel and skids and to avoid damage to the equipment.
5.2 — Control Settings: Steam and Hot Water

See Chapter 6 for adjustment instructions for the following controls:
5.2.1 — Operating Limit Control

Inspect the operating limit control for proper setting.
• The pressure control of a steam boiler should be set slightly above the highest desired steam pressure, but at least 10%
lower than the setting of the safety valve.
• The temperature control on a hot water boiler should be set slightly above the highest desired water temperature and
within the limits of the pressure vessel.
5.2.2 — High Limit Control

Inspect the high limit control for proper setting.
• On a high pressure steam boiler, the control should be set approximately 10 psig above the operating limit pressure con-
trol setting, if feasible, or midway between the operating limit pressure and the safety valve setting. The setting on a low
pressure steam boiler may be 2 or 3 psig above the operating limit setting, but must not exceed the safety valve setting.
• On a hot water boiler, the high limit temperature control should be 5º to 10º F above the operating limit temperature
control setting but within the limits of the design pressure of the pressure vessel.
5.2.3 — Modulating Control

Inspect the modulating control for proper setting. The control must be set and adjusted so that the modulating motor
returns to low fire position before the operating limit control opens. It is further desirable to have its low point setting
5-2 750-94 (revised 2009)

5.3 — Gas Pilot
somewhat below the cut-in setting of the limit control so that the burner operates in low fire position for a brief period on
each start rather than immediately driving to a high fire position.
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.
5.2.4 — Low-Water Cutoff and Pump Control

Inspect the low-water cutoff and pump control as well as the auxiliary low-water cutoff (if equipped with this optional
device). Check for freedom of float movement. Float movement can be verified by observing the level of water in the gauge
glass when the water supply has been cut off either by the stopping of the feed pump or by the closing of a valve, and the
restarting of the pump or opening of the valve when water is drained from the pressure vessel. The importance of proper
functioning of low-water controls cannot be over-emphasized. Be sure that the control and the piping are level.
5.2.5 — Additional Considerations

The settings of controls relating to fuel, either oil or gas, are covered in subsequent sections.
In the event the boiler is equipped with optional control devices not listed here, be certain to ascertain that their settings are
correct. If additional information is required, see your local Cleaver-Brooks authorized representative.
On initial startup or whenever the boiler is placed into operation from a “cold” start, the manual-automatic selector switch
should be set at “manual” and the manual flame control set at “close.” After the boiler is in operation and thoroughly
warmed, the selector switch should be turned to “automatic,” so that the burner firing rate may be controlled by the modu-
lating control in accordance with load demands.
5.3 — Gas Pilot

The gas pilot should be checked for satisfactory performance prior to initial firing. Follow the pilot flame adjustment
instructions given in Chapter 6.
On initial starting attempts, several efforts might be required to fully bleed the pilot line. While checking pilot adjustment,
observe whether the pilot flame is extinguished promptly when the burner switch is opened. A lingering flame indicates a
leaking gas pilot valve, which is a condition requiring correction before proceeding.
750-94 (revised 2009) 5-3


The supply and pressure of the atomizing air on an oil-fired burner should be checked. Before starting, inspect the oil pump
lube oil level. Add oil if necessary to bring the level to the midpoint or slightly higher in the sight glass. Use SAE 20 deter-
gent oil of a grade mentioned in Chapter 8 and fill in accordance with instructions given there.
FIGURE 5-1. Atomizing Air Compressor
Check the oil level of the air intake strainer.
To verify air flow and pressure, place the burner run/test switch on the program relay to the “test” position. If the burner is
a combination fuel burner, be sure that the gas/oil selector switch is set to “oil.” Turn the burner switch on. The burner will
cycle to the low fire pre-purge position and stop there.
FIGURE 5-2. Atomizing Air Pressure Gauge
5-4 750-94 (revised 2009)

Observe the reading on the air pressure gauge. With no oil flow, the pressure should be a minimum of 7 psi.
If there is no pressure, determine the cause and correct it before proceeding. Check for obstructions in the air inlet line,
incorrect rotation (air pump rotation is clockwise), or a loose oil nozzle or other leaks. If the pressure is much higher with-
out any oil flow, check for obstruction in the discharge line or at the oil nozzle.
The air pressure will increase when an oil flow exists. At low firing rate, the air pressure may rise to 12 psi or more.
NOTE: The air pressure should not exceed 35 psi at high fire. Greater air pressure causes excessive wear of the air pump.,
increases lube oil usage, and can overload the motor, thus causing damage to the equipment.
NOTE: Abnormally high pressure indicated on the nozzle air pressure gauge is an indication that the burner nozzle has become
clogged. In the event of clogging check the nozzle and clean as necessary.
After air flow has been verified, turn the burner switch off and return the run/test switch to the “run” position.

Prior to initial firing, oil flow and pressure should be established and verified. Atomizing air pressure should also be estab-
lished as outlined in Section 5.4. The schematic flow diagram (see Chapter 2) indicates the flow of fuel and atomizing air.
If the burner is a combination fuel model, be certain that the main gas shutoff cock is closed and set the gas/oil selector
switch to “oil.” Insert the burner drawer gun into its most forward position and latch it in place.
5.5.1 — Oil Flow

2. If the oil supply tank is located above the level of the pump and flow to the pump is by gravity, then it will usually be nec-
essary to vent the suction line to allow oil to fill the line. Venting the suction line can generally be accomplished by crack-
ing a union fitting, or by opening the cap of the oil strainer using care to prevent spillage of oil. Tighten the fitting or the
cap as soon as oil flow appears.
If the oil supply tank is below the level of the oil pump, it is MANDATORY that the suction line to the pump be com-
pletely filled with oil prior to starting the pump to avoid the possibility of damage to the pump gears. Non-lubricating
fluids such as kerosene should not be used for priming.
3. Prior to priming the suction line and the initial start, check to make certain that all plugs, connections, etc., have been
securely tightened to prevent leaks.
4. If the fuel oil supply originates from a pressurized loop, it is assumed that the pressure of the loop will be at a minimum
of 75 psi. Under these conditions, the relief valve at the terminal block should be adjusted to the point where it becomes
inoperative (or removed and openings plugged). To render inoperative, turn the adjusting screw in as far as possible.
5. A standard equipped boiler has a selector switch incorporated in the oil pump motor starter. Momentarily energize the
starter to check for proper pump rotation. With the rotation verified, operate the pump to determine that oil circulation
exists.
6. Observe the oil burner pressure gauge for indication that flow is established. If no pressure shows on the gauge after a
few moments, stop the oil pump and re-prime.
750-94 (revised 2009) 5-5

If the supply tank is lower than the pump, it is possible that the initial priming of the suction line, followed by operation
of the pump, will not establish oil flow. This might be caused by obstruction in the suction line, excessive lift, inadequate
priming, suction line leaks, etc.
If oil flow is not readily established, avoid prolonged operation of the pump to minimize risk of damage to internal parts
of the pump.
NOTE: If oil flow is not established after a second or third priming attempt, a full investigation is required to determine
the cause.
7. A vacuum (or a compound pressure-vacuum) gauge should be installed at the suction port of the pump and its reading
observed and recorded for future guidance. If a vacuum condition exists, the reading will reveal the tightness of the sys-
tem. It is advisable to maintain the vacuum reading at less than 10” Hg. A vacuum in excess of 10” Hg. may allow oil to
vaporize, causing cavitation, loss of prime, and unstable firing condition.
FIGURE 5-3. No.2 Fuel Oil Control

1. Oil supply pressure is regulated by adjusting the pressure relief valve at the oil terminal block. A pressure gauge should
be installed in the terminal block and the relief valve adjusted to obtain a minimum reading of 75 psi when the burner is
firing at maximum rate.
2. When oil is supplied from a pressurized loop to a multiple boiler installation, the relief valve in the loop should be prop-
erly adjusted to provide this reading. In this circumstance, the relief valve at the terminal block should be adjusted to the
point when it will be inoperative (or removed and openings plugged). To render inoperative, turn the adjusting screw in
as far as possible.
3. Adjustment may also be required to the regulator on the fuel oil controller. The pressure regulating valve is equipped
with tubing that directs and adds atomizing air pressure to the adjustable spring pressure. Since the air pump is not run-
ning 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.
4. The pressure gauge will indicate a higher reading when the flame is present and will increase as the firing rate increases.
After the burner is firing and when the air pump is running, final adjustment can be made at the fuel oil controller.
5. Final regulation of oil flow to the nozzle can be done later, if necessary, by adjusting the metering cam screws as outlined
in Chapter 6.
5-6 750-94 (revised 2009)

5.5.3 — Starting
When all the conditions covered in Sections 5.1, 5.2, 5.3, 5.4, and 5.5 are assured, the burner is ready for firing. Refer to Sec-
tion 5.8 for further starting and operating information.

Prior to initial firing, oil flow, pressure, and temperature should be established and verified. Atomizing air pressure should
also be established as outlined in Section 5.4. The schematic flow diagram (see Chapter 2) indicates the flow of fuel and
atomizing air.
If the boiler is a combination fuel model, be certain that the main gas shutoff cock is closed and set the gas/oil selector
switch to “oil.” Insert the burner drawer gun into its most forward position and latch it in place.
5.6.1 — Oil Flow

2. Open the bypass valve on the fuel oil controller until oil flow is established. Normally, the orifice valve is left in a closed
position. however, on cold starts, it may be opened for brief periods to aid in establishing oil flow. The bypass and orifice
valves must be returned to the closed positions as soon as oil flow is established as indicated by a reading on the oil sup-
ply pressure gauge. Do not at temp to set pressures while valves are open.
FIGURE 5-4. No. 6 Fuel Oil Control
3. Momentarily energize the fuel oil pump starter to check for proper pump rotation. With the rotation verified, prime the
suction line strainer with oil and turn the fuel oil pump switch to the “ON” position.
4. Check the oil supply pressure gauge for indication that oil flow is established. If no pressure shows on the gauge after a
few moments, stop the oil pump and re-prime. Heavy oil in the storage tank must be at a temperature to produce an oil
viscosity that will allow the oil to flow through the oil pump and suction line. If oil flow is not established after several
750-94 (revised 2009) 5-7

attempts, the conditions preventing oil flow must be determined and corrected to avoid damage to the pump’s internal
mechanism.
5. A vacuum gauge should be installed in the oil suction line and its reading observed and recorded for future guidance.

Oil pressure is regulated at several points. The first is at the relief valve at the oil heater. The relief valve should be set so 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.
Since the air pump is not running at this time, only tentative adjustments can be made. Without the air supply, adjust the fuel
oil pressure regulator so that the burner oil gauge registers approximately 35 psi. Adjust the back pressure relief valve so that
its gauge reads about 10 psi less than the burner gauge.
After the burner is firing, further adjustments can be made, if necessary, to the valves.
The pressure gauges will indicate higher readings when a flame is present. The pressure will increase as the firing rate
increases. The pressure reading on the two gauges on the controller will, despite the fluctuation, retain a nearly constant dif-
ference of 10 psi.
Final regulation of oil flow to the nozzle can be done, if necessary, by adjusting the metering cam screws as outlined in
Chapter 6.
5.6.3 — Oil Temperature


Oil Burner Pressure Gauge 30 - 45 psi
! Caution
Before turning on the electric oil heater switch, be certain that the heater shell is filled with fuel oil and the flow is estab-
lished. Failure to follow these instructions could result in equipment damage.
1. After determining that the heater shell is filled and that fuel oil circulation exists, turn the oil heater switch to “on.”
2. Adjust the electric oil heater thermostat to maintain oil temperature at approximately 200º F.
The electric heater on burners equipped for No. 6 fuel oil is sized so that it is capable of supplying heated oil at a rate no
greater than that required for low fire operation and is primarily supplied for convenience on cold starts. Heating coils
utilizing either steam or hot water are supplied to provide sufficient heat so that higher rates of firing can be accom-
plished once steam pressure or hot water is available. In normal operation, the thermostat governing the electric heating
element is kept at a lower setting than the thermostat governing admission of steam to the heater, or of hot water circu-
lation, so that heating is not performed electrically except when steam or hot water is not available.
5-8 750-94 (revised 2009)

3. Set the steam thermostat or the hot water thermostat to maintain an oil temperature of 220º - 230º F. The electric heater
will be turned off automatically as soon as steam or hot water provides heat.
NOTE: The temperatures listed are tentative. The composition of the fuel oil in a given grade can vary, necessitating a higher or
lower preheating temperature. The viscosity of the oil at the nozzle should be less than 300 SSU and preferably less than 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. Review this chapter for additional information.
4. Close the manual bypass valve after the temperature rise on the fuel oil controller thermometer is noted. Be certain that
hot oil is moving through the controller. The orifice gate valve must also be closed. If the temperature drops, open the
orifice gate valve until a rise is noted, then close it.
5. Once the correct setting of the heater thermostats has been established, set the low oil temperature switch at the point
approximately 30º F lower than the normal burning temperature. If the system is equipped with a high oil temperature
switch, it should be set to open at 20º to 30º F higher than normal burning temperature.
5.6.4 — Starting
When all the conditions covered in Sections 5.1, 5.2, 5.3, and 5.4 are assured, the burner is ready for firing. Refer to Section
5.8 for further starting and operating information.

1. Prior to initial starting, check the linkage attached to the gas butterfly valve to assure that movement is free from binding.
2. Verify the presence and availability of gas. On a new installation, representatives of the gas utility should be present when
gas first flows into the system to supervise purging of the new gas line, unless they have already done so.
3. Determine that the pilot is operating properly, as outlined in Section 5.3.
4. Determine that sufficient pressure exists at the entrance to the gas train by installing a test gauge downstream of the reg-
ulator.
5. The gas pressure regulator must be adjusted to the proper pressure level. Since the regulator is generally supplied by oth-
ers, adjustment should proceed according to instructions supplied by its manufacturer.
It is necessary for the operator to know the burner requirements in gas quantity and pressure. The information can gen-
erally be found on the Dimension Diagram (DD) supplied by Cleaver-Brooks for the specific installation. Should the
information not be readily available, consult the Cleaver-Brooks Service Department, and be prepared to provide the
correct boiler serial number. Chapter 6 contains additional information along with standard gas flow and pressure
requirements.
6. If the burner is a combination fuel model, set the gas/oil switch to “gas.” Withdraw the oil burner gun and latch it in its
rearward (OUT) position.
FIGURE 5-5. Latch Oil Burner Gun “IN” and “OUT” Positions
750-94 (revised 2009) 5-9

7. On initial startup, it is recommended that the main gas shutoff cock remains closed until the programmer has cycled
through pre-purge and pilot sequences. When the fuel light on the control panel comes on, observe the action of the
motorized gas valve stem to determine that it opens when energized.
8. As soon as it is confirmed, turn the burner switch “OFF” and let the programmer finish its cycle.
9. Check that the gas valve has closed.
10. Again, turn the burner “ON.”
11. When the fuel valve light flows, slowly open the main gas cock. Main flame should ignite unless there is air present in the
line.
12. If the flame is not established within about 5 seconds, turn the burner switch “OFF” and allow the programmer to recy-
cle normally for a new lighting trial. Several efforts may be necessary to “bleed” air from the line.
! Warning
Do not repeat unsuccessful lighting attempts without rechecking the burner and pilot adjustments. Failure to follow these
NOTE: The burner and control system is designed to provide a “pre-purge” period of fan operation prior to establishing
ignition spark and pilot flame. Do not attempt to alter the system or to take any action that might circumvent the feature.
13. Once the main flame is established, turn the burner switch to the “OFF” position and observe that the flame is extin-
guished promptly. The flame may continue to burn for a second or two after normal shutdown due to the gas remaining
downstream from the fuel valve.
14. If the flame continues to burn for a longer period or during blower motor spindown, it could indicate a main gas valve
leak. Immediately turn the burner switch off and close the main gas cock.
15. Investigate and correct the cause of the valve leakage before relighting the burner.
NOTE: The main gas valve should provide a tight seal, provided nothing prevents tight closure. Foreign material may be
present in either the new or renovated gas lines unless adequate care is taken in cleaning and purging.
When the conditions covered in Section 5.7 and in Sections 5.1, 5.2, and 5.3 are assured, the burner is ready for firing. Refer
to Section 5.8 for further starting and operating information.
5.8 — IFGR Setup
NOTE: Initial IFGR linkage settings and adjustments must be established by a Cleaver-Brooks authorized representative.
Setup of the LE option requires simultaneous consideration of air-to-fuel ratios and NOX levels. This can only be accom-
plished with proper combustion emissions monitoring equipment with NOX, O2, CO, and smoke spot measuring capability.
It is recommended that the final “installed” settings be recorded for future reference. The settings should be marked on the
linkage as well.
Normally, once the system has been set and adjusted, the settings should not be changed unless conditions (including boiler
settings) change. In that case, it will be necessary to contact your local Cleaver-Brooks authorized representative for assis-
tance.
5-10 750-94 (revised 2009)

5.8 — IFGR Setup
After the IFGR system is initially set up, it will start up with the boiler as an integrated boiler system. After shutdown peri-
ods in which maintenance and/or adjustments have been performed on the fuel cams, fuel and air linkages, or IFGR con-
trol linkages, the recommended approach to startup is as follows:
1. Set all boiler components to their initial settings as discussed in the appropriate chapters of this manual.
2. Check fan impeller and motor rotation. Correct rotation is counterclockwise when viewed from the front of the boiler.
3. Verify that all the IFGR components are set to the settings recorded on the Startup Report (as noted by the Cleaver-
Brooks authorized representative during original set up). Be sure that all linkages are secure.
4. Start and warm the boiler as described in this manual.
5. Adjust the boiler components as described in this manual to achieve proper boiler operation.
Refer to Chapter 8 for instructions on cassette removal and installation.
NOTE: The IFGR system can be equipped with either a single or dual linkage arm, depending on the number of fuels used and
the NOX levels desired. All single-fueled boilers have a single drive arm. Dual-fueled boilers may or may not have a dual arm,
depending on the options purchased.
FIGURE 5-6. Jackshaft Linkage Settings
750-94 (revised 2009) 5-11

FIGURE 5-7. Overtravel Linkage Settings
FIGURE 5-8. Flange Collar and Damper Settings (Top View)
5-12 750-94 (revised 2009)


Depending upon the fuel being burned, the applicable previous sections in this chapter should be reviewed for preliminary
instructions.
1. When firing with oil, be certain that the burner gun is in its most forward position and latched in place. When firing with
gas, the burner gun should be properly withdrawn and latched in place. The fuel selector switch should be, accordingly,
set to either oil or gas.
2. Set the manual-automatic switch to “manual” and turn the manual flame control to “close.”
3. Turn the burner switch to “ON.” The load demand light should glow. The low-water level light should remain out, indi-
cating a safe water level in the boiler. The programmer is now sequencing. See Chapter 4 for sequence details.
NOTE: On an initial starting attempt, several efforts might be required to accomplish “bleeding” of fuel lines, main, or pilot. If
ignition does not then occur, do not repeat unsuccessful attempts without rechecking the burner and pilot adjustment.
4. 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 resetting the lockout switch.
! Warning
Do not re-light the pilot or attempt to start the main burner, either oil or gas, if the combustion chamber is hot and/or if gas or
oil vapor combustion gasses are present in the furnace or flue passages. Failure to follow these instructions could result in seri-
! Warning
The burner and control system is designed to provide a “pre-purge” period of fan operation prior to establishing ignition spark
and pilot flame. Do not attempt to alter the system or take any action that might circumvent the “pre-purge” feature. Failure to
follow these instructions could result in serious injury or death.
5. After main flame ignition, the burner should be set on manual control at its low-fire setting (that is, with manual flame
control at “close”) until the boiler is properly warmed. Close the steam header.
In the case of a steam boiler, CLOSE the test valve when the steam begins to appear.
A hot water boiler must have a continuous flow of system water through the vessel during the warmup period. The
entire water content of the system and boiler must be warmed prior to increasing fuel input.
6. If the flame at low-fire provides insufficient heat to reach normal operating pressure or temperature after 30 minutes,
gradually increase the firing rate by turning the manual flame control in one point increments to no higher than the third
cam screw. Operate at the increased fuel input rate for a period of time until an increase is noted in pressure or tempera-
ture.
7. After the boiler is thoroughly warmed, turn the manual flame control to high-fire. At this point a combustion analysis
should be made, with instruments, and fuel flow regulated as required. Refer to the adjustment procedures in Chapter 6.
After making the high-fire adjustment, manually decrease the firing rate, stopping at each cam screw to analyze combus-
tion gasses, and adjust as required.
To properly perform the testing and adjusting, it is necessary that the burner be allowed to fire at a maximum rate long
enough to achieve desired results.
750-94 (revised 2009) 5-13

5.9.1 — Operating
Normal operation of the burner should be with the switch in the automatic position and under the direction of the modu-
lating control. The manual position is provided for initial 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.
NOTE: The hot flame to cool air cycling subjects the pressure vessel metal and refractory to undesirable conditions.
With the switch set at “automatic,” the burner will operate on a modulating basis according to the load demand.
The burner will continue to operate with modulated firing until the operating limit pressure or temperature is reached,
unless:
• The burner is manually turned “off.”
• The low-water condition is detected by low-water level control.
• The electrical or fuel supply is interrupted.
• The combustion air pressure or atomizing air pressure drops below minimum level.
NOTE: There can be other reasons for shutdown, such as motor overload, flame outages, tripped circuit breakers, blown
fuses, or through other interlock devices in the circuitry.
When the burner is shut down normally, by either the operating limit control or by manually switching the burner off, the
load demand light no longer glows.
Shutdown through conditions causing safety or interlock controls to open will actuate the flame failure light (and alarm if so
equipped) and the load demand light will remain lit. The cause of this type of shutdown will have to be located, investigated,
and corrected before operation can be resumed. Refer to the “troubleshooting” section in Chapter 7.
5.9.2 — 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 de-energized and the flame is extinguished. The timer begins operation and the blower motor continues
running to force air through the furnace in the post-purge period.
At the end of the programmed post-purge period, the blower motor is turned off. The air pump motor of an oil-fired
burner is also turned off. The timer has returned to its original starting position and stops. The unit is ready to restart.
! Warning
It is advisable to check for tight shut-off of fuel valves. Despite precautions and strainers, foreign material in either new or
renovated fuel lines may lodge under a valve seat and prevent tight closure. The situation is especially true in new installa-
tions. Promptly correct any conditions causing leakage. Failure to follow these instructions could result in serious injury or
death.
5-14 750-94 (revised 2009)


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 pro-
gram.
The operating limit control may be checked by allowing steam pressure or water temperature to increase until the burner
shuts down. Depending upon the load, it may be necessary to manually increase the firing rate to raise steam pressure to the
burner shut off point. If the load is heavy, the header valve can be closed or throttled until the pressure increases. Observe
the steam gauge to check the cutoff pressure as the operating limit control shuts the burner down. Slowly open the header
valve to release steam pressure and check the cut-in setting as the burner restarts. Check the modulating control for the
desired operating pressure range. See Chapter 6 for instructions on the adjustment of controls.
The water temperature on a hot water boiler that may be operating at less than full load may be raised by manually increas-
ing the firing rate until the burner shuts down through the action of the operating limit control. Observe the thermometer
to verify the desired settings at the point of cut-out and again when the burner restarts. Return the manual automatic switch
to “automatic” and check the modulating control for the desired temperature range. See Chapter 6 for instructions on the
adjustment of the controls.
Check the proper operation and setting of the low-water cutoff (and pump operating control, if used).
Proper operation of the flame failure device should be checked at startup and at least once a week thereafter. Refer to Chap-
ter 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.
Check for tight shutoff of all fuel valves. Despite precautions and strainers, foreign material may lodge under a valve seat
and prevent tight closure. Promptly correct any conditions that cause leakage.
Refer to the adjustment procedures and maintenance instructions given in Chapters 6 and 8.
750-94 (revised 2009) 5-15

5-16 750-94 (revised 2009)

CHAPTER 6 Adjustment Procedures
6.1 — Overview
Each Cleaver-Brooks boiler is tested for correct operation before shipment from the factory. However, variable conditions
such as burning characteristics of the fuel and operating load conditions may require further adjustment after installation to
assure maximum operating efficiency and economy.
A combustion efficiency analysis made during the initial startup will help to determine what additional adjustments are
required in a particular installation.
Prior to placing the boiler into service, a complete inspection should be made of all controls, connecting piping, wiring, and
all fastenings such as nuts, bolts, and setscrews to be sure that no damage has occurred, or that adjustments have not
changed during shipment and installation.
The adjustment procedures in Chapter 6 apply to standard components furnished on steam or hot water boilers fired with
gas and/or the various grades of oil.
6.1.1 — High Turndown Burner

In order to reduce stress on boiler components and to improve boiler operating efficiency, burners have been designed for
enhanced fuel turndown capabilities. A High Turndown Burner (HTB) is installed on boilers equipped to fire light oil
(Series 100), or gas (Series 700), or both (Series 200). Air and fuel inlets, the diffuser, and the air damper control linkage
have been modified for these burners.
NOTE: Observe that proper air damper linkage and fuel metering adjustment procedures are followed for standard (Series 400
or 600) or HTB (Series 100, 200, or 700) burners to avoid damage to the equipment. The burner series is identified on the boiler
data plate affixed to the front head of the boiler.
Contact your local Cleaver-Brooks authorized representative or the Cleaver-Brooks Service Department for recommenda-
tions covering special controls that are not included in Chapter 6.
750-94 (revised 2009) 6-1


The linkage consists of various arms, connecting rods, and swivel ball joints that transmit motion form the modulating
motor to the metering cam(s), rotary air damper, and gas butterfly valve.
NOTE: On combination gas and oil boilers, the gas butterfly valve might not be used. Also on combination gas and oil
boilers, the oil metering valve might not be used.
When properly adjusted, a coordinated movement of the damper and metering cams within the limits of the modulating
motor travel is attained to provide proper fuel-air ratios through the firing range.
In linkage adjustments there are several important factors that must serve as guides.
• The modulating motor must be able to complete its full travel range.
! Caution
Do not restrict the full travel of the modulating motor. Failure to follow these instructions could result in equipment dam-
age.
• Initial adjustment should be made with the motor in full closed position, that is with the shaft on the power end of the
motor in its most counterclockwise position.
• 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 farther that arm will travel.
• Over-travel linkage, where used, should not be required in order to extend its spring to the fullest stretch.
6-2 750-94 (revised 2009)

FIGURE 6-1. Complete Linkage Assembly: Combination Gas and Oil
With the modulating motor in the low-fire position, the arm on its shaft should be at an angle of 45º below the horizontal.
The driven arm on the jackshaft should also be 45º below horizontal. Secure both arms and fit the connecting linkage rod in
place between them.
750-94 (revised 2009) 6-3

Position the oil and/or gas modulating cams on the jackshaft so that the cam follower assembly is between the first and sec-
ond cam adjusting screws (under the first adjusting screw for High Turndown Burners). In this position, fuel delivery is at
low-fire rate. Tighten the set screws to secure the cams on the jackshaft.
FIGURE 6-2. Rotary Air Damper
The stop screw in the rotary air damper limits damper travel at both closed (low-fire) and fully opened (high-fire) positions.
The screw is provided so that it is possible to tell, even with the burner in place, whether the damper rotor is in fully opened
or closed position. Rotating the damper clockwise to the stop screw closes the damper. Rotating the damper counterclock-
wise to the stop screw opens the damper. Normally, the rate of flow of air through the damper with the rotor in low-fire
position is about one-third of maximum for a standard burner or one-sixth for a HTB.
The amount of angular movement controlling the rate of air flow is determine by the location of the ends of the rotary air
damper rod in both the jackshaft arm and the air damper arm. When the air damper is in low-fire position, the jackshaft
arm should be at 45º (47-1/2º for HTB) and the rotary air damper arm should be at an angle of approximately 60º below
the horizontal. This will ensure that the angular movement of the damper starts slowly, increasing in rate as the high fire
position is approached.
Prior to initially firing a boiler it is advisable to check for free movement of the linkage. The damper motor must be allowed
to complete its full stroke and the damper must move freely from low- to high-fire position. Adjustment of linkage con-
nected to a gas butterfly valve is describe in Section 6.17.
6.3 — Modulating Motor

The modulating motor has a 90º shaft rotation. The motor manufacturer also provides a 160º stroke model for other appli-
cations. If a replacement is obtained from someone other than a Cleaver-Brooks Service or Parts representative, it may have
an incorrect stroke. To prevent damage, determine the 90º stroke prior to installing a replacement.
6-4 750-94 (revised 2009)

The stroke may be determined by powering the motor and connecting terminals R-B to actually determine the stroke as the
motor drives to an open position.
FIGURE 6-3. Modulating Motor

The modulating motor contains either one or two internal switches, depending upon application. The microswitches are
actuated by adjustable cams attached to the motor shaft.
Factory replacement motors have the cams preset. The low-fire start switch is set to make the red and yellow leads at
approximately 8º on motor closing. The high-fire purge air proving switch (located in the modulating motor) is set to make
red and blue tracer leads at approximately 60º 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.
NOTE: Adjustments to the boiler operating controls should be made by an authorized Cleaver-Brooks Service Technician.
Refer to the appropriate boiler operation and maintenance manual for specific information on boiler startup and operation.
The standard boiler operating control package consists of three separate controls.
1. High Limit Control: Senses the hot water temperature or steam pressure. It is used as a safety limit to turn the burner
off in the event the operating limit control fails. The high limit control should be set sufficiently above the operating
limit control to avoid nuisance shutdowns.
2. Operating Limit Control: Senses temperature or pressure and automatically turns the burner on to initiate the startup
sequence when required and turns the burner off to initiate the shutdown sequence when the demand is satisfied. The
control must be set to initiate startup only at the low-fire position.
750-94 (revised 2009) 6-5

3. Modulating Control: Senses changes in the hot water temperature or steam pressure and signals the modulating motor
to control the flow of fuel and air to the burner. With either steam or hot water boilers, the modulating control must be
set to ensure the burner is at its minimum low-fire position before the operating limit control either starts or stops the
burner.
When adjusting or setting controls, first be sure all control devices are securely mounted and level. With the temperature
sensing control, make sure the sensing bulb is properly bottomed in its well and is secured against movement. Be sure the
connecting tubing is not kinked.
The dial settings are generally accurate, although it is not unusual to have a slight variation between a scale setting and an
actual pressure gauge or thermometer reading. Always adjust the control setting to agree with pressure gauge or thermom-
eter readings. Accurate instrument readings are required. When necessary use auxiliary test equipment to set controls.
Burner controls correctly set to match load demands will provide operational advantages and achieve the following desir-
able objectives:
• The burner will be operating in low-fire position prior to shutdown.
• The burner will operate at low-fire for a brief period on each start during normal operation.
• Elimination of frequent burner on-off cycling.
Separate and independent controls affect modulated firing and burner on-off cycling.
FIGURE 6-4. Firing Graph
The burner will be “on” whenever the pressure or temperature is less than point B (see Figure 6-4) and “off ” whenever
pressure or temperature is greater than point A. The distance between points A and B represents the “on-off ” differential
of the operating limit control.
6-6 750-94 (revised 2009)

In normal operation, the burner will shut down whenever the pressure or temperature rises above setting A. At that point
the switch in the operating limit control will open. As the pressure or temperature drops back to B, the operating limit con-
trol closes and the burner will restart. The modulating control will signal the modulating motor to be in a low-fire position.
If the load demands exceed the low fire input potential, the modulating control will increase the firing rate proportionately
as pressure or temperature falls toward point D. The modulating motor will stop at any intermediate point between C and D
whenever the fuel input balances the load requirement.
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 high-fire. In the event pressure or temperature drops while the
burner is firing at high-fire, it indicates that the load exceeds the capacity of the boiler.
The firing graph (Figure 6-4) shows that point B and point C do not coincide. Extreme load conditions could require the
points be closely matched.
When set as shown, with a time lag between B and C, the burner will be in a low-fire position upon a restart and will fire at
that rate for a short period of time before falling pressure or temperature requires an increase in the firing rate.
NOTE: On-off cycling in excess of 8 cycles per hour will shorten the life of the combustion air motor and cause excessive wear
on switch gear and pilot electrodes.
If points B and C overlap when restart occurs, the burner would drive to a higher firing position immediately after the main
flame was proven.
NOTE: It is not recommended that the boiler controls be set so as to overlap the modulating control range and operating con-
trol range.
When firing a cold boiler, it is recommended that the burner be kept at low-fire, under manual flame control, until normal
operating pressure or temperature is reached. If the burner is not under manual control on a cold start, it will immediately
move toward high-fire as soon as the program control releases the circuit that holds the burner in low-fire. The modulating
control will be calling for high-fire and the burner will move to that position as rapidly as the damper motor can complete
its travel.
NOTE: Rapid heat input can subject the pressure vessel metal and refractory to undesirable conditions.
Do not operate the boiler in excess of 90% of the safety valve relief setting. The closer the operating pressure is to the safety
valve relief pressure, the greater the possibility of valve leakage. continued leakage, however slight, will cause erosion and
necessitate early safety valve replacement. The control settings on a hot water boiler must be within the temperature limits
of the boiler.
Ideally, the boiler operating controls should be set under actual load conditions. Especially under new construction condi-
tions, the boiler is initially started and set to operate under less than full load requirements. As soon as possible thereafter,
the controls should be reset to provide maximum utilization of the modulating firing system. To accomplish maximum uti-
lization, and assuming that air/fuel combustion ratios have been set, make the required adjustments to the controls to bring
the boiler pressure or temperature up to meet the load requirements.
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.
750-94 (revised 2009) 6-7

When the modulating control is set and the burner is in full high-fire, the scale setting of the modulating pressure control
on a steam boiler will indicate the low point of the modulating range. The scale setting of the modulating temperature con-
trol on a hot water boiler will have a reading that indicates the midpoint of the modulating range.
The operating limit control should now be adjusted and the differential established. In an installation that does not require
a very close control of steam pressure or water temperature, the adjustable differential should be set as wide as conditions
permit, since a wide setting will provide less frequent burner cycling.
The high limit control provides a safety factor to shut the burner off in the event the operating limit control should fail. The
setting of the control should be sufficiently above the operating limit control to avoid nuisance shutdowns. The setting,
however, must be within the limits of the safety valve settings and should not exceed 90% of the valve setting. The control
requires manual resetting after it shuts off the burner.
In the setting of the controls, consideration must be given to the time required for a burner restart. Each start, requires a
pre-purge period, plus the fixed time required for proving the pilot and main flame. In addition, approximately one-half
minute is required for the damper motor to travel from low to high-fire. The time lag may allow pressure or temperature to
drop below desirable limits.
6.6 — Modulating Pressure Control: Steam

Turn the adjusting screw until the indicator is opposite the low point of the desired modulating range. Modulated firing will
range between the low point and a higher point equal to the modulating range of the particular control.
• in 0 - 5 psi controls the range is 1/2 lb
! Caution
To prevent burner shutdown at other than low-fire setting, adjust the modulating pressure control to modulate to low-fire
BEFORE the operating limit pressure control shuts off the burner. Failure to follow these instructions could result in dam-
age to the equipment.
6.7 — Operating Limit Pressure Control: Steam

Set the “cut-out” (burner off) pressure on the main scale using the large adjusting screw. Set the differential on the short
scale by turning the small adjusting screw until the indicator points to the desired difference between cut-out and cut-in
pressures. The “cut-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.
6.8 — High Limit Pressure Control: Steam

Set the “cut-out” (burner off) pressure on the main scale using the adjusting screw. The control will break a circuit when
pressure reaches this point. The setting should be sufficiently above the operating limit pressure control to avoid shut-
6-8 750-94 (revised 2009)

downs, and preferably not exceed 90% of safety valve setting. The control requires manual resetting after tripping on a pres-
sure increase. To reset, allow pressure to return to normal and then press the reset button.

Turn the knob on the front of the case until the pointer indicates the desired setpoint temperature. The desired setpoint is
the center point of a proportional range. The control has a 3º to 30º differential and may be adjusted to vary the tempera-
ture range within which modulating action is desired.
FIGURE 6-5. Hot Water Controls
With the cover off, turn the adjustment wheel until the pointer indicates the desired range.
! Caution
To prevent burner shutdown at other than low-fire setting, adjust the modulating pressure control to modulate to low-fire
BEFORE the operating limit pressure control shuts off the burner. Failure to follow these instructions could result in damage
to the equipment.

Set “cut-out” (burner off) temperature on the scale by inserting a screwdriver through the cover opening to engage the slot-
ted head adjusting screw. The “cut-in” (burner on) temperature is the cut-out temperature minus the differential. The differ-
ential is adjusted from 5º to 30º F.
750-94 (revised 2009) 6-9

6.11 — High Limit Temperature Control: Hot Water

Set the “cut-out” (burner off) temperature on scale using the adjusting screw. The control will break the circuit and lock out
on a rise in water temperature above the setting. The setting should be sufficiently above the operating limit temperature to
avoid unnecessary shutdowns. On a 30 psig hot water boiler, the setting is not to exceed 240º F. The control requires man-
ual resetting after tripping on a temperature increase. To reset, allow the water temperature to drop below the cut-out set-
ting less differential, and then press the manual reset button.
6.12 — Low Water Cutoff Devices: Steam & Hot Water

No adjustment is required since LWCO controls are preset by the original manufacturer. However, if the water level is not
properly maintained, inspect the devices immediately and replace as required.
6.13 — Combustion Air Proving Switch

Air pressure against the diaphragm actuates the switch which, when made, completes a circuit to prove the presence of
combustion air. Since the pressure of the combustion air is at its minimum value when the damper is full open, the switch
should be adjusted under that situation. It should be set slightly below the minimum pressure, but not too close to that
point to cause nuisance shutdowns.
The run/test switch on the program relay should be set to TEST. Turn the burner switch on. The blower will start (pro-
vided that all limit circuits are completed) and the programmer will remain in the low-fire (damper closed) portion of the
pre-purge.
NOTE: On an oil fired boiler, the atomizing air proving switch (AAPS) must also be closed.
On a combination fuel fired burner, the fuel selector switch could be set at “gas” to eliminate the atomizing air proving
switch from the circuitry.
To have the modulating damper motor drive to high-fire (damper open), remove the cover from the motor and remove the
wire from terminal W.
Slowly turn down the air switch adjusting screw until it breaks the circuit. Here the programmer will lock out and must be
manually reset before it can be restarted. Add a half turn or so to the adjusting screw to remake its circuit.
Recycle the program relay to be sure that normal operation is obtained. Replace the wire on terminal W and re-install the
cover. Return the test switch to the RUN position.
6.14 — Atomizing Air Proving Switch

The air pressure against the diaphragm actuates the switch which, when closed, completes a circuit to prove the presence of
atomizing air. Since the pressure of the atomizing air is at its minimum value when there is no fuel present at the nozzle,
adjustment of the switch should be done while the unit is running but not firing. The control should be set slightly below
the minimum pressure, but not too close to that point to cause nuisance shutdowns.
6-10 750-94 (revised 2009)

The control adjustment may be made during the pre-purge period of operation by stopping the programmer during the pre-
purge period through the use of the TEST switch. Refer to the control instruction bulletin for details.
The adjustment screw of the atomizing air proving switch can then be adjusted until it breaks the circuit. Here, the pro-
grammer 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.
Since the adjustment of the air switch may be made either during the damper closed or damper open position of pre-purge,
it is also possible to make the adjustment with the relay stopped in the damper open position in a similar manner to the
adjustment of the combustion air proving switch described in Section 6.13.
After making the adjustment, recycle the control to be sure that normal operation is obtained. The TEST switch must be set
to RUN position.

The size of the gas pilot flame is regulated by adjusting the gas flow through the pilot gas regulator and the adjusting cock.
The flame must be sufficient to ignite the main flame and to be seen by the flame detector. But an extremely large flame is
not required. An overly rich flame can cause sooting or carbon buildup on the flame detector. Too small a flame can cause
ignition problems.
Although it is possible to visibly adjust the size of the pilot flame, it is preferable to obtain a microamp or voltage reading of
the flame signal.
The correct voltage or microamp readings can be found in the information supplied with the flame safeguard system.
The program relay used may be of the type that provides message information that includes a constant flame signal of DC
voltage. In this case a separate DC voltmeter is not required.
6.15.1 — Measure and Adjust Pilot

1. When making a pilot adjustment, turn the manual-automatic switch to “manual” and the manual flame control to
“close.”
2. Open both the cutoff cock and the pilot adjusting cock. The main gas cock should remain closed.
The regulator in the pilot line, if provided, is to reduce the gas pressure to suit the pilot’s requirement of between 5” to
10” WC. Regulator adjustment is not critical, however, with a lower pressure the final adjustment of the pilot flame with
adjusting cock is less sensitive.
3. Connect the micro-ammeter.
4. Turn the burner switch on. Let the burner go through the normal pre-purge cycle. When the ignition trial period is sig-
naled, set the test switch to the TEST position to stop the sequence.
5. If the pilot flame is not established within 10 seconds, turn off the burner switch. Repeat the lighting attempt.
NOTE: On an initial starting attempt, portions of the fuel lines may be empty and require “bleeding” time. It is better to
accomplish this with repeated short lightning trial periods with intervening purge periods than to risk prolonged fuel introduc-
tion. If the pilot does not light after several attempts, check all components of the pilot system.
6. When the pilot flame is established, and with the pilot adjusting cock wide open, remove the flame detector from the
burner plate. The pilot flame can then be observed through this opening.
750-94 (revised 2009) 6-11

! Warning
Wear a protective shield or suitable glasses and keep eyes sufficiently away from the sight tube opening to avoid serious per-
sonal injury. Never remove the flame detector while the main burner is firing.
Failure to follow these instructions could result in serious injury or death.
7. To make the final adjustment, slowly close the gas pilot adjusting cock until the flame can no longer be seen through the
sight tube. Then slowly open the cock until a flame providing full sight tube coverage is observed.
The adjustment must be accomplished within the time limit of the safety switch or approximately 30 seconds after the
detector is removed. If the control shuts down, manually reset it. Replace the detector and repeat the process from step
6.
8. When a suitable flame is obtained, replace the detector. Observe the reading on the micro-ammeter. The reading should
be between 2-1/4 and 5 microamps when using a lead sulfide detector and a standard amplifier. See the flame signal
table in the manufacturer's bulletin for values of other combinations.
The flame signal indicated on the annunciator type relay should not be less than 10 Vdc, and may be as high as 20 Vdc
or greater.
The reading must be steady. If the reading fluctuates, recheck the adjustment. Be sure that the flame detector is properly
seated and that the lens is clean.
10. If main flame has not been previously established, proceed to do so in accordance with proper instructions.
11. The reading of the main flame signal should also be checked. Observe the flame signal for pilot alone, pilot and main
burner flame together, and the main burner flame at high, low, and intermediate firing rate positions. Readings should be
steady and in the range indicated in Step 8. If there are any deviations, refer to the troubleshooting section in the techni-
cal bulletin.

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. Once the optimum pressure has been established, it should be recorded and periodic checks made to
verify that the regulator is holding the pressure at this level. Occasional modification in fuel composition or pressure by the
supplier may, at times, require readjustment to return the burner to peak efficiency. Since the gas pressure regulator itself is
usually furnished by others, detailed adjustment instructions and adjusting procedures recommended by the manufacturer
should be followed.
6.16.1 — Pressure
The gas supplied must provide not only the quantity of gas demanded by the unit, but must also be at a pressure high
enough to overcome the pressure-loss due to the frictional resistance imposed by the burner system and the control valves.
6-12 750-94 (revised 2009)

The pressure required at the entrance to the burner gas train for rated boiler output is termed “net regulated pressure.” The
gas pressure regulator must be adjusted to achieve the pressure to assure full input.
Pressure Required at Gas Train Entrance with Two Valves and 3” Pipe
Boiler HP Standard HTB LE
400 17.5” WC 19.0” WC 23.0” WC
500 26.0” WC 31.0” WC 36.0” WC
600 38.5” WC 40.0” WC 48.0” WC
700 58.0” WC 64.0” WC 70.0” WC
800 73.0” WC 80.5” WC 92.0” WC
FIGURE 6-6. Minimum Net Regulated Gas Pressure for Rated Boiler Output
The pressure requirement varies with boiler size, altitude, and type of gas train. The pressures listed are based on 1000 Btu/
cu. ft. natural gas at elevations up to 700 feet above sea level. For installation at higher altitudes, multiply the selected pres-
sure by the proper factor from Figure 6-7.
Altitude
Feet Above Sea Level Correction Factor
1000 1.04
2000 1.07
2500 1.09
3000 1.11
4000 1.16
5000 1.21
6000 1.25
7000 1.30
8000 1.35
9000 1.40
FIGURE 6-7. Pressure/Altitude Correction Factors

400 16,750,000 4,190,000
500 20,925,000 5,230,000
600 25,100,000 6,275,000
750-94 (revised 2009) 6-13


700 29,300,000 7,325,000
800 33,500,000 8,375,000
FIGURE 6-8. Standard Burner Required Input

400 16,750,000 1,675,000
500 20,925,000 2,092,500
600 25,100,000 2,510,000
700 29,300,000 2,930,000
800 33,500,000 3,350,000
FIGURE 6-9. High Turndown Burner Required Input

1 1.05
2 1.11
3 1.18
4 1.25
5 1.32
6 1.39
7 1.45
8 1.53
9 1.59
10 1.66
11 1.72
12 1.81
13 1.86
14 1.93
15 2.00
FIGURE 6-10. Pressure Correction Factors
6-14 750-94 (revised 2009)

6.16.2 — Gas Flow

The volume of gas flow is measured in terms of cubic feet and is determined by a meter reading. The gas flow rate required
for maximum boiler output depends on the heating value (Btu/cu. ft.) of the gas supplied and boiler efficiency. The supply-
ing utility can provide the information.
EFFICIENCY
GAS FLOW = INPUT

GAS Btus/Ft3
= OUTPUT x 100
EFFICIENCY x GAS BTUs/Ft3
6.16.3 — Pressure Correction

The flow rate outlined in Section 6.16 is based on a “base” pressure, which is usually atmospheric or 14.7 psia.
Meters generally measure gas in cubic feet at “line” or supply pressure. The pressure at which each cubic foot is measured
and the correction factor for the pressure must be known in order to convert the quantity indicated by the meter into the
quantity which would be measured at “base” pressure.
To express the volume obtained from an actual meter reading into cubic feet at base pressure, it is necessary to multiply the
meter index reading by the proper pressure factor obtained from Figure 6-10.
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. This answer indicates the number of cubic feet at line
pressure which must pass through the meter to deliver the equivalent number of cubic feet at base pressure.
For example, assume that a 600 horsepower boiler is installed at 2,000 feet above sea level, is equipped with a standard gas
train and a high turndown burner, and that 1,000 Btu natural gas is available with in incoming gas pressure of 3 psig. The
pressure and flow requirements can be determined as follows:
PRESSURE
Correction for the 2,000 feet altitude must be made since altitude has a bearing on the net regulated gas pressure. The stan-
dard gas train requires 37.5” WC gas pressure at sea level. Figure 6-7 indicates a correction factor of 1.07 for 2,000 feet.
Multiplying results in a calculated net regulated gas requirement of approximately 40.1” WC. This is the initial pressure to
which the regulator should e adjusted. Slight additional adjustment can be made later, if necessary, to obtain the gas input
needed for burner rating.
FLOW
Since the gas flow rate is based on standard conditions of flow, correction must be made for the supply pressure through
the meter of 3 psig. Determine the flow rate by dividing the Btu content of the gas into the burner input (Figure 6-8) and
“correct” this answer by applying the correction factor for 3 psig (Figure 6-9).
750-94 (revised 2009) 6-15

Btu/hr input = CFH (Cubic feet/hour)

Btu/cu. ft.
OR
25,100,000 = 25,100 CFH (at 14.7 lb atmospheric base pressure)

1,000
THEN
25.100 = 21,271 CFH

1.18
This is the CFH (at line pressure) that must pass through the meter so that the equivalent full input requirement of 25,100
CFH (at base pressure) will be delivered.
6.16.4 — Checking Gas Flow

Your gas supplier can generally furnish a gas meter flow chart from which gas flow can be determined. After a short obser-
vation period, the information aids in adjusting the regulator to increase or decrease flow as required to obtain the rating.
Final adjustment of the gas fuel is carried out be means of the adjusting screws in the gas modulating cam, while perform-
ing a combustion efficiency analysis. See Section 6.17 for details.
NOTE: The information given in this section is for all practical purposes sufficient to set and adjust controls for gas input.
Your gas supplier can, if necessary, furnish exact correction factors that take into consideration Btu content, exact base
pressure, specific gravity, temperature, etc. of the gas used.

After operating for a sufficient period of time to assure a warm boiler, adjustments should be made to obtain efficient com-
bustion.
Burner efficiency is measured by the amount or percentage of O2 present in the flue gas. O2 readings determine the total
amount or excess air in the combustion process, above the point of stoichiometric combustion or perfect combustion. Stoi-
chiometric combustion is a term used to describe a condition when there is the exact amount, molecule for molecule, of air
for the fuel burned. This can be accomplished under laboratory conditions, however, it’s not practical to attempt to meet
this condition in a boiler. Stoichiometric combustion, however, is the reference point used when setting air/fuel ratios in a
boiler.
There must always be excess air in the combustion process to account for changes in boiler room temperature and atmo-
spheric conditions, and to ensure the combustion is on the proper side of the combustion curve (see Figure 6-11).
Proper setting of the air/fuel ratios at all rates of firing must be established by the use of a combustion or flue gas analyzer.
6-16 750-94 (revised 2009)

The appearance or color of the gas flame is not an indication of its efficiency, because an efficient gas flame will vary from
transparent blue to translucent yellow.
FIGURE 6-11. Flue Gas Analysis for Natural Gas
Most flue gas analyzers in use today measure the content, by percentage of oxygen (O2) and carbon monoxide (CO) either
by percent or parts per million (ppm). Carbon dioxide (CO2) is not normally measured with today’s flue gas analyzers, but
may be displayed via a calculation.
The O2 levels through the entire firing range of the burner, low-fire to high-fire should be tested. The burner manufacturer’s
recommendations on turndown should also be followed and the turndown range of the burner should not be exceeded.
It is important to understand what the readings shown on an instrument refer to when setting combustion in a boiler. To
assist with this understanding Figure 6-11 shows the relationship between O2 levels (excess air) and the products of com-
bustion for a typical flue gas analysis (natural gas).
One of the products of combustion is CO2 (carbon dioxide). This is shown in percentage.
Another product of combustion is CO (carbon monoxide) and is shown in both percentage and parts per million (ppm).
The maximum CO level standardly allowed is less than 400 ppm. However, this may change subject to local regulations.
The percent O2 recorded on an instrument equates to percent excess air, i.e., 3% O2 is approximately 15% excess air and 4%
O2 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 O2 readings of between 3% and 4% be attained with less than 400 ppm CO, at high-fire.
Using information from section 6.16, determine the standard conditions of gas pressure and flow for the boiler size and
attached gas train. Calculate the actual pressure and flow through the use of correction factors that compensate for incom-
ing gas pressure and altitude.
750-94 (revised 2009) 6-17

Basically, gas adjustments are made with a gas pressure regulator, which controls the pressure and with the butterfly gas
valve which directly controls the rate of flow.
FIGURE 6-12. Butterfly Gas Valve
In initially setting the linkage:

1. Back off the low fire stop screw on the butterfly valve so that the valve is closed.
2. Then run the screw out to touch the arm, and give it two complete turns.
3. Adjust the connecting rod so that the override tension is released and so that the arm is now just touching the stop
screw.
4. Tighten the locknuts on all ball joints.
The low fire setting should be regarded as tentative until the proper gas pressure for high-fire operation is established. To
reach high-fire rate:
1. Turn the manual flame control switch toward “OPEN” in minor increments while monitoring combustion for overly
rich or lean conditions.
2. At high-fire the gas butterfly valve should be open as wide as indicated by the slot on the end of the shaft. Set and lock
the high-fire stop screw so that it is just touching the valve arm.
3. Determine the actual gas flow from a meter reading.
4. With the butterfly valve open and with regulated gas pressure set at the calculated pressure, the actual flow rate should
be close to the required input. If corrections are necessary, increase or decrease the gas pressure by adjusting the gas
pressure regulator, following the manufacturer’s directions for regulator adjustment.
When proper gas flow is obtained, take a flue gas reading. The O2 should be between 3% and 4% at high-fire.
If the fuel input is correct, but the O2 values do not fall within this range, the air damper travel may need to be adjusted.
Adjustment of the air damper linkage is described in Section 6.2.
With the high-fire air/fuel ratio established, the gas pressure regulator needs no further adjusting.
6-18 750-94 (revised 2009)

After being certain that the air control damper and its linkage are correctly adjusted to provide the proper amount of sec-
ondary air, and after adjusting the gas pressure regulator, final adjustment can be made, if necessary, to the gas modulating
cam to obtain a constant air/fuel ratio throughout the entire firing range.
Since the input of combustion air is ordinarily fixed at any given point in the modulating cycle, the flue gas reading is deter-
mined 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 decrease it. Flow rate is highest when the cam follower assembly is closest to the
jackshaft.
FIGURE 6-13. Fuel Modulating Cam
Through the manual flame control switch, position the cam so that the adjusting screw adjacent to the end or high-fire
screw contacts the cam follower. Perform a combustion analysis at this point. If an adjustment is necessary, turn the adjust-
ment screw accordingly to increase or decrease fuel flow. Take a combustion reading to verify input. Repeat as necessary
until the desired flow is obtained. Repeat the process, stopping at each adjusting screw, until the low-fire adjusting screw is
reached.
NOTE: Do not use any lubricant on the adjusting setscrews. The setscrews have a nylon locking insert intended to provide
locking torque and resistance to loosening and a lubricant could damage the equipment.
6.17.1 — Standard Burner Low-Fire Adjustment

The fuel input should be adjusted using the low-fire cam screw, to approximately 25% of that at high-fire (see Figure 6-8).
At low-fire the O2 flue gas reading should be between 6% and 7%.
It may be necessary to readjust the setting of the low-fire stopscrew to obtain the proper air/fuel ratio at the low-fire rate.
To ensure that the low-fire position of the gas butterfly valve is always the same, allow one turn of the stop screw for over-
travel.
If the air damper needs to be adjusted in order to provide the correct low-fire air/fuel ratio, combustion must be rechecked
at higher firing rates and adjusted as required.
750-94 (revised 2009) 6-19

If all cam screws are properly adjusted, none will deviate from the general overall contour of the cam face.
6.17.2 — High Turndown Burner Low-Fire Adjustment

The fuel input should be adjusted using the low-fire cam screw, to approximately 10% of that at high-fire (see Figure 6-9).
At low-fire the O2 flue gas reading should be between 9.5% and 11%.
It may be necessary to readjust the setting of the low-fire stopscrew in order to obtain the proper air/fuel ratio at low-fire.
To ensure that the low-fire position of the gas butterfly valve is always the same, allow a half turn of the stop screw for
overtravel.
If the air damper must be reset to meet the low-fire air/fuel requirements, combustion at higher firing rates must be
rechecked.
The second cam adjusting screw may need to be adjusted in order to maintain a smooth cam profile. If all screws are prop-
erly adjusted, none will deviate from the general overall contour of the cam face.

Adjust the scale setting to slightly below the normal burning pressure. The control circuit will be broken when pressure falls
below this point. Since gas line distribution pressure may decrease under some conditions, shutdowns may result if the set-
ting is too close to normal. However, regulations require that the setting may not be less than 50% of the rated pressure
downstream of the regulator.
Manual resetting is necessary after a pressure drop. Press the reset lever after pressure is restored. Be sure that the mercury
switch equipped control is level.
6.19 — 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.
6-20 750-94 (revised 2009)

Manual resetting is necessary after a pressure rise. Press the reset lever after pressure falls. Be sure that the mercury switch
equipped control is level.
FIGURE 6-14. Gas Train Pressure Switches

Variations in burning characteristics of the fuel oil may occasionally require adjustments to assure highest combustion effi-
ciency. The handling and burning characteristics may vary from one delivery of oil to another. Therefore, it is recommended
that the oil system be inspected from time to time to verify that pressures and viscosity are at the proper operating levels.
Because of variation in oils, including chemical content, source, blends, and viscosity characteristics, the temperatures and
pressures listed in Chapter 5, and mentioned in the adjusting of the controls in the following paragraphs, will vary and thus
may be regarded as tentative and to be changed to provide best firing conditions. Figure 6-15 is an oil viscosity-temperature
chart. It may be used as a guide, although your oil supplier will be able to give you more exact information based on an anal-
ysis of the oil.
750-94 (revised 2009) 6-21

FIGURE 6-15. Oil Viscosity Chart
Review of the applicable maintenance instructions given in Chapter 8 will aid in maintaining an efficient fuel system.
NOTE: To prevent oil heater coking, the fuel oil pump must be in operation during all times that an oil heater is in service.
During any time that the oil pump is not operating, the oil heating system must be electrically shut down by manually turn-
ing the oil heater switch to the “off ” position.
When the boiler is shut down, or switched over to gas firing, the pump must operate for a sufficient period of time to cool
the oil heater. Similarly, if an electric, steam, or hot water oil heater is removed for servicing, the temperature of the heater
should be reduced by circulating oil until it has cooled.

After operating for a sufficient period of time to assure a warm boiler, adjustments should be made to obtain efficient com-
bustion.
Burner efficiency is measured by the amount or percentage of O2 present in the flue gas. O2 readings determine the total
amount or excess air in the combustion process, above the point of stoichiometric combustion or perfect combustion. Stoi-
chiometric combustion, however, is the reference point used when setting air/fuel ratios in a boiler.
There must always be excess air in the combustion process to account for changes in boiler room conditions and to ensure
the combustion is on the proper side of the combustion curve.
Proper setting of the air/fuel ratios at all rates of firing must be established by the use of a combustion gas analyzer. Effi-
cient combustion cannot be solely judged by flame condition or color, although they may be used in making approximate
settings. Combustion settings should be done so that there is a bright sharp flame with no visible haze.
6-22 750-94 (revised 2009)

Most flue gas analyzers in use today measure the content, by percentage, of oxygen (O2) and in some cases, smoke. Carbon
dioxide (CO2) is not normally measured with modern gas analyzers, but may be displayed as a calculation.
The O2 levels through the entire firing range of the burner, low-fire to high-fire should be tested. The burner manufacturer’s
recommendations on turndown should also be followed and the turndown range of the burner should not be exceeded.
It is required to set the burner to operate with a reasonable amount of excess air to compensate for minor variations in the
pressure, temperature, or burning properties of oil. 15% to 20% excess air is considered reasonable. This would result in an
O2 reading of 3% to 4% at high-fire.
Final adjustment to fuel input must be made to produce a minimum of smoke. A maximum smoke spot density of a No. 2
for light oil, or a No. 4 for heavy oil is acceptable, as measured in conformance to ASTMD 2156-63T.
Through the use of the manual flame control, slowly bring the unit to high-fire by stages while monitoring combustion for
overly rich or lean conditions. At the high-fire position, the air damper should be fully opened and the air and oil pressure
readings should be on the order of the readings given in Chapter 5.
Take a flue gas analysis reading. If necessary, adjust the fuel oil controller to increase or decrease oil pressure. Adjustments
to the pressure should be done before attempting to adjust the screws in the metering cam. Ideally, the cam profile spring
should be as close to the cam casting as practical. It is more desirable to lower the oil pressure to reduce flow, if necessary,
than to extend the adjusting screws to an extreme position in an effort to cut back flow.
After being certain that the air control damper and its linkage are operating properly, final adjustment can be made, if neces-
sary, to the oil modulating cam to obtain a constant air/fuel ratio through the entire firing range.
Since the input of combustion air is ordinarily fixed at any given point in the modulating cycle, the flue gas reading is deter-
mined by varying the input of fuel at that setting. The adjustment is made to the metering cam by means of adjusting screws,
which are turned out (counterclockwise from the hex-socket end) to increase the flow of fuel and in (clockwise from the
hex-socket end) to decrease it. Flow rate is highest when the cam follower assembly is closest to the jackshaft.
If oil pressure, primary air pressure, and linkages are properly adjusted, the metering cam should require minimal adjust-
ment.
Using the flame control switch, position the cam so that the adjusting screw adjacent to the end, high-fire screw, contacts
the cam follower. Make a combustion analysis at this point.
If an adjustment is necessary, turn the adjustment screw accordingly to increase or decrease fuel flow. Take a combustion
reading to verify input. Repeat as necessary until the desired flow is obtained. Continue this pressure, stopping at each
adjusting screw, until the low-fire position is reached.
NOTE: Do not use any lubricant on the adjusting setscrews. These have a nylon locking insert intended to provide locking
torque and resistance to loosening and a lubricant could damage the equipment.
6.21.1 — Standard Burner Low-Fire Adjustment: Heavy Oil

The fuel input should be adjusted with the low-fire cam screw, to approximately 25% of that at high-fire. At low fire the O2
flue gas reading should be between 7% and 8%.
750-94 (revised 2009) 6-23

6.21.2 — High Turndown Burner Low-Fire Adjustment: Light Oil

Fuel input at low-fire should be approximately 12.5% of that at high-fire. The low-fire screw should be adjusted to obtain
the necessary input for the fuel turndown required. At low-fire the O2 flue gas reading should be between 7% and 9%. The
second cam adjusting screw may need to be adjusted in order to maintain a smooth cam profile.

There are relatively few adjustments that can be made to the burner, however, a check should be made to assure that all
components are properly located, and that all holding screws are properly tightened.
The diffuser location on gas fired boilers is quite important. There should be 1/4” distance between the edges of the dif-
fuser fins and gas outlet tubes (spuds) (see Figure 6-16). The setting of an oil fired burner is less exacting and the diffuser
should be located with the skirt approximately 1-1/8” from the end of the burner tube.
FIGURE 6-16. Standard Burner
When the proper diffuser location is ascertained, the setting of the nozzle in relation to the diffuser should be checked. This
generally is set at time of manufacture and seldom needs altering. It is most important that oil spray does not impinge upon
the diffuser. The distance that the nozzle is behind the diffuser has some latitude, and individual installations may require a
slight deviation. The spacing indicated is 2”.
6-24 750-94 (revised 2009)

Check the setting of the ignition electrode(s) for proper gap and position. Be sure that the porcelain insulator is not cracked
and that ignition cable connections are tight.
FIGURE 6-17. Burner Drawer With Gas Pilot
The oil nozzle tip should be seated tightly in the body with the swirler and the seating spring in place. See Section 8.7 for
additional nozzle tip information.
FIGURE 6-18. Electrode Setting: Oil Pilot
Check to see that the flame detector sight tube and the gas pilot tube extend through their respective openings in the dif-
fuser face.
750-94 (revised 2009) 6-25

6.23 — Oil Drawer Switch

The integral contacts of the control are closed by proper positioning and latching of the oil drawer in its forward position.
Adjustment of the switch must be such that its contacts open if the oil drawer is not properly positioned for oil firing. The
switch is electrically removed from the circuit when a combination fuel burner is fired on gas.

The LOTS prevents the burner from starting, or stops its operation, if the temperature of the oil is below normal operating
temperature.
To adjust the control:

1. Insert a screwdriver into the center slot in the control cover and turn the dial until the fixed (center) pointer is approxi-
mately 30º F lower than the oil heater thermostat setting.
2. Turn the differential adjusting screw (located above dial) until the movable indicator is approximately 5º F above the set-
ting on the main scale.
On a hot water boiler, the low oil temperature switch is an integral part of the electric oil heater. The switch is non-adjust-
able and is factory set at approximately 40º F below the maximum operating temperature of the heater.
6.25 — High Oil Temperature Switch (Optional)

The HOTS prevents the burner from starting, or stops its operation, if the temperature of the oil exceeds the normal oper-
ating temperature.
To adjust, turn the dial until the pointer is approximately 25º F above the normal operating temperature. The controls gen-
erally have a set differential and will close 5º F below the setpoint.
6.26 — Low Oil Pressure Switch (Optional)

The LOPS prevents burner ignition, or stops its operation, when the oil pressure is below the setpoint. Adjust the control
by turning the screw on top of the control case to an indicated pressure 10 psi below the established primary oil pressure
setting indicated on the oil supply pressure gauge. The switch will remain in a closed position as long as the oil pressure
exceeds this setting. The control normally used automatically resets when pressure is restored after a drop.
6.27 — Electric Oil Heater Thermostat (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 clock-
wise using the thermometer in the fuel oil controller as a guide.
6-26 750-94 (revised 2009)

6.28 — Steam Oil Heater Thermostat: No. 6 Oil
The final setting of this thermostat should be at a temperature approximately 15º F lower than the steam heater thermostat.
This eliminates the electric heater operation when the steam heater is functioning. The electric heater is sized to provide suf-
ficient heated oil for low-fire operation on cold starts before steam is available.
6.28 — 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 clock-
wise using the thermometer in the fuel oil controller as a guide.
The final setting of the thermostat should provide oil at a sufficient temperature for efficient combustion based on flue gas
analysis. There is no need to heat the oil in excess of the temperature.
6.29 — Hot Water Oil Heater Thermostat (400 and 600 Series)
To adjust the thermostat, insert a screwdriver into the center slot in the control cover and turn the dial until the pointer is at
the desired temperature level. The control generally has a set differential, and will close 5º F below the setpoint.
The thermostat contacts close to energize the booster water pump, which pumps water from the boiler through the heater.
On cold starts, it is normal practice to manually close the valve in the pump discharge line until the boiler water temperature
exceeds the temperature of fuel oil entering the heater.
The electric oil heater on a hot water boiler burning No. 6 oil and equipped with a hot water oil heater has a built-in adjust-
able thermostat. The maximum temperature setting is stamped on its dial. The desired temperature can be obtained by turn-
ing the adjusting screw. The thermostat should be set at a temperature approximately 15 degrees lower than the hot water
heater thermostat. Such a temperature prevents the electric heater from operation when the water heater is functioning. The
electric heater is sized to provide sufficient heated oil for low-fire operation on cold starts before hot water is available.
6.30 — Steam Heater Pressure Regulator (400 and 600 Series: Steam)
The regulator is provided on a boiler designed to operate at pressures above 15 psi and reduces boiler steam pressure to the
level necessary for proper operation of the steam oil heater. The pressure should be reduced to a point that permits suffi-
cient temperature to heat the oil, while allowing as continuous a steam flow as possible. Pressure that is too high will result
in frequent cycling of the steam solenoid valve.
It is best to adjust the regulator under typical flow conditions. To do so, it is suggested that the globe valve in the steam sup-
ply line be closed so that there is no pressure on the regulator. Turn out the adjusting screw fully to relieve compression on
the regulator spring, thus closing the regulator. With steam at normal pressure, open the globe valve and then set the sec-
ondary pressure by turning the adjusting screw or handle until the downstream gauge shows the desired pressure.
750-94 (revised 2009) 6-27

6-28 750-94 (revised 2009)

CHAPTER 7 Troubleshooting
7.1 — Overview
! Warning
Troubleshooting should be performed only by personnel who are familiar with the equipment and who have read and under-
stand the contents of this manual. Failure to follow these instructions could result in serious injury or death.
! Warning
Disconnect and lock out the main power supply in order to avoid the hazard of electrical shock. Failure to follow these instruc-
sequence applies regardless of the make or model. Please refer to the Wiring Diagram (WD) prepared by Cleaver-Brooks for
your specific installation.
Chapter 7 assumes that the unit has been properly installed and adjusted, and that it has been running for some time. It is
further assumed that the operator has become thoroughly familiar with both burner and manual by this time. The points
under each heading are set down briefly as possible causes, and suggestions or clues to simplify locating the source of trou-
ble. Methods of correcting the trouble, once it has been identified, may be found elsewhere in this manual.
If the burner will not start or operate properly, the troubleshooting chapter should be referred to for assistance in pinpoint-
ing problems that may not be readily apparent.
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 programmer and other controls in the system may be obtained by studying the contents of this manual.
Knowledge of the system and its controls will make troubleshooting much easier. Costly downtime or delays can be pre-
vented by systematic checks of actual operation against the normal sequence to determine the stage at which performance
750-94 (revised 2009) 7-1

Troubleshooting
deviates from normal. Following a routine may possibly eliminate overlooking an obvious condition, often one that is rela-
tively simple to correct.
If an obvious condition is not apparent, check the continuity of the circuits with a voltmeter or test lamp. Each circuit can
be checked and the fault isolated and corrected. Most circuitry checking can be done between appropriate terminal on the
terminal boards in the control cabinet or the entrance box. Refer to the schematic wiring diagram for terminal identifica-
tion.

BURNER DOES NOT 1. No voltage at program relay power input terminals.
START A. Main disconnect switch open.
3. Limit circuit not completed - no voltage at end of limit circuit program
relay terminal.
A. Pressure or temperature is above setting of operation control. (Load
demand light will not glow.)
1) Low-water light (and alarm horn) should indicate this condition.
2) Check manual reset button (if provided) on low-water control.
C. Fuel pressure must be within settings of low pressure and high pres-
sure switches.
D. Oil fired unit - burner gun must be in full forward position to close
oil drawer switch.
7-2 750-94 (revised 2009)

7.1 — Overview

C. Loose terminal on ignition cable - or cable shorted.
A. lack of fuel - no gas pressure, closed valve, empty tank, broken line,
etc.
D. Too much air.
3. Low-fire switch open in low-fire proving circuit.
A. Combustion or atomizing air proving switches defective or not
properly set.
PILOT FLAME, BUT 1. Insufficient pilot flame.

NO MAIN FLAMW 2. Gas fired unit:
3. Oil fired unit:
C. No fuel.
E. Check oil nozzle, gun, and lines.
BURNER STAYS IN 1. Pressure or temperature above modulating control setting.

LOW-FIRE 2. Manual-automatic switch in wrong position.
3. Inoperative modulating motor.
750-94 (revised 2009) 7-3

Troubleshooting

DURING FIRING 2. Defective fuel valve, loose electrical connection.
5. If the programmer lockout switch has not tripped, check the limit cir-
cuit for an opened safety control.
D. The flame failure light is energized by ignition failure, main flame
failure, inadequate flame signal, or open control in the running
interlock circuit.
7. Improper air/fuel ratio (lean fire):
C. Fluctuating fuel supply:
1) Temporary obstruction in fuel line.
2) Temporary drop in gas pressure.
3) Orifice gate valve open.
MODULATING 1. Manual-automatic switch in wrong position.

MOTOR DOES NOT 2. Linkage loose or jammed.
OPERATE
3. Motor does not drive to open or close during pre-purge or close on
burner shutdown:
A. Motor defective.
4. Motor does not operate on demand:
A. Manual-automatic switch in wrong position.
C. Motor defective.
E.Damper motor transformer defective.
7-4 750-94 (revised 2009)

CHAPTER 8 Inspection and Maintenance
8.1 — Overview
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.
A well planned maintenance program will help avoid unnecessary downtime or costly repairs, promote safety, and aid boiler
inspectors. An inspection schedule with a listing of procedures should be established. It is recommended that a boiler room
log or record be maintained. Recording of daily, weekly, monthly, and yearly maintenance activities provides a valuable guide
and aids in obtaining economical and lengthy service from Cleaver-Brooks equipment. A sample boiler inspection schedule
is provided at the end of this chapter. It is important to realize that the frequency of inspection will depend on variable con-
ditions such as load, fuel, system requirements, boiler environment (indoor/outdoor), etc.
Good housekeeping helps maintain a professional appearing boiler room. Only trained and authorized personnel should be
permitted to operate, adjust, or repair the boiler and its related equipment. The boiler room should be kept free of all mate-
rial and equipment not necessary to the operation of the boiler or heating system.
Even though the boiler has electrical and mechanical devices that make it automatic or semi-automatic in operation, the
devices require systematic and periodic maintenance. Any automatic feature does not relieve the operator from responsibil-
ity, but rather frees the operator from certain repetitive chores providing time to devote to upkeep and maintenance.
Alertness in recognizing an unusual noise, improper gauge reading, leaks, etc., can make the operator aware of a developing
malfunction and permit prompt corrective action that may prevent extensive repairs or unexpected downtime. Any leaks —
fuel, water, steam, exhaust gas — should be repaired promptly and under conditions that observe necessary safety precau-
tions. Preventive maintenance measures, such as regularly checking the tightness of connections, locknuts, setscrews, pack-
ing glands, etc., should be included in regular maintenance activities.
750-94 (revised 2009) 8-1

8.1.1 — Periodic Inspection

Insurance regulations and local laws require periodic inspection of the pressure vessel by an authorized inspector. Section
3.8 in Chapter 3 contains information relative to the inspection.
Inspections are usually, though not necessarily, scheduled for periods of normal boiler downtime, such as an off season.
This major inspection can often be used to accomplish maintenance, replacement or repairs that cannot easily be done at
other times. Inspection also serves as a good basis for establishing a schedule for annual, monthly, or other periodic mainte-
nance programs.
While the inspection pertains primarily to the waterside and fireside surfaces of the pressure vessel it provides the operator
an excellent opportunity for 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.
Replacement spare parts, if not on hand, should be ordered sufficiently prior to shutdown.
NOTE: Cleaver-Brooks genuine parts should be used to ensure proper operation. Contact your local Cleaver-Brooks rep-
resentative for parts information and ordering.
Cleaver-Brooks boilers are designed, engineered, and built to provide long life and excellent service. Good operating prac-
tices and conscientious maintenance and care will assure efficiency and economy from their operation, and will contribute
to many years of performance.
A total protection plan includes a Planned Maintenance Program that covers many of the items included in this chapter.
For information regarding a total protection plan, contact your local Cleaver-Brooks authorized representative.
8.2 — 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 cor-
rosive acids that will deteriorate fireside metal.
Cleanout should be performed at regular and frequent intervals, depending upon load, type, and quality of fuel. internal
boiler temperature, and combustion efficiency. A stack temperature thermometer can be used as a guide to cleanout inter-
vals since an accumulation of soot deposits will raise the flue gas temperature.
Tube cleaning is accomplished by opening the front and rear doors. Tubes may be brushed from either end. All loose soot
and accumulations should be removed. Any soot, or other deposits, should be removed from the furnace and tube sheets.
Refer to Section 8.17 for instructions on properly closing rear heads.
The flue gas outlet and stack should be inspected annually and cleaned as necessary. Commercial firms are available to per-
form the work. The stack should be inspected for damage and repaired as required.
The fireside should be thoroughly cleaned prior to any extended lay-up of the boiler. Depending upon circumstances, a pro-
tective coating may be required. See Section 3.9 in Chapter 3.
8-2 750-94 (revised 2009)


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.
Always be sure of the boiler water level. On steam boilers, the water column should be blown down daily. Check samples of
boiler water and condensate in accordance with procedures recommended by your local Cleaver-Brooks authorized repre-
sentative. Refer to Sections 3.7 and 3.8 in Chapter 3 for blowdown instructions and internal inspection procedures.
Since low-water cutoff devices are generally set by the original manufacturer, no attempt should be made to adjust these
controls to alter the point of low-water cutoff or point of pump cut-in or cut-out. If a low-water device should become
erratic in operation, of if its setting changes from previously established levels, contact your local Cleaver-Brooks authorized
representative.
FIGURE 8-1. Low Water Cutoff
The low water cutoff controls normally function for long periods of time, which may lead to laxity in testing on the assump-
tion that normal operation will continue indefinitely.
! Warning
Safe operation of your generator demands periodic inspection and maintenance of all low water cutoff devices. Open and
inspect them at least once a month. Under constant attendance and with the burner in lo-fire position, check operation fre-
quently by stopping water flow to the generator and allowing the water level to lower. If controls do not cut off the burner
at the proper safe water level, or appear to be in poor physical condition, repair or replace at once.
On a steam boiler, the head mechanism of the low water cutoff device(s) should be removed from the bowl at least semi-
annually to check and clean the float ball, the internal moving parts, and the bowl or water column.
750-94 (revised 2009) 8-3

Remove the pipe plugs from the tees or crosses and make certain the cross-connecting piping is clean and free of obstruc-
tions. Controls must be mounted in a plumb position for proper performance. Determine that piping is vertically aligned
after shipment and installation and throughout life of the equipment.
A blowdown of the water controls on a steam boiler should be performed daily.

It is impractical to blowdown the low water cutoff device(s) on a hot water boiler since the entire water content of the sys-
tem would become involved. Many hot water systems are fully closed and any loss of water will require make-up and addi-
tional feedwater treatment that might not otherwise be necessary. Since the boiler and system arrangement usually make it
impractical to perform daily and monthly maintenance of the low water cutoff device(s), it is essential to verify proper oper-
ation. Remove the operating mechanism from the bowl annually or more frequently, if possible, to check and clean the float
ball, internal moving parts, and the bowl housing. Also check the cross-connecting piping to be certain that it is clean and
free of obstruction.
8.4 — Water Gauge Glass

A broken or discolored glass should be replaced at once. Periodic replacement should be a part of the maintenance pro-
gram. 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.
1. Close the valves when replacing the glass.
2. Slip a packing nut, a 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.
3. Slide the packing nuts onto each valve and tighten.
4. It is recommended that the boiler is off and cool when the glass is replaced. However, if the glass is replaced while the
boiler is in service, open the blowdown and slowly bring the glass to operating temperature by opening the gauge valves
slightly.
5. After the glass is warmed up, close the blowdown valve and open the gauge valves completely.
! Warning
Do not attempt to change the gauge glass while the boiler is in service. Failure to follow these instructions could result in
serious injury or death.
6. Check try cocks and gauge cocks for freedom of operation and clean as required. It is imperative that the gauge cocks
are mounted in exact alignment. If they are not, the glass will be strained and may fail prematurely.

The operating controls should be inspected monthly. Examine tightness of electrical connections and keep the controls
clean. Remove any dust that accumulates in the interior of the control using a low pressure air. Take care not to damage the
mechanism.
Examine any mercury tube switches (if older device is being used) for damage or cracks. Dark scum over the normally
bright surface of the mercury may lead to erratic switching action. Be certain that controls are correctly leveled. The piping
leading to the pressure control actuators should be cleaned, if necessary. Covers should be left on controls at all times.
8-4 750-94 (revised 2009)

Dust and dirt can cause excessive wear and overheating of motor starter and relay contacts. Use a burnishing tool or a hard
surface paper to clean and polish contacts. Starter contacts are plated with silver and are not harmed by discoloration and
slight pitting. Replacement of the contacts is necessary only if the silver has worn thin.
! Caution
Do not use files or abrasive materials such as sandpaper on the contact points. Failure to follow these instructions could result
in equipment damage.
FIGURE 8-2. Recommended Maximum “Fusetron” Fuse Sizes
Thermal relay units (overloads) are of the melting-alloy type and, when tripped, the alloy must be given time to re-solidify
before relay can be reset. IF the overloads trip out repeatedly when the motor current is normal, replace them with new
overloads. If the condition continues after replacement, it will be necessary to determine the cause of excessive current draw
at the overloads.
750-94 (revised 2009) 8-5

Power supply to the boiler must be protected with dual element fuses (fusetrons) or circuit breakers. Similar fuses should be
used in branch circuits. Standard one-shot fuses are not recommended. Refer to the chart in Figure 8-2 for fuse requirement
guidance.

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. Also check to see that the amplifier and the program module are tightly inserted.
The relay’s self-diagnostic ability includes advising when it or its plug-in modules are at fault and require replacement.
Your spare control should be stored in a dry atmosphere and wrapped in plastic. During an extended shutdown (e.g., sea-
sonal) the active control should be removed and stored. Moisture can cause problems with control operation.
It is recommended that service be rotated between the active and a spare control to assure a working replacement is avail-
able.
! Warning
When replacing a control, be sure to lock out the main power supply switch since the control is “hot” even though the burner
switch is off. Failure to follow these instructions could result in serious injury or death.
Be sure the connecting contacts on the control and its base are not bent out of position.
The flame detector lens should be cleaned as often as operating conditions demand. Use a soft cloth moistened with deter-
gent to clean the lens.
A safety check procedure should be established to test the complete safeguard system at least once a month, or more often.
Tests should verify safety shutdown and a safety lockout upon failure to ignite the pilot, upon failure to ignite the main
flame, and upon loss of flame. Each of the conditions should be checked on a scheduled basis.
The following tests should be used to test the complete safeguard system. If the sequence of events is not as described, then
a problem may exist. Contact your local Cleaver-Brooks authorized representative for assistance.
8.6.1 — Checking Pilot Flame Failure

1. Close the gas pilot shutoff cock and shut off the main fuel supply.
The pilot ignition circuit will be energized at the end of the pre-purge period. There should be an ignition spark, but no
flame. Since there is no flame to be detected, the program relay will signal the condition. The ignition circuit will de-
energize and the control will lock out on a safety shutdown. The flame failure light (and optional alarm) will be activated.
The blower motor will run through the post-purge and stop.
5. Re-open the gas pilot shutoff cock and re-establish main fuel supply.
8-6 750-94 (revised 2009)

8.6.2 — Checking Failure to Light Main Flame

1. Leave the gas pilot shutoff cock open.
2. Shut off the main burner fuel supply.
The pilot will light upon completion of the pre-purge period. The main fuel valve(s) will be energized, but there should
be no main flame.
The fuel valve(s) de-energize 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. The blower motor will run through the
post-purge and stop.
8.6.3 — Checking Loss of Flame

1. With the burner in normal operation, shut off the main burner fuel supply to extinguish main flame.
The fuel valve(s) will be de-energized and the relay will signal the condition within 4 seconds. The control will then lock
out on a safety shutdown. The flame failure light (and optional alarm) will be activated. The blower motor will run
5. The flame detector lens should be cleaned as often as operating conditions demand. Use a soft cloth moistened with
detergent, if necessary.

The burner should be inspected for evidence of damage due to improperly adjusted combustion. Any soot buildup on the
diffuser or the oil nozzle should be removed. The setting of the oil nozzle in relation to the diffuser and other components
is important for proper firing and should be checked.
8.7.1 — Oil Strainers

Oil strainers should be cleaned frequently to maintain a free and full flow of fuel.
8.7.2 — Light Oil Strainers

The fuel oil strainer screen must be removed and cleaned at regular intervals. It is advisable to remove the screen each
month and clean thoroughly by immersing it in solvent and blowing it dry with compressed air. To remove:
1. Loosen the cover cap screw, being careful not to lose the copper gasket. If necessary, tap the strainer cover gently to
loosen.
2. Check the cover gasket for damage and replace if necessary.
3. Slip pliers into the cross on the top of the strainer and twist counterclockwise to remove the basket.
4. Reassemble in reverse order.
750-94 (revised 2009) 8-7

8.7.3 — Heavy Oil Strainers

Keep the cartridge of the oil strainer clear by regularly giving the exterior handle one complete turn in either direction. Do
this often until experience indicates the frequency of cleaning necessary to maintain optimum condition of flow. If the han-
dle turns hard, rotate the handle back and forward until it can be turned through a complete revolution. Do not force it
with a wrench or other tool.
Drain the sump as often until experience indicates the draining frequency necessary to maintain optimum condition.
Remove the sump, or the head and cartridge assembly, for thorough cleaning and inspection at frequent intervals. Exercise
care not to damage the cartridge discs or the cleaner blades. Wash the cartridge in solvents. Do not attempt to disassemble
the cartridge.
8.7.4 — Cleaning the 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 noz-
zle during periods of operation. A routine check and any necessary cleaning should be made during off periods or when the
burner is firing on gas.
If at any time the burner flame appears “stringy” or “lazy,” it is possible that the nozzle tip or swirler has become partially
clogged or worn. Any blockage within the tip will cause the air pressure gauge to increase above its normal value.
FIGURE 8-3. Standard Burner Nozzle Components
Disassemble with the power off:

1. Unlatch and withdraw the burner gun.
2. Insert the nozzle body into the hanger vise and use the spanner wrench to remove the tip.
3. Carefully remove the swirler and seating spring being careful not to drop or damage any parts.
4. Perform any necessary cleaning with a suitable solvent. Take the necessary precautions when working with solvents. Use
a soft fiber brush or pointed piece of soft wood for cleaning. Do not use wire or a sharp metallic object, which could
scratch or deform the orifices as well as the precision ground surfaces of the swirler and tip.
5. Inspect for scratches or signs of wear or erosion, which may make the nozzle unfit for further use.
8-8 750-94 (revised 2009)

The tip and swirler are a matched set, which are precision lapped at the time of assembly. The close fit of the lapped sur-
faces must be maintained in order to provide optimum performance. Additional lapping may be required to provide bet-
ter atomization for more efficient combustion. Do not interchange parts if a spare is kept.
6. In reassembling, be certain that the seating spring is in place and that it is holding the swirler tightly against the tip. The
swirler is stationary and does not rotate, but rather imparts a swirling motion to the oil.
7. See that the plugged hole is at the bottom of the nozzle body when the gun is installed.
8.7.5 — Cleaning Air Purge Nozzle (No. 6 Oil) and Back Pressure Orifice Nozzle (No. 2 Oil)
The air purge nozzle and its strainer should be inspected periodically and cleaned. The nozzle consists of a tip and internal
core.
1. Clean all internal surfaces of the tip and the slotted parts of the core using a wood splinter to avoid damage from scratch-
ing.
2. Replace the core, setting it tightly but not excessively so.
3. Clean the strainer screen carefully to remove any foreign matter. Use suitable solvents for cleaning. Extremely hot water
at high velocity is also helpful in cleaning.
4. Replace strainer by screwing it into the nozzle body only finger tight. Do not use an orifice of a size other than originally
installed.
8.7.6 — Ignition System

For best results, maintain the proper gap and dimensions of the ignition electrode(s).
1. Inspect the electrode tip for signs of pitting or combustion deposits and dress as required with a fine file.
2. Inspect the porcelain insulator(s) for any cracks that might be present. If cracks are present, replace the electrode since
cracks in the insulator can cause grounding of the ignition voltage.
3. Wipe the insulating portion of the electrode(s) clean of any carbon, if present. Carbon is an electrical conductor. Ammo-
nia will aid in removing carbon and soot.
4. Check the ignition cables for cracks in the insulation.
5. Check to see that all connections between the transformer and the electrodes are tight.
6. Periodically remove the access plug from the gas pilot aspirator and clean out any accumulated lint or other foreign
material.

The gas burner components should be inspected for evidence of damage due to improperly adjusted combustion. Combus-
tion adjustments should be checked monthly.
Check periodically for a proper seal between the end of the burner housing and boiler refractory. Any deterioration of the
seal should be corrected, as an improper or poor seal allows air leaks, which can cause overheating or burning of the burner
housing.
Whenever the burner is removed, the diffuser, gas housing and gas spuds (HTB model only) should be checked for any
deterioration. Verify that the diffuser skirt conforms to the bore of the burner housing so as to minimize the amount of
combustion air which bypasses the diffuser. If the burner is a high turndown burner (HTB) model, check to see that the dif-
fuser is properly located in reference to the gas spuds. There should be 1/4” between the edge of the diffuser fins and the
750-94 (revised 2009) 8-9

gas spuds when the burner is installed. Check to see that the diffuser fins don not interfere with the gas ports or gas spuds
in the burner housing.
Check the electrode setting for any cracks that might be present on the porcelain insulator. Replace the electrode if cracking
is evident, since cracking can cause grounding of the ignition voltage. Inspect the tip of the electrode for signs of pitting,
combustion deposits, and wear, and dress as required with a fine file.
Periodically remove the access plug from the gas pilot aspirator and clean out any accumulated lint or other foreign mate-
rial.
Check the ignition cables for cracks in the insulation. Verify that all connections between the transformer and the electrode
are tight.

The motorized gas valve (hydramotor) operating mechanism is completely immersed in oil and little maintenance is
required because of the sealed design. However, proper operation should be checked on a routine periodic basis.
Keep outer parts of the valve clean, especially the stem between the operator and the valve. A nicked, scored or otherwise
damaged valve stem can cause leakage. Do not remove dust covers if installed.
The packing gland is of the O-ring type. If oil is noticed around the operator base or if leakage occurs, repair by replacing
any leaking O-rings and refilling the actuator with oil.
If the actuator is sluggish or fails to operate, even after the oil level is checked, replace the entire operator portion.
8.10 — 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.
A low hum or buzzing will normally be audible when the coil is energized. If the valve develops a loud buzzing or chattering
noise, check for proper voltage and clean the plunger assembly and interior plunger tube thoroughly. Do not use any oil. Be
sure that the plunger tube and solenoid are tight when reassembled. Take care not to nick, dent, or damage the plunger
tube.
! Warning
Be sure to turn off power to the valve in order to avoid electrical shock. Failure to follow these instructions could result in seri-
8-10 750-94 (revised 2009)

Check coil position and make sure that any insulating washers or retaining springs are reinstalled in proper order.

The burner air control damper should be checked for free movement as a part of the monthly inspection. With the burner
off and the jackshaft damper control rod disconnected, the air control damper should rotate freely through its entire range
of movement. Any resistance to movement or excessive play in the support bearing should be investigated and corrected
before the burner is put back in operation.
The overall tightness of the linkage assembly should be checked monthly. If necessary, tighten the setscrews and the con-
nections at the uniballs. Check the uniballs for wear and replace if necessary.
The linkage assembly should be tight but should not bind. If the linkage assembly is binding, determine the cause of the
binding and correct as necessary.
Linkage rod end attachment points should be marked on the variable displacement linkage arms as an aid in subsequent
reassembly.
Inspection of the air damper and linkage bearings should be performed on a more frequent basis if the boiler is operating in
a dirty environment.
The fuel cam profile spring should be inspected monthly for wear, scoring or distortion. If any of the questionable condi-
tions are found, the spring must be replaced immediately to avoid the possibility of breakage in service. Use care to avoid
damaging the cam or spring during installation.
Lubricate occasionally with a non-gumming, dripless, high-temperature lubricant such as graphite or a silicone derivative.
! Caution
Combustion should be checked and readjusted whenever the burner is removed or any control linkage is disturbed. Failure
to follow these instructions could result in equipment damage.

The position of the fan housing and the clearance between it and the fan (impeller) is extremely important to the output
capacity of the fan.
To install and adjust:

4. Place external tooth lockwashers next to the spacers and install the fan housing on the studs.
5. Hold the fan housing in place with nuts and lockwashers. Tighten the nuts by hand.
750-94 (revised 2009) 8-11

6. Slide the impeller outward until its vanes contact the fan housing. The housing must be parallel to the impeller. Adjust
the spacers as necessary to align the housing with the impeller.
7. Slide the impeller toward the motor. Use a feeler gauge to obtain a .030” - .050” clearance between the impeller and the
housing.
8. Secure the key and then tighten the impeller hub setscrews.
9. Using a selected vane, rotate the impeller while checking to see that the clearance between the impeller and the housing
remains constant and within the specified .030” - .050” clearance.
10. Install the air duct assembly through the head opening. Tighten the screws securing the air duct to the fan housing only
enough to create a seal between the neoprene gasket and the housing.
11. After connecting the motor leads, verify that the impeller rotation is counterclockwise when viewed from the motor end.
NOTE: If the boiler is installed in a dusty location, check the vanes occasionally for deposits of dust or dirt. These build-
ups can cause a decrease in air capacity, or lead to an unbalanced condition or cause damage to the equipment.
FIGURE 8-4. Forced Draft Fan Mounting
8-12 750-94 (revised 2009)


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. To remove the fan/motor:
! Warning
Disconnect and lock out electrical power to the boiler before removing the fan/motor cassette. Failure to follow these instruc-
2. Ensure the front door is securely bolted to the boiler.
! Warning
Do not remove the davit arm assembly without first ensuring that the front door is securely bolted to the boiler. Failure to
follow these instructions could result in serious injury or death.
3. Release the davit arm by removing the retaining bolt at the top center of the boiler.
! Warning
When suspending the fan/motor cassette from the davit arm, all equipment used must be of adequate strength to safely
support the complete cassette. Failure to follow these instructions could result in serious injury or death.
4. Connect the davit arm to the fan/motor cassette using the suspension system.
! Warning
Chains or other devices used to attach a lifting device to the fan/motor cassette must be arranged so the cassette does not
rotate or tilt when removed from the front head. Failure to follow these instructions could result in serious injury or death.
5. Arrange the attaching chains so the lifting point is over the motor shaft centerline and the center of balance for the fan/
motor cassette. This point is approximately 4 inches from the motor backplate for 600 - 800 hp units, and 3 inches for
250 - 500 hp units.
7. Swing the fan/motor cassette to the side and secure it to the boiler using high strength cord. Do not over extend the
motor wires.
! Caution
Be sure that the fan motor wiring and conduit are not stretched during the fan/motor cassette removal. Failure to follow
these instructions could result in equipment damage.
750-94 (revised 2009) 8-13

FIGURE 8-5. Fan/Motor Cassette Removal
NOTE: For 96” (400 - 800 hp) units, it is recommended to use a 3-point davit attachment from the davit arm to the fan/motor
cassette.
8.14 — Inspection and Adjustment

NOx levels should be checked periodically to ensure compliance with all local and federal regulations, as well as to ensure
that the boiler is operating at maximum efficiency. Linkages should be inspected and free movement (no binding) of the
IFGR damper confirmed.
Increasing or decreasing NOx levels could indicate incorrect damper positioning, loose linkages, an improper air-to-fuel
ratio, or stack draft changes. If adjustment is required, or if problems persist, contact your local Cleaver-Brooks authorized
representative for further assistance.
As ash and products of combustion pass through the IFGR damper, there will be some accumulation on the damper, wind-
box, and other parts of the IFGR system and burner.
To ensure proper operation of the IFGR system and burner, inspection and cleaning should be performed at regular inter-
vals, depending on the load, type of fuel, and combustion temperatures.
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. Check for free movement of the linkage by separating the external
linkage from the jackshaft drive arm(s) and cycling the exterior linkage through its range of movement.
8-14 750-94 (revised 2009)

2. Check the clearance between the impeller and backplate (see Figure 8-6). Adjust, if necessary.
30 PPM
Standard 60 PPM 25 PPM 20 PPM
.040 + .010 .050 + .010/-.005 .060 + .005/-.000
FIGURE 8-6. Impeller Clearances
3. The impeller clearance is checked by inserting a long feeler gauge of the proper thickness between the impeller and the
impeller housing. Impeller clearances should be checked at the highest fin on the impeller (that fin which is closest to the
impeller housing), and must be checked at each point where the housing is attached to the motor backplate.
4. If the impeller clearance is not correct at all points, adjust as necessary:
A. Loosen retaining nuts on both sides of the impeller housing.
B. Adjust retainers for the correct impeller clearance at two housing attachment points 180º apart.
C. Adjust retainers for correct clearance at the housing attachment points 90º from those initially adjusted.
D. Adjust for correct impeller clearance at the remaining attachment points.
5. Check and replace any gaskets that have been damaged. Gaskets that have been in use for one year or more should be
replaced. In particular, inspect the airbox gasket for damage and replace if necessary.
FIGURE 8-7. Induced Flue Gas Recirculation System (IFGR)
750-94 (revised 2009) 8-15

If the fan/motor cassette is opened for any reason after the unit has been in operation for one year, the airbox gasket
should be replaced.
! Caution
When replacing the airbox gasket, use only Cleaver-Brooks components. Failure to use components designed for this applica-
tion can result in improper combustion. Failure to follow these instructions could result in equipment damage.
Attach the airbox gasket to the inlet box with high-temperature silicone adhesive/sealant, using two beads of silicone about
1/4” in from each side of the gasket (gasket surface is 2” wide).
1. Secure the gasket in position with clamps, using strips of wood on top of the gasket for a bearing surface.
2. After the silicone has dried (approximately 24 hours), remove the clamps and strips of wood.
8.16 — Fan/Motor Cassette Installation

To close the fan/motor cassette:
1. Check that all adjustment screws are tight, and check the linkage and IFGR damper for free movement before closing
the unit.
3. Slide the cassette into position until it begins to contact the inlet gasket, then measure the clearance between the cassette
flange and the front door mounting face. There must be clearance of at least 1/4” to provide adequate gasket compres-
sion when the cassette is mounted tightly to the door.
! Warning
Do not remove the davit arm assembly from the motor/fan cassette without first verifying that the cassette is securely bolted to
the boiler. Failure to follow these instructions could result in serious injury or death.
5. After the cassette has been secured to the front head, reconnect the davit to the front door by screwing in the retaining
bolt at the top centerline.
6. Check occasionally that the fan is securely tightened to the motor shaft. Check the clearance between the fan vanes and
housing.

The safety valve is a very 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 the 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 in accordance with sections VI and VII of the ASME Boiler and Pressure
Vessel Code.
8-16 750-94 (revised 2009)

8.18 — Fuel Oil Metering Valve, Adjusting, Relief Valves
Avoid excessive operation of the safety valve — even one opening can provide a means of leakage. Safety valves should be
operated only often enough to assure that they ar in good working order. When a pop test is required, raise the operating
pressure to the set pressure of the safety valve, allowing it to open and reseat as it would in normal service.
Do not hand operate the valve with less than 75% of the stamped set pressure exerted on the underside of the disc. When
hand operating, be sure to hold the valve in an open position long enough to purge accumulated foreign material from the
seat area and then allow the valve to snap shut.
Frequent usage of the safety valve will cause the seat and disc to become wire drawn or steam cut. This will cause the valve
to leak and necessitate downtime of the boiler for valve repair or replacement. Repair of a valve must be done only by the
manufacturer or his authorized representative.
Avoid having the operating pressure too near the safety valve set pressure. A 10% differential is recommended. An even
greater differential is desirable and will assure better seat tightness and valve longevity.
8.18 — Fuel Oil Metering Valve, Adjusting, Relief Valves

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. Excessive tightening of the packing nut prevents free movement of the
metering stem. Failure to follow these instructions could result in equipment damage.
750-94 (revised 2009) 8-17

If replacement of the metering valve packing is necessary, procure kit P/N 880-370 and install:
FIGURE 8-8. Metering Valve Packing Sequence
2. Match-mark the cam hub and drive shaft. Match-marking will enable replacement of the cam in its original position and
result in a minimum of cam adjustment when the burner is refired.
4. Loosen the setscrews in the cam hub and rotate, or move the cam to a position where it does not interfere with stem
removal.
5. Withdraw the metering valve stem and spring. Do not drop or mishandle. Check for nicks or scratches. Check that the
pin holding the metering portion is not protruding. Back off the packing gland.
6. Remove the capscrews holding the jackshaft support bracket so that the bracket can be moved. It may also be necessary
to loosen the supporting bracket on the far end of the shaft.
7. Remove the existing packing and guides. Do not reuse the packing and guides.
8. Lightly coat the stem with the lubricant provided with the packing kit. Place the new packing, O-rings and guides onto
the stem in the sequence shown in Figure 8-8. The beveled face of the guides and the teflon rings must face upward,
with the exception of the upper brass guide which is facing down. Be sure that the O-rings are properly located.
9. Using the stem as a guide, insert the assembled packing into the cavity, then withdraw the stem.
10. In the event the packing is too high, remove one teflon packing from each side of the middle brass guide as needed.
Under no circumstance eliminate the two teflon packings on only one side of the brass guide.
11. Replace the gasket, put the support in place, and secure all fastenings.
12. Replace the metering stem and spring. Lightly lubricate the stem to facilitate insertion and easy movement. Use care
when inserting so that the orifice and the stem are not damaged.
8-18 750-94 (revised 2009)

13. Snug the packing gland, but only sufficiently to place slight tension on the packing. The stem must move freely from the
force of the spring.
14. Work the stem up and down several times to ensure that it moves freely.
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.
17. Tighten the packing gland after a period of operation, if necessary, to maintain proper tension on the packing. Do not
over tighten.
If there are indications that the oil metering valve has become clogged at its orifice, it will be necessary to disassemble the
control to remove the obstruction. Clean the slotted stem of the oil metering valve with suitable solvent and blow-dry with
an air line. Follow the procedure outlined above when removing or reinstalling the metering valve stem. Also check all fuel
line strainers.
Should a pressure adjusting or relief valve become clogged, disassemble by releasing the locknut and backing off the screw
to relieve tension on the diaphragm. Remove the valve cover and the diaphragm to expose any dirt or foreign material which
may have entered the valves. The diaphragms should be replaced annually.

The air pump requires little maintenance. However, the life of the pump is dependent upon a sufficient supply of clean cool
lubricating oil. The oil level in the air-oil tank must be observed closely. Lack of oil will damage the pump making replace-
ment necessary. Disassembly or field repairs to the pump are not recommended.
8.19.2 — Lubricating Oil

Lubricating oil must be visible in the gauge glass at all times. There is no specific level required as long as oil is visible. Do
not operate if oil is not visible.
Oil with proper viscosity must be used. SAE 20 detergent is recommended, although SAE 10 detergent is also permissible.
When adding oil:

1. Remove the cover from the fill pipe and add oil through the conical strainer in the pipe with the unit running.
! Caution
Oil must NEVER be added unless the pump is in operation and the strainer screen is in place. Failure to follow these
instructions could result in equipment damage.
The oil and its container should be clean. Although there is a strainer in the lube oil line, its purpose is to remove any
unwanted materials rather than to act as a filter for unclean oil.
750-94 (revised 2009) 8-19

8.19.3 — Lubricating Oil Strainer and Cooling Coil

Air pressure from the pump forces lubricating oil from the tank through a cooling coil 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. It is possible to visually verify oil flow during oper-
ation by removing the filler cap and checking the flow. If necessary, the strainer may be cleaned during operation.
In the event it is necessary to clean the strainer during operation, clean it an replace immediately. It can be cleaned by
immersing in solvent and blowing it dry with compressed air. Do not operate without the strainer any longer than neces-
sary, and never add new oil unless it is in place. A spare strainer basket can be obtained, if desired, and used on a rotating
basis while the other is serviced.
8.19.4 — Air Cleaner

Never operate the air pump without the air cleaner in place. The cleaner itself must be periodically checked and its element
flushed and cleaned semi-annually.
8.19.5 — Air-Oil Tank
FIGURE 8-9. Air Oil Receiver Tank
Pads of steel wool are used in the air oil receiver tank as a filtering medium to separate the lube oil from the compressed air.
The pads play a very important role and should be replaced semi-annually. It is also important that a proper grade of steel
wool be used. Only No. 3 coarse grade American steel wool or equivalent (CB919-124) should be used. Three pads are
required. When replacing the wool:
1. Insert two pads into the cylinder.
2. Alternate the grain of the pads.
3. Install the spacer with its stub end toward the opening and fit one pad over the stub. Be careful not to overly compress
the wool and be sure that it is fluffed out to fill all available space. Improper packing can cause high oil consumption.
4. After the last pad is in place, slip the retainer screen onto the cylinder.
8-20 750-94 (revised 2009)

5. Be sure to fit an O-ring gasket under the cover so that a tight seal is obtained.
8.19.6 — Lube Oil Cooling Coil

The fins on the tubing must be kept clean and free of any dust or dirt that would resist air flow and cause overheating. Use
an air hose to blow away debris. Internal cleaning of the tubes is seldom required if a good quality lube oil is used.
8.19.7 — Flexible Coupling Alignment

Alignment of the pump and motor through the flexible coupling is extremely important for trouble free operation. Check
the coupling alignment semi-annually and replace the coupling insert as required. Keep the coupling guard in place.
The most commonly used tools for checking alignment are a small straightedge and a thickness gauge.
The coupling must be checked for both parallel (offset) alignment and angular (gap) alignment. Parallel misalignment exists
when shaft axes are parallel but not concentric. Angular misalignment is the reverse situation — shaft axes 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. The check should be done on the top of
the coupling and at 90 degrees. A useful practice is to hold a flashlight behind the straightedge so that any gap can readily be
seen.
Shim stock of appropriate thickness and area is then used under either the feet of the pump or the motor to establish paral-
lel alignment. A tolerance of .008” is a permissible limit.
FIGURE 8-10. Coupling Alignment
After parallel alignment is established, check for angular alignment, which is done by checking the gap between the coupling
halves. The coupling should have a minimum gap of 1/16” and a maximum of 3/32”.
Set the spacing between the halves at one point by using a thickness gauge and then rotate the coupling slowly to be sure
that clearance at that point remains the same through 360 degrees of rotation. Adjust to obtain proper gap by loosening the
hold-down bolts and shifting either the pump or the motor as required. Generally, a slight tapping on either the front or rear
legs is all that is needed to obtain lateral adjustment. Rear legs may require shimming for vertical correction.
750-94 (revised 2009) 8-21

Tighten the hold-down bolts after adjustments are made and recheck alignment.
Calipers can also be used to check angular alignment. Measure the overall distance of the outer ends of the coupling halves
at 90º intervals. Shift the pump or motor, as required, so that the ends of the coupling are the same distance apart at all
points. The coupling will then have proper angular alignment.
Remember that alignment in one direction may alter alignment in another. Recheck both angular and parallel alignment pro-
cedures after making any alteration.
A properly aligned coupling will last longer and will provide trouble free mechanical operation.
8.19.8 — Air Compressor Replacement

Use the following procedures when replacing the pump. Be sure to tag the motor leads if disconnected to simplify recon-
nection.
FIGURE 8-11. Air Compressor
8.19.8.1 — Dismantling
1. Lift out the two front cylinder pins that hold the screen and remove the screen.
2. Disconnect the flared nut on tubing (behind screen) and lift tubing high enough to prevent drainage of lubricating oil
from the tank.
4. Remove the two sheet metal screws that hold the cylinder in place. One screw is located at the top rear of the cylinder,
the other is at the bottom front.
5. Remove the entire heat exchange assembly, consisting of the cylinder, the finned tubing, and the oil line.
8. Remove the coupling guard by pushing in on both sides until it clears the clamp.
9. Loosen the clamp at the rear of the tank and remove the tank with copper tubing attached.
8-22 750-94 (revised 2009)

10. Leave the rear pump bracket (coupling end) in place to aid in realignment of the replacement pump. Do this by removing
the two capscrews that extend through the bracket into the pump housing. Temporarily leave the front bracket attached
to the pump.
11. Remove the screws holding the front bracket to the base and lift off the pump with its attachments. Note the location of
the pipe fittings and brackets prior to removing for installation on the replacement pump. If piping is dismantled, be sure
that the check valve is reinstalled so the gate swings towards the pump.
8.19.8.2 — Reassembly
Reassemble in reverse order of disassembly. With the rear pump bracket left in place, realignment and spacing between the
pump shaft and the motor shaft is greatly simplified.
There should be approximately 7/8” space between the two shafts. Place the coupling insert between the coupling halves
prior to reassembly. Check that both shafts rotate freely.
If shims were used originally under either pump brackets or motor feet, be sure that they are correctly reinstalled.
When reinstalling the fan, slide the hub on the pump shaft so that it is bottomed. Tighten the setscrew and cap screws. If
the fan blades were removed from the hub, be sure that the side of the blade marked “Blower” faces the hub when reassem-
bling. When tightening the coupling halves or the fan hub, tighten the setscrews against the key first, then tighten the set-
screw against the shaft. Clean or remove any dust or grime from the blades prior to reinstalling.
When replacing the retainer screen, a slight force may be required to push the cooling coil into the air cylinder so that the
pins may be fitted into place.
If the motor was replaced or if motor leads were disconnected, be sure that pump rotation is proper before starting opera-
tion. The air pump should rotate in a clockwise direction, as viewed from the drive shaft end.
NOTE: Keep the motor and other components free from dust and dirt to prevent overheating and damage. Motor lubrica-
tion should follow manufacturer’s recommendations.
750-94 (revised 2009) 8-23

8.20 — Refractory
The boiler is shipped with completely installed refractory. The refractory consists of the rear head, the inner door, and the
furnace liner. Normal maintenance requires little time and expense, and prolongs the operating life of the refractory.
FIGURE 8-12. Refractory Liner Tile
Preventive maintenance through periodic inspection will keep the operator informed of the condition of the refractory, and
will guard against unexpected and unwanted downtime and major repairs.
Frequent wash coating of the refractory surfaces is recommended. High-temperature bonding, air-dry type mortar, diluted
with water to the consistency of light cream, is used for wash coating. Re-coating intervals will vary with operating loads and
are best determined by the operator when the boiler is opened for inspection.
8.20.1 — Furnace Liner

Maintenance consists of occasional wash coating of the entire liner. Face all joints or cracks by applying high temperature
bonding mortar with a trowel or fingertips. Wash coating should be done as soon as cracks are detected.
Should segments of the liner burn away or fall out, replace the entire refractory. Any refractory that may break out should
be removed as soon as detected so that it will not fuse to the bottom of the furnace and obstruct the flame.
If replacement is necessary, refer to Chapter 9 and order proper replacement materials. Remove existing refractory. Thor-
oughly clean the furnace to remove all old refractory cement or other foreign material to ensure the new liner seats firmly
against the steel. Inspect the furnace metal.
Depending upon the design pressure of the boiler, the furnace may be of the corrugated type. It is necessary to fill in the
corrugation valleys under the furnace liner tile from 4 o’clock to 8 o’clock with insulating cement. The liner tile should be
fitted tightly against the crown of the corrugation.
NOTE: The area between the burner housing and the throat tile requires a good seal. An improper or poor seal allows air leaks
that can cause overheating and burning of the burner housing metal. The area should be inspected semi-annually. Contact your
local Cleaver-Brooks representative for information and service.
8-24 750-94 (revised 2009)

8.20 — Refractory
FIGURE 8-13. Refractory Throat Tile
8.20.2 — Throat Tile and Liner Installation

The throat tile must be installed to maintain an approximately 16” inside diameter, and be centered in the furnace. Since the
thickness of the furnace metal varies with the boiler design pressure, a shim of appropriate thickness must be used to com-
pensate 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.
The liner tile can be fitted tightly against the furnace, since the finished diameter is not critical.
FIGURE 8-14. Furnace Liner Refractory
750-94 (revised 2009) 8-25

It is recommended that the tile be dry-fitted, match-marked, removed, and then reinstalled with the proper amount of
refractory cement. Thin joints (less than 1/16”) are desirable. Generally, it will be necessary to shave a portion from one or
more tiles to obtain a fit. If a fill piece is required, cut it to fit and install the piece at the bottom of the furnace. When
installing the housing, or the tile against the housing, liberally coat the surface with refractory cement. Remove any cement
that is squeezed out.
Allow refractory to air dry as long as possible. If immediate use is required, fire intermittently at a low rate for several hours
to thoroughly dry the refractory.
For detailed information, request Bulletin C10-5921 from your local Cleaver-Brooks representative.
8.20.3 — Installation
The following procedure is typical for all standard 96” diameter boilers with the exception of steps 6, 7, and 8 which are not
used for an 1.p. (plain furnace) boiler. Disregard these steps when working with 1.p. boilers.
FIGURE 8-15. Throat Tile and Furnace Liner
1. Install studs, bricking tool, creafelt, bottom and top arch bricks as shown on “Detail A” to check for correct fit up. If
interference is present at the arch brick, measure this distance and trim inside diameter (I.D.) of all bricks.
NOTE: The arch bricks must be trimmed to 16” on excessive pressures to maintain brick I.D.
2. Install the bottom half of arch bricks as shown on “Detail B.”
3. Mix the vee block to a mortar-like consistency (per manufacturer’s instructions) and pack the front valleys of the furnace
corrugations with the mixture, flush with the furnace I.D. up to 3 o’clock and 9 o’clock from the centerline of the fur-
8-26 750-94 (revised 2009)

8.20 — Refractory
nace. Install both pieces of cerafelt to insulate the tile from the corrugation and begin bottom half of first row of tiles as
shown on “Detail C.”
4. To begin top half of arch bricks and tiles, measure off upper half of furnace arch bricks and tiles with templates, mark
with chalk, and determine if a cut brick or cut tile is needed (see “Detail B”). If a cut brick is required, locate it below the
2 o’clock and 10 o’clock positions. If the brick is cut, the angle of the cut surface should be the same as the original brick.
If cut brick or tile measures less than 1/2 full width, cut two pieces.
5. Install bricking tool as shown on “Detail A” and continue installing upper half by alternating one arch brick and one cor-
responding tile.
6. For the last two rows of tiles, pack all remaining valleys of furnace corrugations (measure 36” from inside surface of arch
bricks) with vee block mixture flush with furnace I.D. up to the 3 o’clock and 9 o’clock centerline of the furnace.
7. After joint cement hardens (approximately 2 hours), remove bricking tool, wooden tile supports, and discard cerafelt
shims.
INSTALLATION NOTES:
1. No cerafelt, cut bricks, or cut tiles to be installed in the upper 120º section of the furnace. See “Detail
A” and “Detail B.”
2. Pack all bricks and tiles tightly with mallet and remove excess cement: 1/16” typical joint, 1/8” maxi-
mum.
3. No cement applied between cerafelt and bricks, tiles, or furnace. Only applied between bricks and
tiles.
4. Do not cover furnace weld seam with cerafelt. cut and space to suit as shown on “Detail B” and
“Detail C.”
5. Support upper tiles with wooden boards to suit assembly. Two boards per tile as shown on “Detail
C.” (For 96” diameter, use 3/4” x 1-1/2” x 38”. For 78” diameter, use 3/4” x 1-1/2” x 28”.)
6. To insure tight fit and maximum I.S. of arch bricks, cut a 3” square piece of scrap cerafelt and use as
a shim between bricking tool O.D. and I.D. of upper half of bricks.
7. Stagger cemented joints (seams) between all arch bricks and tiles.
8. After each half course of bricks or tiles installed, clean up excessive cement and fill open joint areas
where necessary.
9. For 78” diameter boilers, use bricking tool #98-d-280 and fasten with two 1/2”-13 nuts. For 96”
boilers, use bricking tool #98-d-279 and fasten with two 5/8”-11 nuts.
8.20.4 — Rear Door

The rear door is a steel shell containing horizontal baffle tiles and lined with insulation material and castable refractory.
Burned or discolored paint on the outer surface of the door does not necessarily indicate refractory trouble, but may be an
indication of other conditions such as:
• Leaking gaskets.
• Improper seal.
• Door retaining bolts insufficiently or unevenly tightened.
• The air line to the rear sight tube may be blocked or loose.
• Door was repainted with other than heat resistant paint.
Therefore, before assuming that the refractory requires reworking:
750-94 (revised 2009) 8-27

• Check the condition of the tadpole gasket and rope seal.

• Check for cracks in the castable refractory at ends of the baffle tile.
• Check the tightness of the door bolts.
• See that the air line to the sight tube is clear, and that the connections are tight. If necessary, blow the line clear with an
air hose.
FIGURE 8-16. Rear Door Sealing
It is normal for refractories exposed to hot gasses to develop thin “hairline” cracks. This is not an indication of improper
design or workmanship. Since refractory materials expand and contract with changes in temperature, they should be
expected to show minor cracks due to contraction when examined at low temperatures. Cracks to approximately 1/8”
across may be expected to close at high temperature. If there are any cracks that are relatively large (1/8” to 1/4” in width),
clean and fill them with high-temperature bonding mortar.
If the refractory or blanket insulation require replacement, contact your local Cleaver-Brooks authorized representative.
A good seal between the rear door and the pressure vessel is necessary to prevent leakage of combustion gasses, loss of
heat, and to aid in obtaining operating efficiency. Leaks can also cause hot spots that can lead to premature refractory failure
and/or damage to the door metal.
8-28 750-94 (revised 2009)

8.20 — Refractory
When opening the door, either for routine maintenance of for an annual inspection, do not do so when the boiler or the
door is hot. The refractory will hold its temperature for some time and exposure to ambient temperature or rapid cooling
may cause refractory cracking and/or harm to the boiler and door metal.
! Warning
Be certain that the davit arm is under tension before opening. Failure to follow these instructions could result in serious
injury or death.
Before loosening the door bolts, tighten the nut on the davit stud to ensure tension on the davit arm. Putting the davit arm
under tension will help eliminate sagging, and will facilitate opening and closing.
The opened door should be supported by blocking or jacking to eliminate possible deformation of the door.
Prior to closing, check all gaskets and sealing surfaces. If the door gasket is hard or brittle, it should be replaced. The fiber-
glass ropes used for the baffle seal and for the door gasket seal should not be reused. The door flange and the tube sheet
area of the baffle seal should be clean and free of old sealing material, scale, etc. Be sure that all of the gasket retaining fas-
teners are in place.
Remove the old rope and insulating cement from the baffle tile or refractory. Be careful not to chip or crack the refractory.
The rope is placed in the groove of the monolithic design and on top of the lip of the tile baffle type construction.
Attach a new length of 1-1/4” diameter fiberglass rope (P/N 853-982) to the baffle. Be certain that it is properly positioned
and use a rapid setting adhesive (P/N 872-481) to hold it in place.
NOTE: A boiler built for high pressure design, such as 150 psi or higher steam or for 60 psi or higher hot water, is constructed
with a flanged tube sheet that fits inside the boiler shell and door flange.
The area between the curved portion of the sheet and the flange is packed with fiberglass rope and covered with cement to
fill the void and to provide a smooth sealing area.
Replacement is not normally necessary, but, if it is, completely remove the old material. Firmly caulk a layer of 1/2” diame-
ter rope (P/N 853-996) into the area. Tamp a second layer of 1” diameter rope (P/N 853-999) over the first layer. Apply a
coating of insulating cement pulp (P/N 872-26) over the ropes to form a smooth surface. Allow the cement pulp to harden
before closing the door.
8.20.5 — Closing and Sealing

Coat the door gasket with an oil and graphite mixture. Apply a small amount of a pulp mixture, consisting of P/N 872-26
cement and water around the inner circumference of the gasket. Press rope into this area. Use 1/2” diameter rope (P/N
853-996) for a boiler of low pressure design. Use 1” diameter rope (P/N 853-999) for a high pressure boiler.
After the rope is installed, the entire rope and gasket area, and the baffle area, should be liberally coated with the pulp mix-
ture. When the door is closed, the pulp will compress to protect the tadpole gasket and form a seal between the refractory
surface and the tube sheet.
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 over tighten. Tighten alternate
bolts until the door is secured and gas tight. After the boiler is back in operation, retighten the bolts to compensate for any
expansion. Loosen the nut on the davit stud to release tension from the davit arm.
750-94 (revised 2009) 8-29

8.21.1 — Electric Motors

Manufacturers of electric motors vary in their specifications for lubrication and care of motor bearings, however, their spe-
cific 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.
Complete renewal of grease, when necessary, can be accomplished by forcing out the old grease with the new grease:
1. Thoroughly wipe those portions of the housing around the filler and drain plugs (above and below bearings).
2. Remove the drain plug (bottom) and free the drain hole of any hardened grease which may have accumulated.
3. With the motor not running, add new grease through the filler hole until clear grease starts to come out of the drain
hole.
4. Before replacing the drain plug, run the motor for 10 to 20 minutes to expel any excess grease.
5. The filler and drain plugs should be thoroughly cleaned before they are replaced.
The lubricant used should be clean and equal to one of the good commercial grades of grease locally available. Some lubri-
cants that are distributed nationally are:
• Gulf Oil - Precision Grease No. 2
• Humble Oil - Andok B
• Texaco - Multifak No. 2
• Phillips - 1B + RB No. 2
• Fiske Bros. - Ball Bearing Lubricant
• Standard/Mobil - Mobilux No. 2
NOTE: Siemens TEFC motors use a different and incompatible grease to those listed above.
For Siemens Motors: Contains re-greasable bearings. The shaft end (impeller end) requires the use of CB’s high temperature
auto grease system (PN 884-133) for proper lubrication.
The opposite shaft end (end opposite impeller) can be greased by the auto grease system or by hand pump, using two or three
pumps every three months with a grease compatible with a high temperature aluminum complex grease.
Daily • Check visually for free movement of IFGR linkage.

Quarterly • Manually check for free movement of IFGR linkage.
• Inspect and clean IFGR damper (oil-fueled system).
• Inspect and clean fan and burner (oil-fueled system).
8-30 750-94 (revised 2009)

Semi-Annually • Inspect and clean IFGR damper (gas-fueled system).

• Inspect and clean fan and burner (gas-fueled system).
• Open motor/fan cassette to check for free movement of IFGR linkage
and damper assembly.
Annually • Inspect fan impeller.
8.21.2 — Control Linkage

Apply a non-gumming, dripless, high-temperature lubricant, such as graphite or a silicone derivative to all pivot points and
moving parts. Work lubricant in well and wipe away excess. Repeat application at regular intervals to maintain freedom of
motion of parts.
8.21.3 — Solenoid and Motorized Valves

8.21.4 — IFGR Lubrication

Motors should be lightly lubricated at startup.
! Warning
Disconnect and lock out electrical power to the boiler before lubricating the fan motor. Failure to follow these instructions
4. Free the drain hole of any hard grease (if necessary, use a piece of wire).
NOTE: The amount and type of grease is very important. Only enough grease should be added to replace the grease used by
the bearing. Either too much or too little grease can be harmful. The grease cavity should be filled 1/3 to 1/2 full, using Chev-
ron SRI 2 grease or equivalent. Shell Dolium R is a suitable substitute lubricant.
6. With the fill and drain plugs still removed, apply electric power to the boiler, start the motor, and let it run for approxi-
mately 30 minutes.
7. Turn the boiler off.
! Warning
Disconnect and lock out electrical power to the boiler before lubricating the fan motor. Failure to follow these instructions
9. Wipe excess grease from the motor, and install the fill and drain plugs. The motor is ready for operation.
10. Reconnect electrical power.
750-94 (revised 2009) 8-31


An annual maintenance of the heaters consists primarily of removing the heating element from the shell and scraping any
accumulation of carbonized oil or sludge deposits that may have collected on the heat exchanging surfaces.
Before breaking any of the electrical connections to the electric heating elements, mark all wires and terminals to assure
rapid and correct replacement of wires.
Finish the cleaning process with a cleaning solvent to cut all hardened deposits from the heater element. Because of the
insulating effect of carbon and sludge, periodic cleaning is necessary to prevent overheating of the elements. If operation of
the heater becomes sluggish, examine the elements at once and clean as required.
Inspect the shell or tank each time the heater is removed. Flush all accumulated sludge and sediment from the tank before
reinstalling the heater.
The condensate from steam oil heaters must be safely discharged to waste. The waste should be checked periodically for
any traces of oil that would indicate leaking tubes within the heater.
The hot water oil heater contains a heat transfer solution. Oil flows through an inner tube while boiler water surrounds the
outer tube. The space between the two tubes is filled with the heat transfer solution and is connected to an expansion
chamber on the rear of the heater. A visual indicator on the chamber reveals the presence of any oil if an oil leak occurs.
A 50/50 solution of permanent antifreeze and water is generally used as the heat transfer solution. If there is no danger of
freezing, plain water may be used as a replenishment if necessary to refill.
Evidence of oil in either the steam heater condensate or in the water heater indicator demands prompt repairs.
8.23 — 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 vis-
ible flame change. Any time maintenance is performed on the burner linkage, the air-fuel ratio should be checked. Readjust-
ment of the burner may be required due to variations in fuel composition. A combustion analyzer should be used to adjust
air-fuel ratio for maximum operating efficiency. If your burner requires adjustments, contact your local Cleaver-Brooks
authorized representative for assistance.
8-32 750-94 (revised 2009)

Daily Monthly Semi-Annually Annually

• Check water level • Inspect burner • Clean low water cutoff • Clean fireside surfaces
• Check combustion visu- • Inspect for flue gas leak • Clean oil pump strainer, • Clean breeching
ally • Inspect for hot spots filter • Inspect waterside sur-
• Blow down boiler • Check cams • Clean air cleaner and faces
• Blow down water col- air/oil separator • Check operation of
• Check for tight closing
umn of fuel valve • Inspect refractory safety valves
• Record feedwater pres- • Check fuel and air link- • Remove and clean oil
sure/temperature age preheater
• Record flue gas tempera- • Check indicating lights • Check air pump cou-
ture and alarms pling alignment
• Record oil pressure and • Check operating and • Inspect/repair burner
temperature limit controls housing to refractory
• Record gas pressure seal
• Check safety and inter-
• Treat water according to lock controls
the established program • Check for leaks, noise,
• Record atomizing air vibration, unusual condi-
pressure tions, etc.
• Check low water cutoff
operation
750-94 (revised 2009) 8-33

8-34 750-94 (revised 2009)

CHAPTER 9 Parts Lists and Drawings
9.1 — Ordering Parts

Furnish complete information when ordering parts by giving the item number, description, and the quantity of parts
desired, together with the complete nameplate data, including all electrical requirements.
Repair and replacement parts should be ordered from your local Cleaver-Brooks authorized representative.
750-94 (revised 2009) 9-1

Parts Lists and Drawings
9.2 — Parts
9.2.1 — Air Compressor and Piping
9-2 750-94 (revised 2009)

9.2 — Parts
750-94 (revised 2009) 9-3

9.2.3 — Air Line Piping
9-4 750-94 (revised 2009)

9.2 — Parts
9.2.4 — Alstrom Heater
750-94 (revised 2009) 9-5

Alstrom Heater (continued)
9-6 750-94 (revised 2009)

9.2 — Parts
9.2.5 — Burner Housing Support
750-94 (revised 2009) 9-7

Burner Housing Support (continued)
9-8 750-94 (revised 2009)

9.2 — Parts
9.2.6 — Control Panel
750-94 (revised 2009) 9-9

Control Panel (continued)
9-10 750-94 (revised 2009)

9.2 — Parts
9.2.7 — Entrance Box
750-94 (revised 2009) 9-11

9.2.8 — Front Davit
9-12 750-94 (revised 2009)

9.2 — Parts
9.2.9 — Front Head Linkage
750-94 (revised 2009) 9-13

9.2.10 — Heavy Oil Piping
9-14 750-94 (revised 2009)

9.2 — Parts
Heavy Oil Piping (continued)
750-94 (revised 2009) 9-15

9.2.11 — Standard Impeller
9-16 750-94 (revised 2009)

9.2 — Parts
9.2.12 — Front Head (Electrical)
750-94 (revised 2009) 9-17

Front Head (Electrical) (continued)
9-18 750-94 (revised 2009)

9.2 — Parts
9.2.13 — Pressure Controls
750-94 (revised 2009) 9-19

9.2.14 — Oil/Air Piping, Front Head (Light Oil)
9-20 750-94 (revised 2009)

9.2 — Parts
Oil/Air Piping, Front Head (continued)
750-94 (revised 2009) 9-21

9.2.15 — Rear Head Sealing-Davit
9-22 750-94 (revised 2009)

9.2 — Parts
9.2.16 — Furnace Liner/Bricking
750-94 (revised 2009) 9-23

9.2.16 — Furnace Liner/Bricking (continued)
9-24 750-94 (revised 2009)

9.2 — Parts
9.2.17 — Throat Tile and Furnace Liner
750-94 (revised 2009) 9-25

Throat Tile and Furnace Liner (continued)
9-26 750-94 (revised 2009)

9.2 — Parts
9.2.18 — Blower Assembly
750-94 (revised 2009) 9-27

Blower Assembly (continued)
9-28 750-94 (revised 2009)

9.2 — Parts
Blower Assembly (continued)
750-94 (revised 2009) 9-29

9.2.19 — Temperature Controls
9-30 750-94 (revised 2009)

CHAPTER 10 Gas Train Parts Lists
10.1 — Standard Main Gas Train

The parts listings and drawings presented in this chapter pertain to the standard main gas train and the standard pilot gas
train for 400, 500, 600, 700, and 800 HP boilers.
NOTE: For parts listings and other information for over- and under-sized main and pilot gas trains, contact your local Cleaver-
10.2 — Starter Gas Train Butterfly Valve: All Boilers
Item QTY Part Number Description

1 1 940-00134 Valve, Gas, Butterfly, 3”
750-94 (revised 2009) 10-1

Gas Train Parts Lists
10.3 — Pilot Gas Trains: All Boilers
10.3.1 — Standard & CSD-1 Pilot Gas Train

1 1 825-00030 Cock, Gas Service, Tee Head, 1/2” NPT, Bronze
2 1 918-00356 Regulator, Gas Pressure, 1/2” NPT, 2-6” WC
3 1 850-00109 Gauge, Pressure, 2-1/2”, 0-35” WC, 1/4” NPT Bottom Mount
4 1 948-00197 Valve, Solenoid, 1/2” NPT, NC, 0-50 PSI, 150#
10.3.2 — NFPA85 Pilot Gas Train

1 1 825-00030 Cock, Gas Service, Tee Head, 1/2” NPT, Bronze
2 1 918-00356 Regulator, Gas Pressure, 1/2” NPT, 2-6” WC
3 1 850-00109 Gauge, Pressure, 2-1/2”, 0-35” WC, 1/4” NPT Bottom Mount
4 2 948-00197 Valve, Solenoid, 1/2” NPT, NC, 0-50 PSI, 150#
5 1 948-00002 Valve, Solenoid, Gas Vent, 3/4” NPT
10-2 750-94 (revised 2009)

10.4 — Standard Main Gas Trains
10.4.1 — 60, 30, &20 PPM Standard Main Gas Train
60, 30, & 20 PPM, 400 HP Standard

1 2 941-01947-000 Valve, Butterball, Bronze, 2”, 175 PSI
2 1 949-00448-000 Valve Body, Gas, 2”
3 1 817-02418-000 LPGS, 12-60” WC Range, MR, 1/4” NPT Mount
4 1 945-00238-000 Actuator, Gas Valve, W/O POC
5 1 945-00234-000 Actuator, Regulating, W/POC, 6 ”-100” WC
6 1 817-02417-000 HGPS, 12-60” Range, MR, 1/4” NPT Mount
7 1 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
60, 30, & 20 PPM, 400 HP W/FM

2 1 949-00448-000 Valve Body, Gas, 2”
4 1 945-00236-000 Actuator, Gas Valve, W/POC
6 1 817-02417-000 HGPS, 12-60” Range, MR, 1/4” NPT Mount
7 1 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
750-94 (revised 2009) 10-3

60, 30 & 20 PPM, 500 HP Standard

1 2 941-00129-000 Valve, Lub Plug, 2-1/2” NPT W/Wrench
2 1 949-00445-000 Valve Body, Gas, 2-1/2”
6 1 817-02423-000 HGPS, 1.5-7 PSI Range, MR, 1/4” NPT Mount
7 1 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
60, 30, & 20 PPM, 500 HP W/FM

2 1 949-00445-000 Valve Body, Gas, 2-1/2”
7 1 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
10-4 750-94 (revised 2009)

10.4.2 — 60, 30, & 20 PPM W/NFPA-85
60, 30, & 20 PPM, 400 HP

2 1 949-00448-000 Valve Body, Gas, 2”
3 1 850-02363-000 Gauge, Pressure, 2-1/2”, 0-15 PSI, 1/4” BTM Conn.
4 1 817-02418-000 LGPS, 12-60” WC Range, MR, 1/4” NPT Mount
7 1 817-02417-000 HGPS, 12-60” WC Range, MR, 1/4” NPT Mount
8 1 850-01093-000 Gauge, Pressure, 2-1/2”, 0-100” WC, 1/4” NPT Bottom Mount
9 3 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
60, 30, & 20 PPM, 500 HP

2 1 949-00445-000 Valve Body, Gas, 2-1/2”
3 1 850-02363-000 Gauge, Pressure, 2-1/2”, 0-15 PSI, 1/4” Btm. Conn.
4 1 817-02418-000 LGPS, 12-60” WC Range, MR, 1/4” NPT Mount
8 1 850-01093-000 Gauge, Pressure, 2-1/2”, 0-100 WC, 1/4” NPT Bottom Mount
9 3 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
750-94 (revised 2009) 10-5

10.4.3 — 60, 30, & 20 PPM, 600 HP Standard Main Gas Train
60, 30, & 20 PPM, 600 HP Standard

2 1 949-00445-000 Valve Body, Gas, 2-1/2”
3 1 817-03591-000 LPGS, 1.5-7 PSI Range, MR, 1/4” NPT Mount
7 1 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
8 1 941-00130-000 Valve, Lub Plug, 3” NPT W/Wrench
60, 30, & 20 PPM, 600 HP W/FM

2 1 949-00445-000 Valve Body, Gas, 2-1/2”
7 1 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
10-6 750-94 (revised 2009)

10.4.4 — 60, 30, & 20 PPM, 600 HP W/NFPA-85
60, 30, & 20 PPM, 600 HP W/NFPA-85

2 1 949-00445-000 Valve Body, Gas, 2-1/2”
4 1 817-03591-000 LGPS, 1.5-7 PSI Range, MR, 1/4” NPT Mount
8 1 850-01093-000 Gauge, Pressure, 2-1/2”, 0-100 WC, 1/4” NPT Bottom Mount
9 3 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
750-94 (revised 2009) 10-7

10.4.5 — 60, 30, & 20* PPM, 700 & 800 HP Standard Main Gas Train
60, 30, & 20* PPM, 700 & 800 HP Standard

2 1 949-00446-000 Valve Body, 3”
7 1 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
60, 30, & 20* PPM, 700 & 800 HP W/FM

2 1 949-00446-000 Valve Body, 3”
7 1 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
10-8 750-94 (revised 2009)

10.4.6 — 60, 30, & 20 PPM, 700 & 800 HP Standard Main Gas Train W/NFPA-85
60, 30, & 20* PPM, 700 & 800 HP W/NFPA-86

2 1 949-00446-000 Valve Body, 3”
4 1 817-03591-000 LGPS, 1.5-7 PSI Range, MR, 1/4” NPT Mount
7 1 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
8 1 850-01093-000 Gauge, Pressure, 2-1/2”, 0-100” WC, 1/4” NPT Bottom Mount
9 3 941-02640-000 Valve, Ball, Brass, 1/4”, 150#
* There is no 800 HP unit for the 20 PPM boiler.
750-94 (revised 2009) 10-9

10-10 750-94 (revised 2009)


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Operation, Service, and Parts Manual

Manual Part No. 750-184

TO: Owners, Operators and/or Maintenance Personnel

Figure 1-1 Firetube Cut Away (Typical)

1-2 Part No. 750-184

The general information in this manual applies directly to Cleaver-

Rated Capacity: 125

The LE option reduces Nitrogen Oxide (NOx) emissions, a major

Part No. 750-184 1-3

1-4 Part No. 750-184

Steam and hot water boilers are defined according to design

Part No. 750-184 1-5

1. Forced draft fan motor 8. Oil strainer

Figure 1-2 CB-LE, Dual Fuel, Typical

1-6 Part No. 750-184

D. STEAM CONTROLS (ALL FUELS)

Part No. 750-184 1-7

7. Water Gauge Glass Drain Valve: Provided to flush the gauge

E. HOT WATER CONTROLS (ALL FUELS)

1-8 Part No. 750-184

6. Auxiliary Low-Water Cutoff (Optional): Breaks the circuit to stop

F. IFGR COMPONENTS (CB-LE)

Part No. 750-184 1-9

COMBUSTION AIR INLET

BACKPLATE GASKET AIRBOX

FLANGE COLLAR DAMPER DRIVE ARM

COMBUSTION AIR FAN

IFGR DAMPER LINKAGE

THROAT AND LINER TILE

INNER PLATE CLAMPS

COMBUSTION AIR FLOW

Figure 1-6 Induced Flue Gas Recirculation System, General Arrangement

1-10 Part No. 750-184

IFGR DAMPER CONTROL 60°* QUICK-DISCONNECT LINKAGE

* NOMINAL: ACTUAL POSITION VARIES

Figure 1-7 IFGR Damper Linkage

Two Pass Design

Part No. 750-184 1-11

the head - opposite the boiler steam space - is almost completely

1-12 Part No. 750-184

2-2 Part No. 750-184

The burner control circuit operates on 115 volt, single phase 60 Hz

1. Forced draft fan motor 7. Control panel

Figure 2-2 Controls/Components Common to All Boilers

Part No. 750-184 2-3

B. CONTROL AND COMPONENT FUNCTION

C. COMPONENTS COMMON TO ALL BOILERS

8. Atomizing Air Proving Switch: A pressure-sensitive switch

2-4 Part No. 750-184

subsequent setting of fuel input throughout the firing range. It

Figure 2-8 Control Panel

Part No. 750-184 2-5

19.Program Relay and Flame Safeguard Control: Automatically

D. CONTROLS FOR GAS FIRING

2-6 Part No. 750-184

MAIN GAS TRAIN

Main Gas Valve Gas Valve w/POC

Shut Off Valve