CleaverBrooks FLX Operation, Service And Parts Manual

Text of CleaverBrooks FLX User Guide:

• CleaverBrooks FLX, Chapter 3 Pressure Vessel Care 3-6 750-177 Boiler Size 150- 250 300- 350 400- 600 700- 900 1000- 1200 Water Capacity (US gal.) Hot Water 91 106 174 228 269 Water Capacity (US gal.) Steam - Flooded 194 215 293 464 562 F. CLEANING Although it may be necessary to clean the system, information in this chapter deals primarily with cleaning the boiler under isolated conditions. System piping connected to the boiler may contain oil, grease, or other foreign matter. These impurities must be removed to prevent damage to the heating surface

• Chapter 5 Adjustment Procedures 5-8 750-177 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% O 2 is approximately 15% excess air and 4% O 2 is approximately 20% excess air. The exact percentage of excess air is a mathematical calculation

• Chapter 5 Adjustment Procedures 5-6 750-177 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 is not maintained, inspect the devices immediately and replace as required. M. COMBUSTION AIR PROVING SWITCH Air pressure against the diaphragm actuates the switch which, when made,

• Sequence Of Operation Chapter 4 750-177 4-7 LLPR Low Limit Pressure Relay LLR Lead Lag Relay LLTC Low Limit Temperature Control LLTR Low Limit Temperature Relay LOPL Low Oil Pressure Light LOPR Low Oil Pressure Relay LOPS Low Oil Pressure Switch LOTL Low Oil Temperature Light LOTR Low Oil Temperature Relay LOTS Low Oil Temperature Switch LPAPS Low Plant Air Pressure Switch LPCO Low

• CleaverBrooks FLX, Chapter 4 Sequence Of Operation 4-8 750-177 POL Power On Light POV Pilot Oil Valve PPL Pre-Purging Light PPR Post Purge Relay PPTD Post Purge Time Delay PR Program Relay PRL Purge Ready Light PRPTD Pre-Purge Time Delay PR Program Relay PRPTD Per-Purge Time Delay PS Power Supply PSF Power Supply Fuse PSS Pump Selector Switch PSV Purge Solenoid Valve PT Purge Timer PTS Pump Transfer Switch PUCR Purge Complete Relay PUR Purge Relay R R Red (Color of Pilot Light) RAR Remote Alarm Relay RATD Remote Alarm Time Delay RES Resistor RML Run Mode Light RMR Release To Modulate Relay RS Range Switch RSR Remote Start Relay RTD Resistance Temperature Detector S SBFPL Stand By Feed Pump Light SBFP

• CleaverBrooks FLX, Chapter 2 Profire V Burner 2-34 750-177 RECOMMENDED MAINTENANCE SCHEDULE ITEM SERVICE BY REMARKS DAILY Gauges, Monitors, and Indicators Operator Make visual inspection and record readings in log. Instrument and Equipment Settings Operator Make visual check against recommended specifications. Low Water, Fuel Cutoff, and Alarms Operator Refer to instructions. WEEKLY Firing Rate Control Operator Verify factory settings. Igniter Operator Make visual inspection. Check flame signal strength. Pilot and Main Fuel Valves Operator Open limit switch. Make audible and visual check. Check valve position indicators, and check fuel meters. Flame Failure Controls Operator Close manual fuel supp

• CleaverBrooks FLX, Chapter 4 Sequence Of Operation 4-2 750-177 Blower Motor Starter Circuit • Blower motor starter (BMS) Running lnterlock Circuit • Blower motor starter interlock (BMSI) • Combustion air proving switch (CAPS) 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 • Main gas valve (MGV) • Main gas ven

• CleaverBrooks FLX, CHAPTER 8 PARTS Flextube Casing, Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2,3 Flextube Casing, Low Pressure Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4,5 Flextube Casing, High Pressure Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6,7 Steam Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Water Level Controls . . . . . . . . . . . . . . . . .

• CleaverBrooks FLX, Chapter 3 Pressure Vessel Care 3-10 750-177 ! DANGER WARNING Materials described in this section may be considered hazardous under the U.S. Occupational Safety and Health Act of 1970. Material Safety Data Sheets should be obtained and understood prior to the use of these products to avoid the possibility of serious personal injury or death. Wet Storage Note: It is always best to consult with a water treatment consultant before proceeding with extended layup. Wet storage is used when the boiler will be out of service for shorter periods of time, when a boiler is held in sta

• CleaverBrooks FLX, MODEL FLX PACKAGED BOILER Operation, Service, and Parts Manual 1,500,000 to 12,000,000 Btu/hr Fuel: Light Oil, Gas or Combination Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative Manual Part No. 750-177 R5 Revised 10/2009 Printed in U.S.A. © Cleaver-Brooks 2009

• CleaverBrooks FLX, Chapter 1 GENERAL DESCRIPTION 1-4 750-177 Figure 1-3: Steam Controls Figure 1-5: Low Water Cut Off Pump Control (Cutaway) 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. ! DANGER 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

• CleaverBrooks FLX, Profire V Burner Chapter 2 750-177 2-15 FULL MODULATION - OPEN DAMPER PURGE Combustion Air Gas Oil COMPONENTS DESCRIPTION A two blade damper is controlled by a proportional modulating actuator (or motor) with mechanical linkage. The modulating actuator is capable of stopping at any point along its 90 degree stroke based on a signal from a remotely connected modulating control or from a burner mounted manual potentiometer which is selected through an auto/manual modulation selector switch. The actuator also contains two internal switches that ensure the damper reach the high fire and low fire positions during purge and before ignition is initiated. Safety shut off valve(s) are provided to

• CleaverBrooks FLX, Troubleshooting Chapter 6 750-177 6-5 2. Cold system startup. A. Any time a boiler is started with a cold system, it will produce condensate until internal surface temperatures exceed 130 °F. Internal condensation will not be produced once a boiler has warmed up. Condensate will dry up after a short time. Limit number of cold starts. 3. Cold return temperatures. A. Return temperatures below 120 °F. will continually produce condensation. Raise return temperatures above 120 °F. 4. Gasket leaks allow

• CleaverBrooks FLX, 750-177 1-1 CHAPTER 1 GENERAL DESCRIPTION A. General The information in this manual applies directly to Cleaver- Brooks FLX Model boilers in sizes ranging from 1,500,000 to 12,000,000 Btu/hr input. Fuel Series 700- Gas 100-No.2 0il 200 - Combination Gas & No.2 Oil Design Pressure 160 psig hot water 15 psig steam 150 psig steam ! DANGER CAUTION The care taken in placing the boiler into initial service is vital to continuous, reliable operation. If the boiler is to be used for temporary heat (for example in new construction), properly treated water must be used. Failure to do so can be detrimental to the boiler. Figure 1-1: FLX Cut Away A. General . . . . . . . . . .

• CleaverBrooks FLX, Chapter 2 Profire V Burner 2-30 750-177 COMBUSTION AND HIGH CO EMISSIONS WILL RESULT. Monitor O 2 and CO levels during this process. The introduction of FGR into the combustion chamber will lower the flue O 2 levels. Too much FGR may induce high levels of CO in the flue gas. It may be nec- essary to adjust the air damper blades to raise the O 2 to proper low-fire values. If the proper NOx values can not be reached by adjusting the cam screw, the FGR linkage will have to be adjusted as well. Please see the section on linkage adjustment for details. 4. Once the low-fire setting is complete, continue with the instructions above, adjusting the cam at each screw, to o

• CleaverBrooks FLX, 750-177 2-1 CHAPTER 2 Profire V Burner A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 C. Startup and Operation . . . . . . . . . . . . . . . . . . . . . . .2-17 D. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 E. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31 F. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35 G. Burner Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39 A. Introduction CB Profire V/Series burners

• CleaverBrooks FLX, Profire V Burner Chapter 2 750-177 2-13 LOW-HIGH-LOW MOD - LOW or 60% DAMPER PURGE Combustion Air Gas Oil COMPONENTS DESCRIPTION: A two blade damper is controlled by a two position, spring return actuator with mechanical linkage. For 60% damper purge a mechanical stop is provided on the damper to ensure sufficient air flow is provided during prepurge. Power to drive the actuator is routed through a low/auto switch and a remote located modulating control. The actuator also contains a limit switch which is used to actuate the second stage of the oil supply system. (see oil at right). Safety shut off valve(s) are pro

• CleaverBrooks FLX, Chapter 7 Inspection and Maintenance 7-4 750-177 E. CONTROLS Relief Valves The relief valve is a very important safety device and deserves attention accordingly. Proper removal, installation or handling of a relief valve is of primary importance. Exercise care when removing, installing or handling a relief valve to ensure proper operation, long service life, and to ensure that the valve functions as designed. ! DANGER WARNING Improper removal, handling or installation of a relief valve may adversely affect the valve's operation, resulting in serious personal injury or death. Observe the following pr

• CleaverBrooks FLX, TABLE OF CONTENTS Chapter 1 Basics of Flexible Watertube Operation A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 B. The Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 C. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 D. Steam Controls (All Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 E. H

• Chapter 2 Profire V Burner 2-2 750-177 transformer is powered, and pilot valve is energized (open). c. MAIN FUEL (green) - Illuminates when the main fuel valve or valves are energized (open). d. FLAME FAILURE (red) - Illuminates when the flame safeguard system fails to detect pilot or main flame. 7. MODULATING MOTOR Operates the air damper and fuel rate valves through a linkage syste

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