Model 4WI 100 800 HP Boilers

Warranty
All equipment is to be guaranteed against defects in materials and/or workmanship for a
period of 12 months from date of start-up or 18 months from date of shipment, whichever
comes first.
Shop Tests
The packaged boiler must receive factory tests to check the construction, controls, and
operation of the unit. All tests may be witnessed by the purchaser, if desired.
Start-up Service
After boiler installation is completed, the manufacturer shall provide the services of a field
representative for starting the unit and training the operator at no additional costs.
A factory approved and authorized start-up report shall be submitted to the customer/user
at the time of start-up.
2.5 GENERAL BOILER DESIGN
A. The boiler shall be a four pass horizontal firetube updraft boiler with five (5) square
feet (except 750 or 800 hp) of heating surface per rated boiler horsepower. It shall be
mounted on a heavy steel frame with integral forced draft burner and burner controls.
B. The complete package boiler shall be approved as a unit by Underwriters
Laboratories and shall bear the UL/ULC label, except in the case where 50 Hz has
been selected.
C. The boiler shall be completely pre assembled and fire tested at the factory. The unit
shall be ready for immediate mounting on floor or simple foundation and ready for
attachment of water, steam, fuel, electrical, vent and blowdown connections.
D. The boiler shall be built to comply with the following insurance and codes _____
(Factory Mutual, ASME CSD-1).
2.6 BOILER SHELL (HOT WATER)
A. The boiler shell must be constructed in accordance with ASME Boiler Code and must
receive authorized boiler inspection prior to shipment. A copy of the inspection report
shall be furnished to the purchaser.
B. The hot water return and outlet connections shall be located on the top center line of
the boiler. The boiler shall be designated to rapidly mix the return water with the
boiler water. Forced internal circulation shall be used.
C. A dip tube shall be included as an integral part of the water outlet.
D. Two lifting eyes shall be located on top of the boiler.
E. Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed
with fiberglass tadpole gaskets and fastened tightly using heavy capscrews that
thread into replaceable brass nuts.
F. Rear refractory and insulation shall be contained in the formed door, which must
swing open for inspection of brick work.
G. The boiler tubes shall not include turbulators, swirlers or other add-on
appurtenances.
H. Front and rear tube sheets and all flues must be fully accessible for inspection and
cleaning when the doors are swung open. The shell must be furnished with adequate
handholes to facilitate boiler inspection and cleaning.
I. The exhaust gas vent shall be located near the front of the boiler on the top center
line and shall be capable of supporting 1000 lbs and shall contain a stack
thermometer.

Section A2-48 Rev. 09-09

Model 4WI 100 800 HP Boilers

2.7 EMISSION CONTROLS

A. Boiler shall be equipped with a low emission (LE) option for guaranteed NOx
performance at _____ ppm, dry volume basis and corrected to 3% O2 when firing
natural gas.
B. The low emission option shall include an integral front head, burner, and boiler
package, providing NOx reduction through an internal flue gas recirculation system
using the combustion air fan, internal recirculation valve, and enhanced boiler design
to achieve the guaranteed NOx levels. The emission control system shall not use an
external fan, control valve, and piping. Boiler fuel-to-steam efficiency and rated boiler
capacity shall be guaranteed while the boiler is operating at the low NOx
performance levels.
C. Burner, boiler, and low NOx system shall be manufactured as a package by a single
manufacturer. The Low Emission Option to the CB Boiler shall included factory
testing as a package, and shall bear the UL packaged label. The boiler nameplate
shall include the approved UL low NOx boiler model designation. No field assembly
of the burner or low NOx equipment shall be required.
2.8 HOT WATER BOILER TRIM
A. Low Water Cutoff
A low water cutoff control (manual reset) shall be mounted on the top centerline of
the boiler wired into the burner control circuit to prevent burner operation if boiler
water falls below a safe level.
B. Pressure and Temperature Gauges
Pressure and temperature gauges shall be mounted on the boiler with temperature
sensing element located adjacent to the hot water outlet.
C. Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall
be shipped loose.
D. Temperature Controls
Temperature controls to regulate burner operation shall be mounted on the unit with
temperature sensing elements located adjacent to the hot water outlet. Controls shall
be high limit (manual reset), operating limit (auto reset), and firing rate control (30-
100 hp).
2.9 BURNER AND CONTROLS
A. Mode of Operation
B. Burner operation shall be full modulation principle. The burner shall always return to
low fire position for ignition.
2.10 BLOWER
A. Air for combustion shall be supplied by a forced draft blower mounted in the front
boiler door, above the burner, to eliminate vibration and reduce noise level.
B. Maximum sound level of the boiler/burner package shall not exceed _____ dbA
(when measured in accordance with ABMA Sound Test Standards).
C. The impeller shall be cast aluminum, radial blade, carefully balanced, and directly
connected to the blower motor shaft.

Section A2-49 Rev. 09-09

Model 4WI 100 800 HP Boilers

2.11 COMBUSTION AIR CONTROL

Combustion air damper and cam operated fuel metering valves shall be operated by a
single damper control motor that regulates the fire according to load demand.
Potentiometer type position controls shall be provided to regulate operation of the
damper control motor (remove this sentence when CB-HAWK flame safeguard is used).
2.12 FUEL SPECIFICATION AND PIPING
Select one of the following fuel types:
1. Fuel series 700 - Gas fired (4.4.1).
2. Fuel series 100 - Light oil (No. 2) fired (4.4.2).
3. Fuel series 200 - Light oil or gas fired (4.4.3).
4. Fuel Series 700 - Gas Fired
2.13 BURNER TYPE
The burner shall be integral with the front head of the boiler and of high radiant multi-port
type for gas. The burner shall be approved for operation on natural gas fuel and equipped
with an LE option.
2.14 GAS PILOT
The gas pilot shall be a premix type with automatic electric ignition. An electronic detector
shall monitor the pilot so that the primary gas valve cannot open until pilot flame has
been established. The pilot train shall include two manual shut-off valves, solenoid valve,
pressure regulator and pressure gauge.
2.15 GAS BURNER PIPING
A. Gas burner piping on all units shall include pressure regulating gas shutoff valve,
motor operated with proof of closure switch and plugged leakage test connection.
The main gas valve(s) shall be wired to close automatically in the event of power
failure, flame failure, low water or any safety shutdown condition. A lubricating plug
cock or butterfly shutoff valve shall be provided as a means for a tightness check of
the primary shut off valve. An additional plug cock on butterfly valve shall be
furnished at entrance to gas train. Select one of the following:
B. 125-300 hp. High and low gas pressure switches shall be provided. A second
motorized safety shutoff valve, plus an additional plugged leakage test connection
shall be provided.
C. 350-800 hp. High and low gas pressure switches shall be provided. A second
motorized safety shutoff valve, plus an additional plugged leakage test connection
shall be provided. A valve proving switch shall be located between the safety shutoff
valves.
2.16 BURNER TURNDOWN
Select one of the following:
1. 125-200 hp. Turndown range of burner shall be 4:1 when firing natural gas.
2. 250-800 hp. Turndown range of the burner shall be 10:1 when firing natural gas
with a 60 or 30 ppm LE option. (Consult with Cleaver-Brooks Representative
regarding high turndown capability based on available gas pressure and 15 and
9 ppm LE options.)
2.17 FUEL SERIES 100
Light Oil Fired

Section A2-50 Rev. 09-09

Model 4WI 100 800 HP Boilers

2.18 BURNER TYPE

The burner shall be integral with the front head of the boiler, and shall be a low pressure
air atomizing type approved for operation with CS12-48, Commercial No. 2 oil and
equipped with an LE option.
2.19 GAS PILOT
The gas pilot shall be a premix type with automatic electric ignition. An electronic detector
shall monitor the pilot so that the primary gas valve cannot open until pilot flame has
been established. The pilot train shall include two manual shut-off valves, solenoid valve,
pressure regulator and pressure gauge.
2.20 OIL PUMP
An oil pump with a capacity of approximately twice the maximum burning rate shall be
included. Separate motor driven pump set, shipped loose to be installed in a location
favorable to the oil storage tank, shall be provided.
2.21 OIL BURNER PIPING
Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering
controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally
mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil
controls into a single casting which is mounted on the front door of the unit. A single tip
retractable nozzle shall be used for the low pressure air atomizing burner. A low oil
pressure switch shall be included in the oil piping.
2.22 LOW PRESSURE AIR ATOMIZING
Separate air compressor module mounted on boiler base rail with low atomizing air
pressure switch.
2.23 BURNER TURNDOWN Fuel Series 200 Light Oil or Gas Fired
125 hp through 200 hp. Turndown range shall be 4:1 when firing No. 2 oil. When Firing
natural gas refer to section 2.23
2.24 BURNER TYPE
The burner, integral with the front head of the boiler, shall be a combination of the low
pressure air atomizing type for oil and high radiant multi-port type for gas. The burner
shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas.
The burner shall be equipped with an LE option.
2.25 GAS PILOT
The gas pilot shall be premix type with automatic electric ignition. An electronic detector
shall monitor the pilot so that the primary fuel valve cannot open until flame has been
established. The pilot train shall include two manual shut-off valves, solenoid valve,
pressure regulator and pressure gauge.
2.26 OIL BURNER
Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate
shall be included. Separate motor driven pump set, shipped loose, to be installed in a
location favorable to the oil storage tank, shall be provided.

Section A2-51 Rev. 09-09