model 5 boiler - RF MacDonald Co.

Model 5
1500 - 6000 MBTU/hr
MODEL 5 BOILER
1,500 - 6,000 MBTU &
7,500-8,000 Low Water Volume
Watertube Boiler
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
Special Insurance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Feedwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Boiler Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-23
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-23
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-31
Section B2-1
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
ILLUSTRATIONS
Model 5 Steam Boiler Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
Model 5 Low Water Volume Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-11
Standard Gas Train Model 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-16
Boiler Room Air Flow - “Engineered Design” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-23
TABLES
Model 5 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Model 5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-9
Model 5 connection sizes and clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-10
Model 5 Low Water Volume dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Model 5 Low Water Volume connection sizes and clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Model 5 Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . B3-15
Model 5 Oil Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15
Model M5 min. req. Natural Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-17
Model M5 min. req. Natural Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-17
Model M5 min. req. Propane Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-18
Model M5 min. req. Propane Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-19
Safety Valve Outlet Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-19
Predicted Efficiency, 10 PSIG operating (includes radiation and convection losses) . . . . . . . . . . . . . . B3-20
Model 5 Emission Data, Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Emission Data, No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-25
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-25
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-26
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-27
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-28
Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Water Quality Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Feedwater Make-up Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Model 5 Fuel, Combustion Air, and Flue Gas Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-30
The Model 5 Commercial Watertube Boiler product line is used for low and high pressure steam applications. Sizes
range from 1.5 to 8 MMBtu/hr. The Model 5 Boiler is an excellent choice where high outputs are required but space
limitations exist. The model number designation is 1500 through 8000, representing MBtu/hr input (1,500,000 to
8,000,000 Btu/hr).
Fuel series designation is as follows:
• Series 100: No. 2 oil firing.
• Series 700: Natural gas firing.
• Series 200: No. 2 oil/natural gas firing.
Design pressure designation is stated as 15 psig, 150 psig, and 250 psig for steam, and 140 psig for hot water. For
example, a Model M5P-700-2500-150 boiler designates a gas-fired, 2,500,000 Btu/hr, 150 psig, steam boiler.
Section B2-2
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
FEATURES AND BENEFITS
33" Cased Width:
• Boiler fits through most standard doorways.
• Reduced installation costs.
Direct Driven, Vibration-Free Centrifugal Impeller:
• Quiet operation.
• Sound levels below 80 dbA.
• Ideal for noise critical areas such as hospitals, churches, etc.
Minimum Refractory:
• Membrane waterwalls reduce the need for refractory by 95%.
• Reduced maintenance costs and refractory repair requirements.
Membrane Waterwalls:
• Enhanced heat transfer area in compact design.
• Sealed combustion chamber improves heat transfer for high efficiency.
Small Boiler Footprint:
• Savings of up to 50% in floor space.
Weighs up to 40% less than Comparable Boilers:
• Lower freight and rigging costs.
• Reduced structural requirements.
Standard Built-in Soot Washers:
• Boiler cleaning without shutdown.
• Maintains peak boiler performance.
Packaged Forced Draft Burner:
• High pressure drop design.
• Optimum fuel and air mixing.
• Improved combustion efficiency.
Low Water Volume Design (optional):
• Meets various provincial operating engineer codes and regulations.
• Reduced operating costs.
• High and low pressure steam.
Steam Design Pressures to 500 psig:
• High performance in a compact design.
• Proven vessel design for high design pressure applications.
Section B2-3
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
PRODUCT OFFERING
The Model 5 (M5) Boiler is a compact carbon steel, extended fin, watertube boiler.
Heat transfer design is configured in a "3-pass" gas travel across the watertube
surfaces. The pressure vessel is constructed to conform to the A.S.M.E. Code,
either Section IV for low pressure steam @ 15 PSIG MAWP (maximum allowable
working pressure) or Section I for MAWP greater than 15 PSIG.
The vessel (boiler) consists of two rows on each side of the vessel, of formed
seamless tubes with extended fin surfaces and downcomers connected to the steam
drum and lower drum. To reduce standby losses, the vessel is insulated with a
fiberglass blanket and removable steel jacket.
Complete with an integral burner for either No.2 fuel oil or Natural Gas, the
complete burner/boiler package is CSA International Approved, listed, and labeled.
Standard Equipment
The standard boiler/burner package is described below. Optional controls, trim, and
devices may be added to meet project requirements, and some of those options are
noted, following this standards list.
1. Boiler
A. Designed, constructed, and hydrostatically tested in accordance with the
A.S.M.E. Boiler and Pressure Vessel Code. The complete vessel is mounted on a
structural steel frame.
B. Steam drum includes a hand hole in the rear head for drum water side
inspection. Connections are included for the following:
Feedwater Makeup w/internal dispersion tube.
Table B3-1. Model 5 Boiler Sizes
MODEL
NO.
INPUT
MBH
HEAT
OUTPUT
MBH
EQUIV
HP
STEAM SHIPPING
OUTPUT WEIGHT
LB/HR
LBS
1500
1500
1200
35
1237
3100
2000
2000
1600
47
1649
3100
2500
2500
2000
59
2062
3700
3000
3000
2400
71
2474
3700
3500
3500
2800
83
2887
4100
4000
4000
3200
95
3299
4100
4500
4500
3600
107
3711
4700
5000
5000
4000
119
4124
4700
6000
6000
4800
143
4949
5400
8000 LWV
8000
6320
194
6516
6200
NOTE: Steam output from and at 212 °F.
LWV = Low Water Volume.
Section B2-4
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Surface Blowoff.
Steam Supply.
Safety Relief Valve.
C.Lower Drum includes hand holes at each end for waterside inspection. A drain/
blowoff tapping is provided at the front, bottom
centerline.
D.Soot washer lances are provided on each side of the vessel between the two rows
of tubes for fireside cleaning. Soot washer drains are located at the bottom of the
boiler, with connections to drain located on each side of the lower drum at the rear.
E.Refractory is limited to the furnace floor, lower drum, and burner throat tile. High
temperature insulation is installed on the front water wall and furnace access door.
F.Two lifting eyes are provided on the top centerline of the upper drum for ease of
installation.
G.Furnace inspection/access door is provided in the furnace rear wall.
The exhaust gas vent is located at the top rear centerline of the boiler. A stack
thermometer is shipped loose for field installation by the installing contractor into
the stack.
I.The complete vessel is fully insulated (2" fiberglass blanket) under a preformed,
sectional steel jacket.
J.Factory painted using hard-finish enamel.
1. Steam Boiler Control Standard Equipment (15 to 150 psig)
A. ASME safety relief valve(s).
B. Steam pressure gauge.
C. Pressure controls:
•
High limit control-manual reset.
•
Operating limit control.
•
High-low fire control (full modulation for gas firing).
D. D. Low water cutoff with pump control.
E. E. Water column gauge glass set and fittings.
F. F. Auxiliary low water cut-off.
G. G. Combustion air proving switch.
2. Electrical Control Panel
A. Mounted at eye level on the front head of the boiler.
B. NEMA rating 1A with gasket dust seal.
C. Contains electronic program relay and switches.
3. Miscellaneous
A. The boiler is Canadian Standards Association (CSA) approved and bears the
CSA label.
Optional Equipment
Optional Equipment
For more detailed information on optional equipment, contact the local CleaverBrooks authorized representative. In summary, options include the following:
1. Boiler
Section B2-5
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Larger pressure gauges or specific manufacturer type.
Bottom Drain Valves for low pressure applications.
Bottom Blowoff Valves for high pressure applications.
Surface Blowoff Valve with internal collector pipe.
Feedwater Stop and Check Valves.
Steam Stop Valve.
ASME Hydro Test of Valves and Valve Piping.
Design pressures above 150 PSIG.
2. Burner/Control Options
Full Modulation Firing on Gas.
Lead/Lag Control.
Day-Night Controls.
Low Fire Hold Control.
Elapsed Time Meter.
Alarm with silence switch.
Additional Indicator Lights.
Main Power Disconnect.
Remote Oil Pump.
Optional NEMA Enclosures.
Special Fan Motor requirements (TEFC).
3. Fuel Options
Automatic Fuel Changeover (combination burner).
Propane Fuel Firing.
Special Gas Pressure Regulators.
Special fuel shut-off valves.
Dual Pilots (gas and oil).
Gas strainer.
"Guarded Plant" status equipment.
4.Low Water Volume Design Options (LWV)
5.Guarded Plant Requirements
Notice
*Not required for low pressure steam applications.
Special Insurance
Requirements
The boiler package can be equipped to meet various insurance or code
requirements. Some of these insurance/code requirements are:
Factory Mutual (FM)
Section B2-6
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
XL GAP (Formerly GE GAP/IRI).
A.S.M.E. CSD-1.
Factory Mutual (FM Global) - Recommended guidelines as described by FM pertain
to boilers rated at greater than 2.5 MMBtu/hr input on gas and 2.8 MMBtu/hr input
on oil. Boilers that are labeled and tested in accordance with an independent
testing lab such as UL or CSA and are below these inputs are exempt from these
recommendations.
The Model 5 boiler is CSA listed and labeled. In addition to the standard CSA
requirements the following are needed to comply with FM when required.
Alarm Bell with silence switch for low water and safety shutdowns.
Low Oil Pressure Switch if the oil pump is not direct driven from the fan motor.
XL GAP (Formerly GE GAP/IRI) Recommended guidelines as described by XL GAP
pertain to boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. For these
boilers, the requirements are the same as for A.S.M.E CSD-1 requirements. Above
12.0 MMBtu/hr input, the requirements defer to the NFPA 85 standards for single
burner boilers.
A.S.M.E. CSD-1 - Recommended guidelines as described by this Code pertain to
boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. Above 12.0
MMBtu/hr input, the requirements defer to the NFPA 85 standards for single burner
boilers. . For the sizes this Code covers, the requirements are as follows, in addition
to the standard CSA package:
Low Oil Pressure Switch for oil firing all sizes.
¾" Pressure Control Piping
If gas supply is > 5 psig, a relief valve is required after the gas pressure regulator in
the main and pilot gas trains.
Lever Handled shutoff cock for the pilot gas train.
Non-fused disconnect to remove boiler from all sources of power.
DIMENSIONS AND RATINGS
For layout purposes, the nominal dimensions and connections for the Model 5
Standard Boiler Packages are shown in Figure B3-1 and Tables B3-1 and B3-2.
Low Water Volume (LWV) Package Boiler Dimensions are shown on Figure B3-2
and Table B3-3 and B3-4. Ratings of each boiler size are noted in Table B3-5.
Additional information is shown in the following figures, tables, and illustrations.
Table B3-6 Recommended steam nozzle sizes for high pressure boilers operating at
lower and higher pressures.
Table B3-7 Model 5 Oil Fuel Requirements.
Figure B3-3 Standard gas train.
Tables B3-8 to B3-11 Gas pressure requirements.
Table B3-12 Safety Valve Outlet Sizes.
Section B2-7
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Figure B3-1. Model 5 Steam Boiler Dimension Diagram
Section B2-8
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
1500
Note 1
2000
2500
3000
Boiler Size
3500
4000
4500
5000
6000
All D imensions are in Inches
Lengths
A
Overall
B
Pressure Vessel w/casing
69.7
69.7
85.8
85.8
104.4
104.4
121.1
121.1
136.7
51.25
51.25
67.375
67.375
83
83
99.625
99.625
115.25
45.5
45.5
61.1
61.1
76.75
76.75
92.4
92.4
108
8
8
8
8
8
8
8
8
8
43
43
58.5
58.5
74.5
74.5
90
90
105.5
17.2
17.2
17.7
17.7
17.7
17.7
21.8
21.8
21.8
13
13
13
13
16
16
16
16
16
16.4
16.4
24.4
24.4
30.1
30.1
36.75
36.75
44.6
Steam Nozzle to Safety Valve 15#
7
7
12
12
11.5
11.5
13
13
17
Steam Nozzle to Safety Vavle 150#
8
8
12
12
17
17
17
17
17
57.5
57.5
57.5
57.5
57.5
57.5
57.5
57.5
57.5
33
33
33
33
33
33
33
33
33
C
Base Fram e
C1
Base to Front Head
C2
Base Fram e Anchor Holes
CC
Rear Casing to Stac k Connec tion
D
DD
HH
Front Head Extension
Front Casing to Steam Nozzle
Widths
E
Overall
F
Center to Water Column
G
Center to Aux. Water Column
23.5
23.5
23.5
23.5
23.5
23.5
23.5
23.5
23.5
H
Center to Outside Casing
16.5
16.5
16.5
16.5
16.5
16.5
16.5
16.5
16.5
I
Base Fram e Inside
20
20
20
20
20
20
20
20
20
J
Base Fram e Outside
28
28
28
28
28
28
28
28
28
K
Soot Washers, Center to Center
21.5
21.5
21.5
21.5
21.5
21.5
21.5
21.5
21.5
10.75
L
Boiler Centerline to Soot W asher
10.75
10.75
10.75
10.75
10.75
10.75
10.75
10.75
M
Boiler Centerline to Base Centerline
12
12
12
12
12
12
12
12
12
N
Boiler Centerline to Soot Drain
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
Heights
OO
Overall [Base to Stack Connection]
78.25
78.25
78.25
78.25
78.25
78.25
78.25
78.25
78.25
OO1
Base to Top of Control Panel
84.5
84.5
84.5
84.5
84.5
84.5
84.5
84.5
84.5
O
Base to Steam Nozzle 15#
73.5
73.5
73.5
73.5
76.5
76.5
76.5
76.5
76.5
O1
Base to Steam Nozzle 150#
73.5
73.5
73.5
73.5
73.5
73.5
76.5
76.5
76.5
62.25
62.25
62.25
62.25
62.25
62.25
62.25
62.25
62.25
P
Base to Steam Drum Centerline
P1
Drum Centerline To Surface Blowoff,
Std. Design & 15# Low W ater Volume.
[See Note C]
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
P1
Drum Centerline To Surface Blowoff;
High Pressure Design Low Water
Volume. [See Note D]
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
R
Base to Sootwasher Lance
54
54
54
54
54
54
54
54
54
S
Height of Base
4
4
4
4
4
4
4
4
4
OS
Base to Oil Supply Connection
26.625
26.625
26.625
26.625
26.625
26.625
26.625
26.625
26.625
OR
Base to Oil Return C onnection
24.625
24.625
24.625
24.625
24.625
24.625
24.625
24.625
24.625
Table B3-1. Model 5 Dimensions
Section B2-9
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Connections
BB
12
12
12
12
12
12
16
16
16
T
Bottom Drum Blow Down, 15# [one]
1.25
1.25
1.25
1.25
1.5
1.5
1.5
1.5
1.5
T1
Bottom Drum Blow Down, 150# [one]
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
U
Steam Nozzle, 15#
4
V
Steam Nozzle, 150#
2.5
2.5
W
Soot Washer D rains [Two]
2
2
2
2
2
X
Surface Blow off [One]
0.75
0.75
0.75
0.75
Y
Feedwater Inlet [One]
1
1
1
1
Z
Soot Washer [Two]
0.25
0.25
0.25
Oil Supply and Return
0.5
0.5
Relief Valve, 15#
1.5
2
0.75
1
GG
JJ
OD Stac k - Sleeve C onnection
Relief Valve, 150#
A
A
A
4
A
4
A
4
A
6
B
6
B
6
B
6
B
3
A
3
A
3
A
3
A
6
B
4
B
4
B
4
B
2
2
2
2
0.75
0.75
0.75
0.75
0.75
1
1
1
1
1
0.25
0.25
0.25
0.25
0.25
0.25
0.5
0.5
0.5
0.5
0.5
0.5
0.5
2
2
2.5
2.5
2.5
2.5
3
1
1
1.25
1.25
1.25
1.25
1.5
33
Clearances
EE
Front Door Swing
33
33
33
33
33
33
33
33
FF
Tube removal eac h s ide
30
30
30
30
30
30
30
30
30
RF
Allowance for Front Door Swing and
30" Rear Aisle Space.
133
133
149
149
167
167
184
184
200
RD
Allowance for Tube Removal Each
Side and Front Door Swing.
94
94
94
94
94
94
94
94
94
NOTES:
1. The above dimens ions , while suffic iently accurate for layout purposes must be confirmed for construc tion via certified prints. For
200 PSIG design pressure and greater, contact Milwauk ee Sales for certified prints.
2. Allow s uff icient s pace at rear of boiler for rem oval of soot washer lance.
3. For access to the furnace, a 13" x 21" access door is provided behind the front door.
4. Control Panel may be larger [up to 4" in height] if certain control options are provided.
A. Connection is a Female Pipe Thread.
B. Connection is a 150# Flange, Flat Face.
C. W hen optional internal collector pipe is reques ted, tapping will be 4.5" from drum centerline.
D. W hen optional internal collector pipe is reques ted, tapping will be 6.8" from drum centerline.
Table B3-2. Model 5 connection sizes and clearances
Section B2-10
Rev. 03-08
OO
O
P
Q
R
M
N
W
Y
Z
Rear Sight Port
Handhole 4” x 6”
9 1/4”
FF
2”
CC
JJ
BB
Section B2-11
C
C2
B
HH
RF
A
V
DD
C1
T
D
GG
Control Panel
Steam Pressure Gauge
EE
2 1/2”
Inspection
Opening
OS OR
F
H
J
E
I
G
S
OO1
Aux Low
Water Cutoff
Model 5
1500 - 6000 MBTU/hr
Figure B3-2. Model 5 Low Water Volume Dimension Diagram
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
7500
Note 1
Boiler Size
8000
All D imensions are in Inches
Lengths
A
Overall
190.1
190.1
B
Pressure Vessel w/casing
138.7
138.7
129.9
C
Base Fram e
117.4
C1
Base to Front
6
6
C2
Base Fram e Anchor Holes
112.4
127.4
CC
Rear Casing to Stac k Connec tion
21.8
21.8
Burner Extension
56.5
56.5
Front Casing to Steam Nozzle
63
63
II
Steam Nozzle to Safety Vavle 150#
17
17
E
Overall
57.5
57.5
F
Center to Water Column
G
D
DD
Widths
33
33
Center to Aux. Water Column
23.5
23.5
H
Center to Outside Casing
16.5
16.5
I
Base Fram e Inside
20
20
J
Base Fram e Outside
28
28
K
Soot Washers, Center to Center
21.5
21.5
L
Boiler Centerline to Soot Washer
10.75
10.75
M
Boiler Centerline to Base Centerli ne
12
12
N
Boiler Centerline to Soot Drain
3.5
3.5
Heights
OO
Overall [Base to Stack Connection]
78.25
78.25
OO1
Base to Top of Control Panel
84.5
84.5
O1
Base to Steam Nozzle 150#
73.25
73.25
P
Base to Surface Blowoff
58.5
58.5
55.75
55.75
54
54
Q
Base to Feedwater Inlet
R
Base to Sootwasher Lance
S
Height of Base
4
4
OS
Base to Oil Supply Connection
26.625
26.625
OR
Base to Oil Return C onnection
24.625
24.625
NOTES:
1. The above dimensions, while sufficiently accurate for layout purposes, must be
confirmed for construction via certified prints. For 200 PSIG design pressure and
greater, contact Milwaukee Sales for certified prints.
2. Allow sufficient space at rear of boiler for removal of soot washer lance.
3. For access to the furnace, a 13" x 21" access door is provided behind the front door.
4. Control Panel may be larger [up to 4" in height] if certain control options are provided.
Table B3-3. Model 5 Low Water Volume dimensions
Section B2-12
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Connections
BB.
OD Stac k - Sleeve C onnection
T1
Bottom Drum Blow Down, 150# [one]
V
Steam Nozzle, 150#
W
Soot Washer D rains [Two]
2
2
X
Surface Blow off [One]
0.75
0.75
Y
Feedwater Inlet [One]
1
1
Z
Soot Washer [Two]
0.25
0.25
GG
Oil Supply and Return
0.5
0.5
JJ
Relief Valve, 150#
2
2
18
18
1.25
1.25
6
6
Clearances
EE
Clearanc e f rom Control Panel
36
36
FF
Tube removal eac h s ide
30
30
RF
Allowance for Front Burner Removal
and 30" Rear Aisle Space.
220
220
NOTES:
1. The above dimensions, while sufficiently accurate for layout purposes, must be
confirmed for construction via certified prints. For 200 PSIG design pressure and
greater, contact Milwaukee Sales for certified prints.
2. Allow sufficient space at rear of boiler for removal of soot washer lance.
3. For access to the furnace, a 13" x 21" access door is provided behind the front door.
4. Control Panel may be larger [up to 4" in height] if certain control options are provided.
Table B3-4. Model 5 Low Water Volume connection sizes and clearances
Section B2-13
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Boiler SIZE
1500
2000
2500
3000
3500
4000
4500
5000
6000
7500 LWV 8000 LWV
1,237
1,649
2,062
2,474
2,887
3,299
3,711
4,124
4,949
6,186
6,600
Rated Steam Capacity [k g/hr from
and at 100 C]
561.0
748.0
935.0
1,122.0
1,309.0
1,496.0
1,683
1,871.0
1,847.2
2,806
2,993.7
Output Btu/hr [1,000 Btu/h]
Ratings [Note A]
Rated Capacity - Steam (lbs.
o
steam/hr from & at 212 F.)
1,200
1,600
2,000
2,400
2,800
3,200
3,600
4,000
4,800
6,000
6,400
Output Kcal/Hr [1,000 Kc al/h]
302
403
504
605
706
806
907
1,007
1,210
1,512
1,613
Output KW
348
464
580
696
812
928
1,044
1,160
1,392
1,740
1,856
Approximate Fuel C onsumption At Rated C apacity [ Input - N ote B]
3
1,465
2,000
2,450
2,952
3,456
3,950
4,444
4,938
5,925
NA
NA
3
1,538
2,077
2,564
3,117
3,590
4,155
4,657
5,194
6,233
7594
8205
Natural Gas [m /hr] - 15# Steam
41.5
56.6
69.4
80.8
97.9
111.9
125.8
139.8
167.7
NA
NA
Natural Gas [m 3/hr] - 150# Steam
43.5
58.8
72.6
88.3
101.6
117.6
131.8
147.0
176.5
215
232.4
Propane G as [ft /hr] - 15# Steam
3
586
800
980
1,181
1,382
1,580
1,778
1,975
2,370
NA
NA
Propane G as [ft /hr] - 150# Steam
3
615
831
1,026
1,247
1,436
1,662
1,863
2,078
2,493
3038
3282
Propane G as [m /hr] - 15# Steam
3
16.6
22.6
27.7
33.4
39.1
44.7
50.3
55.9
67.1
NA
NA
3
17.4
23.5
29.1
35.3
40.7
47.1
52.7
58.8
70.6
86
92.9
No.2 Oil Fuel - 15# Steam, gph
10
14
17
21
24
28
31
35
42
NA
NA
No.2 Oil Fuel - 150# Steam , gph
11
15
18
22
25
28.9
32
36
43
54
59
No.2 Oil Fuel - 15# Steam, lph
38
53
64
79
91
106
117
132
159
NA
NA
No.2 Oil Fuel - 150# Steam , lph
41
56
68
82
95
109
121
136
163
204
223
Natural Gas [ft /hr] - 15# Steam
Natural Gas [ft /hr] - 150# Steam
3
Propane G as [m /hr] - 150# Steam
Pow er Requirements - 3 Phase 60 Hz Standard [Note C]
Blow er Motor HP - Gas Firing
2
2
2
2
2
3
3
3
5
7.5
7.5
Blow er Motor HP - Oi l or Comb.
2
2
2
2
3
5
3
3
5
7.5
7.5
Direct Drive from Fan
Motor
Belt Driven from the Blower Motor
Oil Pump for Oil or Combination
Minimum Ampacity
Blow er Motor - Gas, 230V
6
6
6
6
6
9
9
9
15
22
22
Blow er Motor - Gas, 460 V
3
3
3
3
3
4.5
4.5
4.5
7.5
11
11
Blow er Motor - Oil or Comb, 230 V
6
6
6
6
9
15
9
9
15
22
22
Blow er Motor - Oil or Comb., 460V
3
3
3
3
4.5
7.5
4.5
4.5
7.5
11
11
Blow er Motor - Gas, 575 V
1.6
1.6
1.6
1.6
1.6
2.4
2.4
2.4
4.1
6.1
6.1
Blow er Motor - Oil or Comb., 575V
1.6
1.6
1.6
1.6
2.4
4.1
2.4
2.4
4.1
6.1
6.1
Control Circuit
1.7
1.7
1.7
1.9
1.9
1.9
2.4
2.4
2.4
2.5
2.5
Operati ng Weight, lbs.
3,643
3,643
4,445
4,445
5,040
5,040
5,858
5,858
6,753
6,920
6,920
Operati ng Weight, kg
1,652
1,652
2,016
2,016
2,286
2,286
2,657
2,657
3,063
3,139
3,139
Water Content Normal, Imp.gals
54.4
54.4
74.9
74.9
94
94
116.1
116.1
135.7
71.1
71.1
Water Content Normal, liters
248
248
340
340
428
428
528
528
617
324.7
324.7
Water Content Flooded, Imp. gals
79.94
79.94
109.08
109.08
135.7
135.7
166.5
166.5
194.01
Water Content Flooded, liters
363.4
363.4
459.9
459.9
616.9
616.9
756.9
756.9
881.99
Shipping Weight, approx imate lbs.
3,100
3,100
3,700
3,700
4,100
4,100
4,700
4,700
5,400
6,200
6,200
Shipping Weight, approx imate k g
1,406
1,406
1,678
1,678
1,860
1,860
2,132
2,132
2,449
2,812
2,812
Weights
Notes:
A. Ratings shown for elevation to 1000 Feet. For ratings above 1000 Feet, contact your local Cleaver-Brooks Representative.
B. Input calculated with Nat. Gas @ 1000 Btu/ft3, Propane @ 2500 Btu/ft3, and Oil @ 140,000Btu/gal.
C. For altitudes above 1000 Feet, contact your local Cleaver-Brooks authorized representative for verification of capacity rating.
Table B3-5. Model 5 Steam Boiler Ratings
Section B2-14
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-6. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
Operating
Pressure
(PSIG)
1500
2000
2500
3000
3500
4000
4500
5000
6000
15
4
4
6
6
6
6
8
8
8
20
3
4
4
6
6
6
8
8
8
30
3
4
4
4
4
6
6
6
6
40
2-1/2
3
3
4
4
4
6
6
6
50
2-1/2
3
3
4
4
4
4
4
6
65
2-1/2
2-1/2
3
3
3
4
4
4
4
2-1/2
2-1/2
3
3
3
4
4
4
4
2-1/2
2-1/2
3
3
3
3
4
4
4
1-1/2
2
2
2-1/2
2-1/2
2-1/2
3
3
3
1-1/2
1-1/2
1-1/2
2
2
2-1/2
2-1/2
2-1/2
3
75
95 - 125
150
A
200
250 - 400
BO ILER SIZE
1-1/2
1-1/2
1-1/2
1-1/2
2
2
2
2
2-1/2
A. Standard nozzle size for 150 PSIG MAWP Boiler Design
Example 1: Size 3500, 150# boiler to operate @ 30 PSIG requires 4" steam nozzle in lieu of
standard 3" nozzle.
Example 2: Size 3500, 150# boiler to operate @ 200 PSIG requires 2" steam nozzle in lieu of
standard 3" nozzle.
Table B3-7. Model 5 Oil Fuel Requirements
BOILER
MODEL
1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 LWV
OIL
USAGEA
(GPH)
10.7
14.3
17.9
21.4
25.0
28.6
32.7
35.7
42.8
57.2
NOTES:
1.Oil supply lines to be sized for 125 gph pumping rates.
2.Oil pump suction pressure -10” Hg to 3 psig.
A.Usage Based on #2 Fuel @ 140,000 Btu/gal.
Section B2-15
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
PILOT GAS TRAIN
ITEM
PART
SIZE (IN.)
SIZE 1500 - 3000
1
Gas Inlet
2
Shutoff Cock
1-1/2
3
Main Regulator
4
Pilot Regulator
1/2
5
Solenoid Valve
1/2
7
Valve (POC)
8
Low Gas Pressure (Switch or Sensor)
1/2
1-1/2
1-1/2
MAIN GAS TRAIN
1/4
9
High Gas Pressure Switch
10
Shutoff Valve
1-1/2
1/4
11
Butterfly Valve
1-1/2
SIZES 3500 TO 5000
1
Gas Inlet
2
Shutoff Cock
2
3
Main Regulator
2
4
Pilot Regulator
1/2
5
Solenoid Valve
1/2
7
Valve (POC)
8
Low Gas Pressure (Switch or Sensor)
1/4
1/4
1/2
2
9
High Gas Pressure Switch
10
Shutoff Valve
2
11
Butterfly Valve
2
SIZE 6000 To 8000
1
Gas Inlet
2
Shutoff Cock
2
3
Main Regulator
4
Pilot Regulator
1/2
5
Solenoid Valve
1/2
6
Valve (STD)
7
Valve (POC)
8
Low Gas Pressure (Switch or Sensor)
1/4
1/4
1/2
2-1/2
2
2
9
High Gas Pressure Switch
10
Shutoff Valve
2
11
Butterfly Valve
2
Figure B3-3. Standard Gas Train Model 5
Section B2-16
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-8. Model M5 minimum required Natural Gas pressure at entrance to the standard UL, FM & XL GAP
gas trains (upstream of gas pressure regulator).
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
MIN ("W.C.)
MAX ("W.C.)
REQ UIRED FUEL
FLOW (SC FH)
1500
1.5
1.5
4.3
28.0
1500
2000
1.5
1.5
8.4
28.0
2000
2500
1.5
1.5
11.3
28.0
2500
3000
1.5
1.5
14.9
28.0
3000
3500
2.0
2.0
10.0
28.0
3500
4000
2.0
2.0
11.9
28.0
4500
2.0
2.0
11.5
28.0
4000
4500
5000
2.0
2.0
16.0
28.0
5000
PRESSUR E REQ UIRED
2.0
2.0
20.4
28.0
6000
2.5
19.9
19.9
28.0
8000 LW V
N ote: For altitude above 1000 feet, contact your local Cleaver-Brook s representative.
N atural Gas @ 1000 Btu/c u-ft, specific gravity @ 0.65
6000
8000
Table B3-9. Model M5 minimum required Natural Gas pressure at entrance to the oversized standard UL, FM
& XL GAP gas trains (upstream of gas pressure regulator).
PRESSUR E REQ UIRED
HONEYWELL
VALVE SIZE
(inches)
2.0
MIN ("W.C.)
MAX ("W.C.)
REQ UIRED FUEL
FLOW (SC FH)
1500
INLET PIPE
SIZE
(inches)
2.0
2.3
28.0
1500
2000
2.0
2.0
4.8
28.0
2000
2.0
2.0
6.5
2.5
2.5
5.7
28.0
2500
2.0
2.0
9.0
2.5
2.5
6.8
28.0
3000
3.0
3.0
6.0
2.5
2.5
9.7
3.0
3.0
7.1
28.0
3500
2.5
2.5
11.8
3.0
3.0
8.5
28.0
4000
2.5
2.5
9.8
3.0
3.0
5.6
28.0
4500
2.5
2.5
12.9
3.0
3.0
7.1
28.0
5000
4.0
4.0
5.6
2.5
2.5
17.5
3.0
3.0
10.0
28.0
6000
4.0
4.0
7.9
BOILER
SIZE
2500
3000
3500
4000
4500
5000
6000
3.0
9.8
28.0
4.0
4.0
5.6
N ote: For altitude above 1000 feet, contact your local Cleaver-Brook s representative.
N atural Gas @ 1000 Btu/c u-ft, specific gravity @ 0.65
8000 LW V
3.0
Section B2-17
8000
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-10. Model M5 minimum required Propane Gas pressure at entrance to the standard UL, FM & XL
GAP gas trains (upstream of gas pressure regulator).
PRESSUR E REQ UIRED
HONEYWELL
VALVE SIZE
(inches)
1.5
MIN ("W.C.)
MAX ("W.C.)
REQ UIRED FUEL
FLOW (SC FH)
1500
INLET PIPE
SIZE
(inches)
1.5
6.7
28.0
600
2000
1.5
1.5
10.5
28.0
800
2500
1.5
1.5
13.3
28.0
1000
3000
1.5
1.5
17.0
28.0
1200
3500
2.0
2.0
14.3
28.0
1400
4000
2.0
2.0
16.5
28.0
1600
4500
2.0
2.0
14.8
28.0
1800
5000
2.0
2.0
16.4
28.0
2000
6000
2.0
2.0
19.6
28.0
2400
BOILER
SIZE
2.0
2.0
19.6
28.0
8000 LW V
N ote: For altitude above 1000 feet, contact your local Cleaver-Brook s representative.
Propane @ 2500 Btu/cu-ft, specific gravity @ 1.6
Section B2-18
3200
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-11. Model M5 minimum required Propane Gas pressure at entrance to the oversized standard UL,
FM & XL GAP gas trains (upstream of gas pressure regulator).
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
MIN ("W.C.)
MAX ("W.C.)
REQ UIRED FUEL
FLOW (SC FH)
1500
2.0
2.0
5.9
28.0
600
2000
2.0
2.0
9.0
28.0
800
2.0
2.0
10.8
2.5
2.5
10.5
28.0
1000
2.0
2.0
13.8
2.5
2.5
12.9
28.0
1200
3.0
3.0
12.6
2.5
2.5
13.6
3.0
3.0
12.6
28.0
1400
2.5
2.5
15.8
3.0
3.0
14.5
28.0
1600
2.5
2.5
13.8
3.0
3.0
12.1
28.0
1800
2.5
2.5
14.8
3.0
3.0
12.5
28.0
2000
4.0
4.0
12.0
2.5
2.5
18.0
3.0
3.0
15.0
28.0
2400
4.0
4.0
14.1
2.5
2.5
13.8
2500
3000
3500
4000
4500
5000
6000
PRESSUR E REQ UIRED
28.0
3.0
3.0
12.1
N ote: For altitude above 1000 feet, contact your local Cleaver-Brook s representative.
Propane @ 2500 Btu/cu-ft, specific gravity @ 1.6
8000 LW V
3200
Table B3-12. Safety Valve Outlet Sizes
SAFETY VALVE SETTIN G
15 PSIG STEAM
Boiler Size
1500
2000
2500
3000
3500
4000
4500
5000
6000
8000 LWV
VALVES
REQ'D
OUTLET SIZE
(IN.)**
150 PSIG STEAM
VALVE
CAPACITY
1
2
3161 lbs/hr
1
2
3161 lbs/hr
1
2
3161 lbs/hr
1
2
3161 lbs/hr
1
2
3161 lbs/hr
1
2-1/2
4676 lbs/hr
1
2-1/2
4676 lbs/hr
1
2-1/2
4676 lbs/hr
1
3
6942 lbs/hr
NA
NA
NA
** Fem ale Pipe Thread Connection [FPT]
Section B2-19
VALVES
REQ 'D
OU TLET SIZE
(IN .)**
1
1
1
1
1
1
1
1
1
1
1
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
2
2
VALVE
CAPACITY
1651
2585
2585
2585
4240
4240
4240
4240
6596
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
PERFORMANCE DATA
Efficiency
Efficiency data provided in Table B3 - 13 is based on low pressure steam operation.
For high pressure steam operation contact your local Cleaver-Brooks authorized
representative for expected efficiency data.
Table B3-13. Predicted Efficiency, 10 PSIG operating (includes radiation and convection losses)
Boiler Size
Gas Fuel
O il Fuel
Firing Rate
Firing R ate
Low Fire
High Fire
Low Fire
H igh Fire
1500
81.6
81.9
84.1
84.4
2000
2500
81.1
80.0
83.6
82.5
81.6
81.5
84.1
84.0
3000
81.3
80.3
83.8
82.8
3500
81.6
81.5
84.1
84.0
4000
4500
81.3
81.1
80.7
80.9
83.8
83.6
83.0
83.4
5000
81.3
80.0
83.8
82.5
6000
81.6
79.8
84.1
82.4
Emissions
The following tables denote typical emission levels for Natural Gas and No. 2 Oil.
Please contact your local Cleaver-Brooks authorized representative if an emission
guarantee is required.
Notice
The data in these tables represent typical emission levels only. Please contact your
local Cleaver-Brooks authorized representative if an emission guarantee is required, or for emission level information not shown in these tables.
Table B3-14. Model 5 Emission Data, Natural Gas
POLLUTANT
Table B3-15. Emission Data, No. 2 Oil
POLLUTANT
UNCONTROLLED
UNCONTROLLEDB
CO
ppmA
lb/MMBtu
200
0.15
CO
ppmA
lb/MMBtu
90
0.07
NOx
ppmA
lb/MMBtu
100
0.12
NOx
ppmA
lb/MMBtu
187
0.248
SOx
ppmA
lb/MMBtu
1
0.001
SOx
ppmA
lb/MMBtu
278
0.515
HC/VOCs
ppmA
lb/MMBtu
40
0.016
HC/VOCs
ppmA
lb/MMBtu
50
0.025
PM
ppmA
lb/MMBtu
–
0.01
PM
ppmA
lb/MMBtu
–
0.025
A. ppm levels corrected to 3% O2 dry basis.
NOTES:
A. ppm levels corrected to 3% O2 dry basis.
B. Based on the following fuel oil constituents.
Fuel-bound nitrogen = 0.05% (max) by weight.
Sulfur = 0.5% (max) by weight.
Ash = 0.01% (max) by weight.
Section B2-20
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
ENGINEERING DATA
The following engineering information is provided for the Model 5 steam boiler.
Additional information may be obtained from your local Cleaver-Brooks authorized
representative.
Feedwater
Steam boilers require make-up water for steam production. This make-up can be a
combination of condensate return and raw make-up, 100% condensate return or
100% raw make-up. Proper treatment of make-up water and boiler water is
essential to the longevity and performance of the boiler. Table B3-23 depicts the
rate of make-up required and Table B3-22 shows the recommended water quality
guidelines.
As a minimum, raw make-up should be piped into a water softener and then to a
feed tank, which also can be the container that receives the system condensate
returns. Chemical feed is recommended to be fed via a quill into the water make-up
line feeding the boiler.
Blowdown
As steam is produced; unwanted solids are left behind in the boiler water and
become concentrated within the vessel. If these constituents are allowed to adhere
to the heat transfer surfaces, they will impede the flow of energy into the water.
Their removal requires proper blowdown that will include bottom and possibly
surface blowoff. For proper TDS control, surface blowoff with a TDS monitoring
device is recommended. Local codes will dictate the manner of treating the
blowdown affluent.
Boiler Stacks
General - The Model 5 boiler operates with a positive vent pressure and a vent gas
temperature that is non-condensing. Therefore, the stack must be a positive
pressure design.
Proper design and installation of the flue gas venting is critical to efficient and safe
operation of the burner. The vent should be designed with proper supports and
clearances from combustible materials. Use insulated vent pipe spacers where the
vent passes through walls and roofs.
The design of the stack and breeching must provide the required draft at each boiler
stack connection. Although constant pressure at the flue gas outlet is not required,
it is necessary to size the breeching and stack to limit flue gas pressure variations.
Consideration of the draft must be given where lengthy runs of breeching are
employed or unusually high stacks. Please note: the allowable pressure range for
design of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25"
w.c. (+62 Pa) for proper light offs and combustion. NOTE: This pressure range
does not pertain to the boiler room, that is, the boiler room must be neutral or
slightly positive, never negative when using air from the boiler room for combustion.
When two or more Model 5 boilers are connected to a common breeching/stack,
one should evaluate the affects of pressure variations that may occur during boiler
sequencing while boilers are firing. It may be determined that some type of
mechanical draft system be employed to ensure proper draft at each boiler is
maintained.
Combustion Air - The burner for each boiler must be supplied with adequate volume
of uncontaminated air to support proper combustion and equipment ventilation. Air
shall be free of chlorides, halogens, fluorocarbons, construction dust or other
Section B2-21
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
contaminants that are detrimental to the burner or boiler heating surfaces.
Combustion air can be supplied by means of conventional venting, that is, with
combustion air drawn from the area immediately surrounding the boiler (boiler
room is neutral or slightly positive pressure), or with a direct vent to outside the
boiler room where air is drawn directly from the exterior of the building. Regardless
of the method, all installations must comply with NFPA 54 (National Fuel Gas Code
- NFGC) for U.S. installations and CAN/CSA B149/.1 and B149.2 for Canadian
installations.
Engineered Design - When determining boiler room air requirements for the boiler,
the "Engineered Design" method may be used.
Following this method,
consideration must be given to the size of the boiler room, airflow, and air velocity
as follows:
Two permanent air supply openings in the outer walls of the boiler room are
recommended. Locate one at each end of the boiler room, preferably below a
height of 7 feet. This allows air to sweep the length of the boiler. Refer to Figure
B3 - 4.
Air supply openings can be louvered for weather protection, but they should not be
covered with a fine mesh wire, as this type of covering has poor air flow qualities
and is subject to clogging with dirt and dust.
A vent fan in the boiler room is not recommended as it could create a slight vacuum
under certain conditions and cause variations in the quantity of combustion air.
This can result in unsafe burner performance.
It is forbidden to have the total area of the air supply openings at less than one
square foot.
Size the openings by using the formula (Area in ft2 = cfma/fpma), where cfma =
cubic feet per minute of air; fpma = feet per minute of air.
Amount of air required (cfm):
Combustion Air = Maximum boiler horsepower (bhp) times 8 cfm.
Ventilation Air = Maximum boiler horsepower (bhp) times 2 cfm.
Total Air = 10 cfm per bhp (up to 1000 feet elevation, add 3% more per 1000 feet
of added elevation).
Acceptable air velocity in the boiler room (fpm):
From floor to 7 feet high = 250 fpm.
Above 7 feet from boiler room floor = 500 fpm.
Example of required air openings (Engineered Method):
Determine the area of the boiler room air supply openings for (2) size 4500 Model
5 boilers at 750 feet elevation; each have a rating of 107 boiler horsepower. The
air openings will be 5 feet above the floor level.
The total boiler horsepower (bhp): 107 x 2 = 214 bhp.
From (F.3) above, total air required = 214 bhp x 10 = 2140 cfm.
Air Velocity: From (G.1) above = 250 fpm.
Area required: From the formula in E above, 2140 cfm/250 fpm = 8.56 square
feet total.
Section B2-22
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Area opening: 8.56 divided by 2 = 4.28 ft2 per opening (2 required).
Notice
Consult local codes, which may supersede these requirements.
See Table B3-24 for combustion air and flue gas flow.
Figure B3-4. Boiler Room Air Flow - “Engineered Design”
GAS
VENT
FRESH AIR OPENING
FRESH AIR OPENING
EXTERIOR WALL
Oil Piping
EXTERIOR WALL
General - Oil operation of the Model 5 boiler requires proper oil to the standard
burner mounted oil pump. As the combustion of oil utilizes mechanical pressure
atomization, line sizing to the pump must be sufficient to provide 125 gph of oil to
the suction side of the pump.
Oil Train Components - Oil flow to the burner is controlled by four solenoid valves.
The oil flows through a primary or safety shutoff valve into a manifold block. This
valve and the low fire valve are energized simultaneously by the flame safeguard
control and when opened, allow flow of oil to the low fire nozzle.
As the damper motor moves to high fire position, the damper motor end switches
close to energize in sequence, the intermediate and then high fire oil valve. The
purpose of the intermediate valve is to smooth the transition from low to high fire by
balancing the oil input with increasing flow of air.
High fire rating of the burner is obtained when all three nozzles are firing, assuming
proper oil pressure and normally sized nozzles.
Gas Piping
General - The Model 5 boiler requires appropriate gas supply pressure and volume
for proper operation and long burner life. The gas requirements specified in this
section must be satisfied to ensure efficient and stable combustion. Installation
Section B2-23
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
must follow these guidelines and of the local authorities that have installation
jurisdiction.
Gas Train Components - Model 5 boilers are equipped with a gas train that meets
the requirements of UL as standard. These components also comply with the
recommendations of FM, XL GAP (formerly IRI/GE GAP) and ASME CSD-1. The
gas train and its components have been designed and tested to operate for the
highest combustion efficiency.
Gas Pressure Requirements - For proper and safe operation, each Model 5 boiler
requires a stable gas pressure supply. The pressure requirements are listed in
previous sections for standard gas train size, and oversized trains for reduced
available pressure.
Gas Piping - Model 5 units are standardly equipped with a gas pressure regulator.
If upstream pressure to the standard regulator will be greater than 1 psig, an
additional upstream regulator should be provided with a pressure relief valve.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c., a "full
lockup" type regulator is recommended along with proper overpressure protection.
In addition to the regulator, a plug type or "butterball" type gas shutoff cock should
be provided upstream of the regulator for use as a service valve. This is also
required to provide positive shutoff and isolate the boiler gas train during gas piping
tests.
Drip legs are required on any vertical piping at the gas supply to each boiler so that
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler
gas train. The bottom of the drip leg should be removable without disassembling
any gas piping. The connected piping to the boiler should be supported from pipe
supports and not supported by the boiler gas train or the bottom of the drip leg.
All gas piping and components to the boiler gas train connection must comply with
NFPA 54, local codes, and utility requirements as a minimum. Only gas approved
fittings, valves, or pipe should be used. Standard industry practice for gas piping is
normally Schedule 40 block iron pipe and fittings.
Gas Supply Pipe Sizing - For proper operation of a single unit or multiple units, we
recommend that the gas pipe be sized to allow no more than 0.3" w.c. pressure
drop from the source (gas header or utility meter) to the final unit location. The gas
supplier (utility) should be consulted to confirm that sufficient volume and normal
pressure are provided to the building at the discharge side of the gas meter or
supply pipe. (For installations of new boilers into an existing building, gas
pressure should be measured with a manometer to ensure sufficient pressure is
available).
A survey of all connected gas using devices should be made. If appliances other
than the boiler are connected to the gas supply line, then a determination should be
made of how much flow volume (cfh = cubic feet per hour) will be demanded at
one time and the pressure drop requirements when all appliances are operating.
The total length of gas piping and all fittings must be considered when sizing the
gas piping. Total equivalent length should be calculated from the utility meter or
source to the final connection. As a minimum guideline, gas piping Tables B3 - 16
through B3 - 20 should be used. The data in these tables is from the NFPA source
book, 2006 edition.
Section B2-24
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-16. Gas line capacity - Schedule 40 metallic pipe
Pipe Size
1"
1-1/4"
1-1/2"
2"
Nominal
1.049
1.380"
1.610"
2.067"
Actual I.D.
**Maximum Capacity in Cubic Feet
Length in feet
514
1,060
1,580
3,050
10
363
726
1,090
2,090
20
284
583
873
1,680
30
243
499
747
1,440
40
215
442
662
1,280
50
195
400
600
1,160
60
179
368
552
1,060
70
167
343
514
989
80
157
322
482
928
90
148
304
455
877
100
131
269
403
777
125
119
244
366
704
150
109
209
336
648
175
102
185
313
602
200
**Fuel: Natural Gas
**Inlet Pressure: Less than 2.0 psi
**Pressure Drop: 0.30" w.c.
**Specific Gravity: 0.60
2-1/2"
3"
2.469"
3.068"
of Gas per Hour (cfh)
4,860
8,580
3,340
5,900
2,680
4,740
2,290
4,050
2,030
3,590
1,840
3,260
1,690
3,000
1,580
2,790
1,480
2,610
1,400
2,470
1,240
2,190
1,120
1,980
1,030
1,820
960
1,700
4"
4.026"
17,500
12,000
9,660
8,290
7,330
6,640
6,110
5,680
5,330
5,040
4,460
4,050
3,720
3,460
Table B3-17. Gas line capacity - Schedule 40 metallic pipe
Pipe Size
Nominal
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
Actual I.D.
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
Length in feet
**Maximum Capacity in Cubic Feet of Gas per Hour (cfh)
678
1,390
2,090
4,020
6,400
11,300
10
466
957
1,430
2,760
4,400
7,780
20
374
768
1,150
2,220
3,530
6,250
30
320
657
985
1,900
3,020
5,350
40
284
583
873
1,680
2,680
4,740
50
257
528
791
1,520
2,430
4,290
60
237
486
728
1,400
2,230
3,950
70
220
452
677
1,300
2,080
3,670
80
207
424
635
1,220
1,950
3,450
90
195
400
600
1,160
1,840
3,260
100
173
355
532
1,020
1,630
2,890
125
157
322
482
928
1,480
2,610
150
144
296
443
854
1,360
2,410
175
134
275
412
794
1,270
2,240
200
**Fuel: Natural Gas
**Inlet Pressure: Less than 2.0 psi
**Pressure Drop: 0.50" w.c.
**Specific Gravity: 0.60
Section B2-25
4"
4.026"
23,100
15,900
12,700
10,900
9,600
8,760
8,050
7,490
7,030
6,640
5,890
5,330
4,910
4,560
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-18. Gas line capacity - Schedule 40 metallic pipe
Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
1,510
3,040
5,560
11,400
17,100
32,900
52,500
92,800
189,000
20
1,070
2,150
3,930
8,070
12,100
23,300
57,100
65,600
134,000
30
869
1,760
3,210
6,590
9,880
19,000
30,300
53,600
109,000
40
753
1,520
2,780
5,710
8,550
16,500
26,300
46,400
94,700
50
673
1,360
2,490
5,110
7,650
14,700
23,500
41,500
84,700
60
615
1,240
2,270
4,660
6,980
13,500
21,400
37,900
77,300
70
569
1,150
2,100
4,320
6,470
12,500
19,900
35,100
71,600
80
532
1,080
1,970
4,040
6,050
11,700
18,600
32,800
67,000
90
502
1,010
1,850
3,810
5,700
11,000
17,500
30,900
63,100
100
462
954
1,710
3,510
5,260
10,100
16,100
28,500
58,200
125
414
836
1,530
3,140
4,700
9,060
14,400
25,500
52,100
150
372
751
1,370
2,820
4,220
8,130
13,000
22,900
46,700
175
344
695
1,270
2,601
3,910
7,530
12,000
21,200
43,300
200
318
642
1,170
2,410
3,610
6,960
11,100
19,600
40,000
500
192
401
717
1,470
2,210
4,250
6,770
12,000
24,400
1000
132
275
493
1,010
1,520
2,920
4,650
8,220
16,800
1500
106
221
396
812
1,220
2,340
3,740
6,600
13,500
**Maximum Capacity in Cubic Feet of Gas per Hour (cfh)
**Fuel: Natural Gas
**Inlet Pressure: 2.0 psi
**Pressure Drop: 1.0 psi
**Specific Gravity: 0.60
Section B2-26
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-19. Gas line capacity - Schedule 40 metallic pipe
Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
2,350
4,920
9,270
19,000
28,500
54,900
87,500
155,000
316,000
20
1,620
3,380
6,370
13,100
19,600
37,700
60,100
106,000
217,000
30
1,300
2,720
5,110
10,500
15,700
30,300
48,300
85,400
174,000
40
1,110
2,320
4,380
8,990
13,500
25,900
41,300
75,100
149,000
50
985
2,060
3,880
7,970
11,900
23,000
36,600
64,800
132,000
60
892
1,870
3,520
7,220
10,300
20,300
33,200
58,700
120,000
70
821
1,720
3,230
6,640
9,950
19,200
30,500
54,000
110,000
80
764
1,600
3,010
6,180
9,260
17,800
28,400
50,200
102,000
90
717
1,500
2,820
5,800
8,680
16,700
26,700
47,100
96,100
100
677
1,420
2,670
5,470
8,200
15,800
25,200
44,500
90,300
125
600
1,250
2,360
4,850
7,270
14,000
22,300
39,500
80,500
150
544
1,140
2,140
4,400
6,590
12,700
20,200
35,700
72,900
175
500
1,050
1,970
4,040
6,060
11,700
18,600
32,900
67,100
200
465
973
1,830
3,760
5,640
10,900
17,300
30,600
62,400
500
283
593
1,120
2,290
3,430
6,610
10,300
18,600
38,000
1000
195
407
897
1,380
2,360
4,550
7,240
12,000
26,100
1500
156
327
616
1,270
1,900
3,650
5,820
10,300
21,000
**Maximum Capacity in Cubic Feet of Gas per Hour (cfh)
**Fuel: Natural Gas
**Inlet Pressure: 3.0 psi
**Pressure Drop: 2.0 psi
**Specific Gravity: 0.60
Section B2-27
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-20. Gas line capacity - Schedule 40 metallic pipe
Pipe Size
Nominal
Actual
I.D.
Length
in feet
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
**Maximum Capacity in Cubic Feet of Gas per Hour (cfh)
10
3,190
6,430
11,800
24,200
36,200
69,700
111,000
196,000
401,000
20
2,250
4,550
8,320
17,100
25,600
49,300
78,600
139,000
283,000
30
1,840
3,720
6,790
14,000
20,900
40,300
64,200
113,000
231,000
40
1,590
3,220
5,880
12,100
18,100
34,900
55,600
98,200
200,000
50
1,430
2,880
5,260
10,800
16,200
31,200
49,700
87,900
179,000
60
1,300
2,630
4,800
9,860
14,800
28,500
45,400
80,200
164,000
70
1,200
2,430
4,450
9,130
13,700
26,400
42,000
74,300
151,000
80
1,150
2,330
4,260
8,540
12,800
24,700
39,300
69,500
142,000
90
1,060
2,150
3,920
8,050
12,100
23,200
37,000
65,500
134,000
100
979
1,980
3,620
7,430
11,100
21,400
34,200
60,400
123,000
125
876
1,770
3,240
6,640
9,950
19,200
30,600
54,000
110,000
150
786
1,590
2,910
5,960
8,940
17,200
27,400
48,500
98,900
175
728
1,470
2,690
5,520
8,270
15,900
25,400
44,900
91,600
200
673
1,360
2,490
5,100
7,650
14,700
23,500
41,500
84,700
500
384
802
1,510
3,100
4,650
8,950
14,300
25,200
51,500
1000
264
551
1,040
2,130
3,200
6,150
9,810
17,300
35,400
1500
212
443
834
1,710
2,570
4,940
7,880
13,900
28,400
**Fuel: Natural Gas
**Inlet Pressure: 5.0 psi
**Pressure Drop: 3.5 psi
**Specific Gravity: 0.60
Section B2-28
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-21. Sound Levels
BOILER SIZE (BHP)
SOUND LEVEL /
FIRING RATE
1500
(35)
2000
(47)
2500
(59)
3000
(71)
3500
(83)
4000
(95)
4500
(107)
5000
(119)
6000
(143)
LFG (dBA)
70
70
71
71
72
72
74
75
76
HFG (dBA)
70
70
72
74
74
76
77
78
79
LFO (dBA)
69
69
70
71
72
73
74
75
76
HFO (dBA)
71
71
72
73
74
76
76
77
78
8000
NOTES:
1. Abbreviations: LF=Low Fire, HF=High Fire, O=Oil, G=GAS
2. Measurement: Three (3) feet from front center of boiler and 3-1/2 feet above boiler base. Measurements are
decibel ratings on the A-Weighted scale, and were registered without the addition of sound attenuators, mufflers,
or silencers.
3. N/A to 8000 LWV.
Table B3-22. Water Quality Requirements
Parameter
Boiler Water Limit
pH
8.3 - 10.5
Iron
0.1 ppm
Ox ygen
0.1 mg/liter
Specific Conductivity
2000 µ mho/cm
Suspended Solids
300 ppm
0 ppm as CaC O3
Total Hardness
Table B3-23. Feedwater Make-up Rates
Boiler Size
Gallons/Minute
1500
2.5
2000
3.3
2500
4.1
3000
5
3500
5.8
4000
6.6
4500
7.5
5000
8.3
6000
8000
9.9
13.2
Section B2-29
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Table B3-24. Model 5 Fuel, Combustion Air, and Flue Gas Flow Rates
Boiler Siz e
1500
Fuel Cons um ption
2500
3000
3500
4000
4500
5000
6000
8000 LWV
8000
Gas
cfh
1500
1500
2500
3000
3500
4000
4500
5000
6000
O il
gph
scfh
10.72
15,480
14.29
20,640
17.86
25,800
21.43
30,960
25.00
36,120
28.57
41,280
32.14
46,440
35.71
51,600
42.85
61,920
Gas
Combustion Air
Oil
Gas
Flue Gas
Oil
Notes:
2000
A.
B.
C.
lb/hr
1,207
1,609
2,012
2,414
2,817
3,219
3,621
4,024
4,828
scfh
17,049
22,733
28,414
34,098
39,782
45,463
51,147
56,831
68,196
lb/hr
1,269
1,692
2,115
2,538
2,961
3,384
3,808
4,231
5,077
scfh
17,520
23,360
29,200
35,040
40,880
46,720
52,560
58,400
70,080
lb/hr
1,278
1,704
2,130
2,556
2,983
3,409
3,835
4,261
5,113
scfh
17,914
23,886
29,855
35,827
41,799
47,769
53,741
59,713
71,655
lb/hr
1,357
1,809
2,261
2,714
3,166
3,618
4,070
4,523
5,427
Gas consumption, expressed in cubic feet per hour, is based on 1,000 Btu/cu.ft gas value.
Oil consumption,ex pressed in pounds per hour, is bas ed on 140,000 Btu/gal oil value.
Oil supply l ines must be sized for 125 gph pumping rate. Oil pum p suction pressure to be -10" Hg to 3 psig.
Section B2-30
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Model 5 Boilers
Steam Specifications
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-32
Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-32
Soot Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-33
Boiler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-33
Boiler Trim/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-33
Low Water Volume Design (LWV), 150 Psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-34
Low Water Volume Design (LWV), 15 Psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-34
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-34
Gas Fired Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-35
Oil Fired Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-36
Gas-Oil Fired Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-37
Burner and Flame Failure Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-38
Burner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-38
SAMPLE SPECIFICATIONS
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying your customer’s
specific needs and application.
Section B2-31
Rev. 03-08
Model 5
PART 1 GENERAL
1500 - 6000 MBTU/hr
1.1
BOILER CAPACITY
A. The steam boiler shall be a Cleaver-Brooks Model 5, Series (100,
200, 700) rated at
lbs/hr or
boiler horsepower
designed for (15, 150, 250, 350 or 500) psig steam. The
maximum boiler operating pressure will be
psig. (Series
100 is a No.2 oil fired burner; Series 200 is a gas or No.2 oil fired
burner; Series 700 is a straight gas burner).
Btu/hr or
B. The boiler shall have a maximum output of
boiler horsepower when fired with (No.2 oil) or (natural gas
@
Btu/cu-ft). The boiler shall develop
lbs/hr
psig with feedwater temperature at
when operating at
o F. The boiler safety relief valve(s) shall be set at
psig.
C. Electrical power to the boiler shall be
volts,
phase,
Hz. All electrical service connections shall be made to an
electrical entrance box mounted on the right hand side of the boiler.
PART 2 PRODUCTS 2.1
BOILER DESCRIPTION
A. The boiler shall be an all steel membrane wall watertube design
with 3-pass gas travel. It shall be mounted on a heavy duty steel
frame with an integral forced draft burner and burner controls. The
complete package, boiler-burner unit, shall be certified, tested, and
labeled by CSA (Canadian Standard Association). The package
shall be completely assembled and receive a factory fire test prior to
shipment.
B. The boiler shell must be constructed and hydrostatically tested in
accordance with the A.S.M.E. Boiler and Pressure Vessel Code
Section I or IV and receive an authorized boiler inspection. A copy
of the inspection report shall be furnished to the purchaser.
C. Two downcomers shall be located at the rear of the boiler and totally
insulated from the generating tubes. The downcomers shall be 2-1/
2" OD for 35 and 47 hp; 3" OD for 59 to 83 hp, and 4" OD for 95
hp and greater. Material shall be SA-178A. The 2-1/2" and 3"
downcomers shall have 0.105" wall while the 4" downcomers shall
have 0.135" wall. The generating tubes shall be 2" OD, SA-178
Grade A with 0.095" wall thickness.
D. The upper drum shall be 20" OD Schedule 20, SA-53-B seamless
pipe with 0.375" wall. The lower drum shall be 6" nominal pipe
size, SA-53-B seamless pipe with 0.312" wall up through 150 psig
design.
E. Two lifting eyes shall be located on the top centerline of the upper
drum.
F. Refractory shall be limited to the furnace floor, lower drum, burner
throat tile, and the formed rear furnace access door. High
temperature insulation shall be installed on the front water wall of
the furnace.
G. Observation ports shall be provided at each end of the boiler for
visual inspection of the pilot and main flame conditions.
Section B2-32
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
H.
I.
J.
K.
L.
The exhaust gas vent shall be located at the top rear centerline of
the boiler. A stack thermometer shall be shipped loose for field
installation by the installing contractor into the stack.
Inspection openings shall be provided in the convection area.
The lower drum shall include capped plugs in the front and rear
drum heads, and a handhole shall be provided in the rear upper
drum head for waterside inspection
The vessel shall be insulated with a minimum of 2" fiber glass
blanket. This insulation shall be covered with a sheet metal jacket.
The jacket and insulation shall be arranged for easy removal and
reinstallation if required.
The entire boiler jacket, base frame, and other components shall be
factory painted using hard finish enamel.
2.2
SOOT CLEANING
A. Soot washer lances shall be provided in the upper convection area of
the boiler, measuring the full length of the pressure vessel. Each
lance assembly shall be capable of rotating 360 degrees. This shall
ensure complete washing of the convection zone while the boiler is
operating in the low fire mode.
B. Soot washer drain troughs shall be provided at the bottom of the
boiler. These shall be furnished for each convection side running the
full length of the boiler with 2" drain connections at the bottom rear.
Inspection/cleanout openings for each trough shall be located at the
front of the boiler.
2.3
BOILER CONNECTIONS
A. The steam nozzle shall be located on the top centerline of the upper
drum and sized for steam velocity not to exceed 5000 fpm.
B. A feedwater tapping and an integral feedwater distribution pipe shall
be located in the upper drum. This distribution pipe shall blend the
feedwater with the boiler water.
C. A ¾" surface blowoff tapping shall be provided in the rear head of
the upper drum.
D. For blowdown or boiler drain, a tapping shall be provided in the
bottom of the lower drum near the front of the boiler.
2.4
BOILER TRIM/CONTROLS
A. The primary water column shall be located on the left side of the
boiler when facing the burner. It shall be piped with union
connections for easy removal and include a full size column
blowdown valve. A gauge glass with gauge glass valves shall be
mounted to the water column.
B. A primary low water cutoff switch shall be an integral part of the
water column and shall be wired into the burner control circuit to
prevent burner operation in the event of an unsafe water level
condition.
C. To maintain proper and safe water level within the boiler, an integral
feed pump control switch shall be included within the primary water
column. This switch may be wired to a control relay for pump on/off
operation or wired to control a solenoid water make-up valve.
Section B2-33
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
D.
E.
F.
G.
A secondary low water cutoff control of the manual reset type shall
be provided on the right hand side of the boiler, when facing the
burner. This control shall include a switch wired into the burner
circuit to prevent burner operation in the event that the primary low
water control did not function properly during an unsafe water level
condition. A control blowdown valve shall be included for
maintenance and periodic testing of the level device.
For visual indication of the internal boiler pressure, a steam pressure
gauge shall be mounted near the water column and shall include an
inspector's test cock and test connection point.
For burner operation, a minimum of three controls shall be
provided: one auto reset type for burner start and stop control, one
for burner firing rate (modulation on gas or low high low on oil), and
one manual reset type for burner shutdown in the event of excessive
steam pressure within the boiler.
In compliance with the A.S.M.E. Code, a Code rated safety relief
valve(s) shall be provided. This valve(s) may be shipped loose to
prevent any damage during shipment.
2.5
LOW WATER VOLUME DESIGN (LWV), 150 PSIG
For applications requiring the use of a low water volume vessel, the following trim,
controls and design shall be provided:
A.
B.
C.
D.
E.
The primary water column shall be located on the left side of the
boiler when facing the burner, and shall be a McDonnell-Miller
#193-7 or approved equal. It shall be piped with union
connections for easy removal and include a full size column
blowdown valve. A gauge glass with gauge glass valves shall be
mounted to the water column.
The primary water level control and water level cut-off settings shall
be installed at a level that limits the total water content within the
boiler to 75 U.S. Gallons (283.9 liters) or less at full operating
capacity.
Feedwater into the boiler shall be controlled by means of an electric
proportional feedwater valve, Worchester or approved equal,
complete with stop valve, check valve, and 3-valve by-pass.
Controls shall be provided to comply with "Guarded Plant" status
requirements.
The upper and lower drums shall be properly insulated to prevent
heat transfer onto these surfaces during combustion.
2.6
LOW WATER VOLUME DESIGN (LWV), 15 PSIG
For applications requiring the use of a low water volume vessel, the following trim,
controls and design shall be provided:
A.
B.
2.7
Controls shall be provided to comply with "Guarded Plant" status
requirements.
The upper and lower drums shall be properly insulated to prevent
heat transfer onto these surfaces during combustion.
BURNER
A. Models 1500 - 6000; all air for combustion shall be supplied by a
Section B2-34
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
B.
C.
D.
2.8
forced draft blower mounted in the front head (wind box) above the
burner, to minimize vibration and reduce noise emissions. The
impeller shall be an enclosed centrifugal fan type, properly balanced
and direct connected to the motor shaft. Sound level shall not
exceed 80 dBA measured 3 feet in front of the burner.
Models 7500 - 8000; all air for combustion shall be supplied by a
forced draft blower mounted within the fan housing of the externally
mounted burner. The burner shall be a CB Profire Series V. The fan
shall be a squirrel cage design, properly balanced and direct
connected to the motor. Sound level shall not exceed 85 dBA
measured 3 feet in front of the burner.
When firing gas, the burner shall operate on the full modulation
mode and shall be positioned at the low position for the ignition
sequence, and shall remain in the low fire position during ignition
and until main flame has been proven.
For oil operation, the burner shall operate on the low-high-low
principle and shall be positioned at the low position for the ignition
sequence, and shall remain in the low fire position during ignition
and until main flame has been proven.
GAS FIRED BURNER
A. The burner shall be a high radiant multi-port type approved for
operation on natural gas.
B. Automatic electric ignition of the premix gas pilot shall be furnished.
An ultra violet (UV) flame detector shall monitor the pilot, preventing
the primary fuel valve from opening until the pilot flame has been
established. The gas pilot assembly shall include a pilot solenoid
shutoff valve, pilot regulator, and manual shutoff cock.
C. A single damper motor shall control the combustion air inlet damper
and the fuel input control valve (butterfly type) via linkage
connections. The damper motor shall modulate the burner in
accordance with system demand, responding to the boiler mounted
modulating pressure control.
D. Gas burner piping shall include a primary safety shutoff valve,
controlled by the burner flame safeguard control to start or stop the
burner. The valve shall close automatically in the event of a power
failure, excess steam pressure, low or high gas pressure, or a low
water condition.
E. A main gas pressure regulator shall be piped in the gas train to
regulate the incoming pressure for proper burner operating pressure
including an upstream manual shutoff valve.
F. For tightness checking of the primary shutoff valve, a plugged
leakage test connection and a lubricated plug cock shall be
provided.
G. The primary shutoff valve shall be of the motorized type.
H. For sizes 6000 - 8000, a second motorized gas valve shall be
provided and piped in series with the primary shutoff valve.
I.
Low and High gas pressure switches of the manual reset type shall
be mounted and wired to prevent burner operation if gas pressure is
above or below the settings of these switches.
Section B2-35
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
J.
2.9
To prove proper air is available for pre purge and combustion, a
combustion air proving switch shall be provided.
OIL FIRED BURNER
A. The burner shall be a pressure atomizing type approved for
operation with commercial grade No. 2 fuel oil.
B. For 1500 through 6000 units,
1. Automatic electric spark ignition for the low fire oil supply shall
be provided with a 10,000 volt ignition transformer and heavy
duty electrodes. The ignition period shall be monitored with
an electronic scanner of the UV principle to confirm the
presence of the low fire oil flame.
2. A single damper motor shall control the combustion air inlet
damper and the fuel input control valves via linkage
connections. The damper motor shall operate the burner in
accordance with system demand, responding to the boiler
mounted low high low pressure control.
3. For fuel input control, 4 solenoid type fuel oil valves shall be
piped and wired onto the front head of the boiler. Two valves
shall be used for low fire ignition and the other two for high fire
operation.
4. The fuel oil system shall include supply and return tubing to an
oil terminal block, oil pressure gauge, and shutoff cock.
5. An oil pump shall be provided and shall be integral with the
burner. The pump shall include a built-in pressure relief valve
and self cleaning strainer. Operation of the pump shall be via
belt connection to the fan motor.
C. For 7500 - 8000 units, automatic electric ignition of the premix gas
pilot shall be furnished. An ultra violet (UV) flame detector shall
monitor the pilot, preventing the primary fuel valve from opening
until the pilot flame has been established. The gas pilot assembly
shall include a pilot solenoid shutoff valve, pilot regulator, and
manual shutoff cock.
1.
A single damper motor shall control the combustion air inlet
damper and the fuel input control valve via linkage
connections. The damper motor shall modulate the burner in
accordance with system demand, responding to the boiler
mounted modulating pressure control.
2. For fuel input control, metering type fuel oil valve shall be
piped and onto the burner housing. Two solenoid valves shall
be used for safety shutoff.
3. The fuel oil system shall include supply and return tubing to an
oil terminal block, oil pressure gauge, low oil pressure
interlock, and shutoff cock.
4. An oil pump shall be provided and shall be shipped loose with
the burner. The pump shall include a built-in pressure relief
valve and self cleaning strainer. Operation of the pump shall
be via oil pump starter mounted and wired in the burner
control panel.
Section B2-36
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
2.10
GAS-OIL FIRED BURNER
A. A. General
1. The burner shall be a high radiant multi-port type approved for
operation on natural gas and shall be a pressure atomizing type
approved for operation with commercial grade No. 2 fuel oil.
2. Automatic electric ignition of the premix gas pilot shall be
furnished. An ultra violet (UV) flame detector shall monitor the
pilot, preventing the primary fuel valve from opening until the
pilot flame has been established. The gas pilot assembly shall
include a pilot solenoid shutoff valve, pilot regulator, and
manual shutoff cock.
3. A single damper motor shall control the combustion air inlet
damper and the fuel input control valve via linkage
connections. The damper motor shall regulate the burner in
accordance with system demand, responding to the boiler
mounted pressure control.
4. To prove proper air is available for pre purge and combustion, a
combustion air proving switch shall be provided.
B. Gas System
1. Gas burner piping shall include a primary safety shutoff valve,
controlled by the burner flame safeguard control to start or stop
the burner. The valve shall close automatically in the event of a
power failure, excess steam pressure, low or high gas pressure,
or a low water condition.
2. A main gas pressure regulator shall be piped in the gas train to
regulate the incoming pressure for proper burner operating
pressure including an upstream manual shutoff valve.
3. For tightness checking of the primary shutoff valve, a plugged
leakage test connection and a lubricated plug cock shall be
provided.
4. The primary shutoff valve shall be of the motorized type.
5. For sizes 6000 - 8000, a second motorized gas valve shall be
provided and piped in series with the primary shutoff valve.
6. Low and High gas pressure switches of the manual reset type
shall be mounted and wired to prevent burner operation if gas
pressure is above or below the settings of these switches.
C. Oil System
1. For 1500 through 6000 units,
a. For fuel input control, 4 solenoid type fuel oil valves shall
be piped and wired onto the front head of the boiler. Two
valves shall be used for low fire ignition and the other two
for high fire operation.
b. The fuel oil system shall include supply and return tubing
to an oil terminal block, oil pressure gauge, and shutoff
cock.
c. An oil pump shall be provided and shall be integral with
the burner. The pump shall include a built-in pressure
relief valve and self cleaning strainer. Operation of the
pump shall be via belt connection to the fan motor.
Section B2-37
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
2.
For 7500 - 8000 units,
a. For fuel input control, metering type fuel oil valve shall be
piped and onto the burner housing. Two solenoid valves
shall be used for safety shutoff.
b. The fuel oil system shall include supply and return tubing
to an oil terminal block, oil pressure gauge, low oil
pressure interlock, and shutoff cock.
c. An oil pump shall be provided and shall be shipped loose
with the burner. The pump shall include a built-in
pressure relief valve and self cleaning strainer. Operation
of the pump shall be via oil pump starter mounted and
wired in the burner control panel.
2.11
BURNER AND FLAME FAILURE CONTROLLER
A third party listed and approved safeguard control shall be provided to control
ignition, starting and stopping the burner, and provide pre-combustion and post
combustion air purge. The control shall stop and prevent burner operation in the
event of ignition, pilot, or main flame failures. Trial for ignition shall be limited to
10 seconds.
A.
B.
C.
D.
E.
F.
2.12
The flame safeguard control shall be a microprocessor based burner
management control system, designed to provide proper burner
sequencing, ignition, and flame monitoring protection.
Through SMART LED's, the control shall provide current operating
status and lockout information in the event of a safety shutdown.
A separate preconfigured program module shall plug in to the
microprocessor control.
For trouble shooting and retrieving history, a VFD format display
shall be mounted onto the control. This alpha numeric display shall
provide 2 lines by 16 characters per line display of operating
conditions, fault conditions, flame signal strength, and burner run
history.
In addition to the VFD display, LED Indicator Lights shall be
provided integral with the control for Fan, Open Damper, Close
Damper, Auto Operation, and Ignition.
The control shall be a CB120E or equal.
BURNER CONTROL PANEL
A. The control panel shall be mounted at the front of the boiler on the
burner fan housing (windbox) and conveniently located for the
operator. It shall be mounted within a NEMA 1A type enclosure and
include a key lock.
B. Factory mounted and wired components and controls shall include
the following:
1. Fan Motor Starter
2. Fan Motor Fuses
3. Control Circuit Transformer with fuses
4. Oil Pump Starter (size 7500 - 8000 units) firing oil.
5. Terminals for wiring connections
Section B2-38
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
Flame Safeguard Control
Burner On/Off Switch
Manual Damper Positioning Switch
Indicating lights for low water, flame failure, load demand, and
fuel valve on.
All electrical equipment shall be in conformity with CSA. Oil, heat,
and moisture resistant wire shall be used and number coded relative
to the wiring diagram.
6.
7.
8.
9.
C.
Section B2-39
Rev. 03-08
Model 5 Boilers
Hot Water Specifications
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soot Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No.2 Oil and Gas Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner and Flame Failure Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B3-42
B3-42
B3-43
B3-43
B3-43
B3-29
B3-44
B3-45
B3-45
B3-46
SAMPLE SPECIFICATIONS
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying your customer’s
specific needs and application. A separate specification is provided for hot water boiler and steam boiler
packages.
Section B2-41
Rev. 03-08
PART 1 GENERAL
1.1
PART 2 PRODUCTS 2.1
BOILER CAPACITY
A. The hot water boiler shall be Cleaver-Brooks Model 5, Series
(100, 200, 700),
bhp, designed for 140 psig hot water.
The maximum supply temperature will be
°F, and the
minimum return water temperature will be
°F. The
minimum operating temperature of the boiler shall be 170 °F. (Series
100 - No. 2 oil; 200 - No. 2 oil and gas; 700 - gas.)
Btu/hr, or
B. The boiler shall have a maximum output of
hp, when fired with No.2 oil and/or natural gas
Btu/cu-ft.
Safety relief valves shall be set at
psig.
C. Electrical power available will be
volts,
phase,
Hz. All electrical service connections shall be made to an
electrical entrance box mounted on the right hand side of the boiler.
BOILER DESCRIPTION
A.
B.
C.
D.
E.
F.
G.
H.
I.
The boiler shall be an all steel membrane wall watertube boiler with
3-pass gas travel. It shall be mounted on a heavy duty steel frame
with integral forced draft burner and burner controls. The complete
packaged boiler-burner unit shall be approved by Canadian Standard
Association and shall have the CSA label affixed to the front head.
The boiler shall be completely assembled and fire tested at the
factory.
The boiler shell must be constructed and hydrostatically tested in
accordance with the ASME Boiler and Pressure Vessel Code. It must
receive authorized boiler inspection prior to shipment. A copy of the
inspection report shall be furnished to the purchaser.
Two lifting eyes shall be located on top of the boiler.
Two downcomers shall be located at the rear of the boiler and totally
insulated from the generating tubes. The generating tubes shall be
2" OD SA-178 Grade A with.095” wall thickness. The downcomers
shall be 2-1/2” OD for 35 and 47 hp; 3" OD for 59 to 83 hp and 4"
OD for 95 to 143 hp. Material shall be SA-178-A and the 2-1/2”
and 3" downcomers shall have a 0.105" wall. The 4" downcomers
shall have a 0.135" wall.
The upper drum shall be 20" OD schedule 20, SA-53-B seamless
pipe with.375” wall. The lower drum shall be 6" nominal pipe size,
SA-53-B seamless pipe with.312” wall.
Refractory shall be limited to the furnace floor, insulating the lower
drum, the burner throat tile, and to the formed rear access door
which unbolts for ease of entry and/or inspection. High-temperature
insulation shall be installed on the front wall of the furnace.
Observation ports shall be provided at each end of the boiler for
visual inspection of the pilot and main flame conditions.
The exhaust gas vent shall be located at the rear of the boiler on the
top centerline. A stack thermometer shall be shipped loose for field
installation.
Inspection openings shall be provided in the convection area.
Section B2-42
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
J.
The boiler insulation shall be a minimum of 2" fiber glass blanket.
This insulation shall be covered with a corrugated sheet metal
lagging. The lagging and insulation shall be arranged for easy
removal and reinstallation if required. The entire boiler, base frame,
and other components shall be factory painted before shipment
using a hard finish enamel.
2.2
SOOT CLEANING
A. Soot washer lances shall be provided in the convection area of the
boiler measuring full length of the pressure vessel. Each lance shall
be provided with a shutoff valve and the assembly shall be capable
of rotating 360 °F. This shall ensure complete washing of the
convection zone while the boiler is operating in the low fire mode.
B. Soot washer troughs shall be provided at the bottom of the boiler.
These shall be furnished for each convection side running the full
length of the boiler with 2" drain connections at the boiler rear.
Inspection/cleanout openings for each trough shall be located at the
front of the boiler.
2.3
BOILER CONNECTIONS
A. The hot water outlet connection shall be located on the top
centerline of the boiler and the return connection shall be located at
the rear of the lower drum. The design of the boiler shall provide jet
induced circulation, which shall mix the return water with the hot
water within the boiler.
B. A dip tube shall be included as an integral part of the hot water
outlet. An air vent tapping shall be located on the top centerline of
the boiler for connection to an expansion tank.
C. Handholes shall be provided at the end of the lower drum and in the
rear of the upper drum for inspection of the water side surfaces.
2.4
BOILER TRIM
A. The low water cutoff switch shall be a probe type, mounted in the
top center-line of the boiler. It shall be wired into the burner control
circuit to prevent burner operation if the boiler water falls below a
proper level.
B. A minimum of three controls shall be provided: one auto reset type
for burner on-off control, one for burner firing rate, and one manual
reset type for burner cutout on excessive water temperature. The
sensing elements shall be located adjacent to the outlet connection.
C. A hot water circulating pump shall be mounted between the supply
and return water connections (standard on ASME Section IV heating
boilers only). This pump will blend the supply and the system return
water. It will ensure a minimum continuous circulation at all times
to a level of 10 boiler water changes per hour.
D. A combination pressure-temperature gauge shall be located on the
boiler.
E. Water relief valves shall be provided of a type and size to comply
with ASME Code requirements.
Section B2-43
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
2.5
BURNER
A. Burner Description
1. All air for combustion shall be supplied by a forced draft blower
mounted in the front head (windbox), above the burner, to
minimize vibration and noise level.
2. The impeller shall be an enclosed centrifugal fan type, properly
balanced and directly connected to the blower motor shaft.
3. The maximum sound level shall not exceed 80 dBA measured
3 feet in front of the boiler.
4. The oil burner shall operate on the low-high-low principle and
must return to the low fire position prior to ignition.
5. The gas burner shall operate on the full modulation system and
must return to the low fire position prior to ignition.
6. The burner shall remain in the low fire position during ignition
and until main flame has been proven.
B. Gas Fired Burner
1. The burner shall be integral with the front head of the boiler
and shall be the high radiant multi-port type approved for
operation with natural, manufactured, or mixed gas.
2. Automatic electric ignition of the premix gas pilot shall be
furnished. A UV flame detector shall monitor the pilot,
preventing the primary fuel valve from opening until the pilot
flame has been established.
3. A single damper motor shall control the combustion air damper
and the butterfly gas valve. The damper motor shall regulate
the fire according to system demand in response to the boiler
mounted temperature/pressure control.
4. The gas burner piping system on the unit shall include a
primary gas shutoff valve. It shall be controlled by the
programming relay to start or stop the burner and to close
automatically in the event of power failure, flame failure,
excessive pressure or temperature, high or low gas pressure, or
a low water condition. A lubricated shutoff cock shall be
located ahead of the primary valve for manual shutoff.
5. A plugged leakage test connection and a lubricated plug cock
are provided as a means for a tightness check of the primary
shutoff valve.
6. A gas pressure regulator shall be factory mounted and piped for
proper pressure regulation to the burner.
7. Gas Train Components
8. The primary shutoff valve shall be a motorized type. High and
low gas pressure switches shall be provided.
C. No. 2 Oil Fired Burner
1. The burner shall be integral with the front head of the boiler. It
shall be the pressure atomizing type approved for operation
with commercial grade No.2 oil.
2. The burner shall operate on the low-high-low principle, and
must return to the low-fire position prior to ignition.
Section B2-44
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
3.
4.
The burner shall remain in the low-fire position during ignition,
and until low fire and main flames have been proven.
Automatic electric ignition of the low-fire oil supply shall be
provided with a 10,000 volt transformer and heavy duty
electrodes. The ignition period shall be monitored with an
electric scanner of the UV principle to confirm the presence of
the low fire oil flame.
Notice
Optional insurance compliance may require a premix gas pilot in lieu of electric
ignition.
5.
The combustion air damper, low-fire, and high-fire oil valves
shall be operated by a single damper control motor. This motor
shall regulate the fire according to system demand in response
to the boiler mounted high-low fire temperature/pressure
control.
2.6
OIL SYSTEM
A. An oil pump shall be provided. The oil pump, integral with the
burner, shall include a built-in relief valve and self- cleaning strainer.
The pump shall be belt driven from the blower motor.
B. The fuel oil system shall include supply and return tubing to a
terminal block, oil pressure gauge, shutoff cock, and four solenoid oil
shutoff valves. These items shall be factory mounted on the front
head.
2.7
NO.2 OIL AND GAS BURNER
A. General
1. The burner shall be integral with the front head of the boiler. It
shall be the pressure atomizing type for oil and high radiant
multi-port type for gas. The burner must be approved for
operation with either commercial grade No.2 oil or natural gas.
2. The oil burner shall operate on the low-high-low principle, and
must return to the low-fire position prior to ignition.
3. The gas burner shall operate on the full modulation system and
must return to the low fire position prior to ignition.
4. The burner shall remain in the low-fire position during ignition
and until main flame has been proven.
5. Automatic electric ignition of the premix gas pilot shall be
provided. A UV flame detector shall monitor the pilot to prevent
the primary fuel valve from opening until the pilot flame has
been established.
6. A single damper motor shall control the combustion air
damper, high and low fire oil valves, and the butterfly gas
valve. The damper motor shall regulate the fire according to
system demand in response to the boiler mounted high-low fire
temperature/pressure control.
B. Oil System
1. An oil pump shall be included. The oil pump, integral with the
burner, shall include a built-in relief valve and self-cleaning
strainer. The pump shall be belt-driven from the blower motor.
Section B2-45
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
The fuel oil system shall include supply and return tubing to a
terminal block, oil pressure gauge, shutoff cock, and four
solenoid oil shutoff valves. These items shall be factory
mounted on the front head.
Gas System
1. The gas burner piping system on the unit shall include a
primary gas shutoff valve. It shall be controlled by the
programming relay to start or stop the burner and to close
automatically in the event of power failure, flame failure,
excessive pressure or temperature, high or low gas pressure, or
a low water condition. A lubricated shutoff cock shall be
located ahead of the primary valve for manual shutoff.
2. A plugged leakage test connection and a lubricated plug cock
are provided as a means for a tightness check of the primary
shutoff valve.
3. A gas pressure regulator shall be factory-mounted and piped
for proper pressure regulation to the burner.
Gas Train Components
1. The primary shutoff valve shall be a motorized type. High and
low gas pressure switches shall be provided.
2.
C.
D.
2.8
BURNER AND FLAME FAILURE CONTROLLER
A combustion safeguard control shall be provided to control ignition, starting and stopping the
burner and provide precombustion and postcombustion purge periods. It shall stop burner operation in the event of ignition, pilot or main flame failure. Trial for ignition shall be limited to 10
seconds.
2.9
CONTROL PANEL
A. The control panel shall be mounted on the front head of the boiler
and shall be conveniently located for the operator. It shall be a
NEMA 1A rated enclosure and have a Yale key lock.
B. Each boiler shall be factory-equipped with a flame safeguard
controller that provides technology and functions equal to the
Cleaver-Brooks Model CB100.
C. Flame safeguard controller shall be microprocessor based, with selfdiagnostics, non-volatile memory, and a message center with a
vocabulary of 42 different messages. Messages shall scroll across
an alpha-numeric display and provide sequence status and failure
mode information. The controller shall have a fixed operating
sequence incapable of being manually altered. The sequence will
include start, pre-purge, pilot and main fuel ignition run and postpurge cycles.
D. Controller shall be the non-recycle type for maximum safety that will
shutdown the burner and indicate as a minimum the following trip
functions: pilot and main flame failure, high and low fire proving
switch faults, running interlocks open, false flame signal and fuel
valve open.
Section B2-46
Rev. 03-08
Model 5
1500 - 6000 MBTU/hr
E.
F.
G.
The controller shall have a run/test switch. It will allow interruptions
to sequence just after pre-purge, during pilot ignition trial, and
during run cycles for adjustments to firing rate motor, damper
linkages and pilot flame for turndown tests.
In addition to the above functions, the controller shall:
1. Display history of operating hours and totals of completed onoff cycles.
2. Provide a constant flame signal strength read-out.
3. Have provisions for a remote display capability.
The panel shall contain the blower motor starter, control circuit
fuses, control circuit transformer, and control switches. A damper
positioning switch shall be provided to permit selection of automatic
firing or manual selection of low or high fire.
1. A terminal board shall be provided to which all wires entering
or leaving the panel shall be connected.
2. All electrical equipment shall be in conformity with the
Canadian Standard Association requirements. Oil, heat and
moisture resistant wire shall be used and shall be number
coded.
3. A low fire hold timer shall be mounted in the panel and wired
to hold the boiler in a low firing mode, for a minimum of 10
minutes, each time the boiler cycles on. This low fire hold timer
ensures gradual boiler warm up.
Section B2-47
Rev. 03-08
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