Model icb packaged Boiler 100 to 800 hp operation, Service, and Parts

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Model ICB
Packaged Boiler
100 to 800 HP
Operation, Service, and Parts
750-196 09/2010
Steam and Hot Water

Light Oil, Gas or Combination

Packaged Boiler
Operation, Service, and Parts Manual
100 to 800 Horse Power Steam and Hot Water
Fuel: Light Oil, Gas or Combination
Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative
Manual Part No. Revised Printed in USA Cleaver-Brooks 2010

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 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 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 afford 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 attempting to operate, maintain, service, or repair this equipment.
Because of state, local, or other applicable codes, there area 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, inmost 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 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-con- necting 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 frequently to check for the presence of any mud, sludge, scale or corrosion.
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 his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.

Do not operate, service, or repair this equipment unless you fully understand all
Chapter 2waterside care and requirements
Chapter 3sequence of operation
Chapter 4starting and operating instructions
Chapter 5adjustment procedures
Chapter 6profire d series burner
Chapter 7profire d series burner maintenance
Chapter 8troubleshooting
Chapter 9vessel inspection and maintenance
Chapter 10aparts - f series profire burners
Part no. 750-196
Always order genuine cleaver-brooks parts from your local cleaver-
Chapter 1 — basics of firetube operation
Figure 1-5. front baffle four pass
D. steam controls (all fuels)
Figure 1-7. asme welding on
Figure 1-9. water column and low
Figure 1-15. profire f series
Note: this manual only covers boilers using water. glycol
Water circulation
If care is not taken to ensure adequate or proportional flow through
Chapter 2 — waterside care and requirements
D. cleaning1. hot water and steam piping
Note: temperature of initial fill of water for hydrostatic tests,
Warningbe sure to drain the hot water to a safe point of discharge to avoid
Flushing of pressure vessel interior
E. blowdown steam boiler
F. periodic inspection
Figure 2-8. vent valve on water
G. preparation for extended lay-up
Milwaukee, wisconsin
Chapter 3 — sequence of operation
C. sequence of operation — oil or gas
Table 3-1. electrical nomenclature
Table 3-1. electrical nomenclature (continued)
Figure 4-1. f series oil train
Note: the pressure vessel support legs are welded to mounting skids
C. start-up procedures
Air flow adjustments
Figure 4-10. air box and air shutters
Chapter 4 — starting and operating instructions
Bhpminimum 0
Table 4-2 gas train insurance designations
Figure 4-15. gas butterfly valve
G. start-up, operating and shutdown — all
Warningdo not relight the pilot or attempt to start the main burner, either
The burner is manually turned “off.”
H. control operational tests
Warningit is advisable to check for tight shutoff of fuel valves. despite
B. linkage — modulating motor and air
Service or parts representative, it may have an incorrect stroke. to
D. burner operating controls — general
Figure 5-4. firing graph
H. modulating temperature control
J. high limit temperature control (hot water)
M.atomizing air proving switch
Figure 5-7. combustion air proving
O. gas pressure and flow information
Efficiency x gas btus/ft
P. gas fuel combustion adjustment
Chapter 5 — adjustment procedures
Table 5-2. fuel oil atomizing air requirements
B. operating controls / control panel
Control circuit breaker
Figure 6-1. mounted d series
Separate compressor module.
Figure 6-12. air compressor cutaway
Chapter 6 — profire d series burner
Electrical interference test
Gas pilot flame adjustment
Main gas pressure regulator
High gas pressure switch
Gas combustion adjustment
Secondary valve adjustment
Atomizing air pressure.
Atomizing air proving switch.
Low oil pressure switch
C. control system
E. pilot and ignition electrode
F. oil nozzle.
Oil level sight gauge.
Figure 7-7. integral oil air metering system and tank
I. gas system
J. electrical system
Warningtrouble shooting should be performed only by
Warningthe cause for loss of flame or any other
C. pilot flame, but no main flame
Periodic inspection
B. fireside cleaning
Figure 9-1. authorized cleaver-
D. water gauge glass
Oil pump (oil fired units).
G. flame safety control
O. lubrication
P. combustion
Chapter 9 — vessel inspection and maintenance
Chapter 10aparts
Component lists page 10a-7
Chapter a — parts
Figure 10-15. fan & firing head components, 60 hz (700 ft. altitude)
Motors & mtg. plate selections
Figure 10-22. water column piping 92” & 106” icb steam

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